M32 (English) [PDF]

Zitiervorschau

cvb2

Engineer’s Handbook M 32

January 2015

m

Engineer’s Handbook Contents

M32

c2

General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cylinder arrangement according to DIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine Data / Engine Operating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 M 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 RM 32 C Prop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 RM 32 C IMO II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 VM 32 C IMO II short stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 VM 32 C IMO II long stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 RM 32 E IMO II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 VM 32 E IMO II HFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 VM 32 E IMO II MDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 RM 32 C EPG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 RM 32 C EPG WB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 VM 32 C EPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 VM 32 C EPG WB II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 VM 32 C EPG WB II 500 kW/cyl.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Firing Orders / Valve Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Firing orders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Oil filling quantities for diesel generator sets on base frames . . . . . . . . . . . . . . . 65 Engine Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Covering, crankcase doors, caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Main bearing studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Lubricating oil nozzles for timing gear train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Tightening torques for screw plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Crankcase door with relief valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Cover for timing gear train (RM 32 E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Installation of bearing bushes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

1/15

m

Engineer’s Handbook Contents

M32

c2

Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Removing and installing the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Check for leaks at the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Lifting the cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Differences between M 32 and M 32 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Rocker arm bracket (M 32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Rocker arm bracket (M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Rocker arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Radial clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Adjustment of the valve bridges with respect to the valve spindles . . . . . . . . . . . 74 Valve guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Sealing caps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Fuel injector (M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Fuel injector (M 32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Removing and installing the fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Fuel injector delivery pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Indicator valve and relief valve (RM 32 and VM 32). . . . . . . . . . . . . . . . . . . . . . . 81 Guide bolts for the valve bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Valve bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Valve rotators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Regrinding hard-faced valve stems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Nitrided valve spindles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Checking inlet and exhaust valve spindles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Valve projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Valve seat inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Inserting inlet and exhaust valve seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Oversize steps for valve seat inserts and valve guides . . . . . . . . . . . . . . . . . . . . 86 Valve cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

2/15

m

Engineer’s Handbook Contents

M32

c2

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Caution! Barring with piston removed (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Mahle 1.90.7-26.70.00-08 / 09 / 12 / 13 / 16 / 17 / 18 / 22 / 23 / 24 / 26 / 27 / 28 / 29 / 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Removal of Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 / 09 / 13 / 16 / 18 / 22 / 23 / 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Mahle 1.90.7-26.70.00-19 / 20 / 21 / 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Mahle 1.90.7-26.70.00-25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 MWH 1.90.7-26.70.00-06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Kolbenschmidt 1.90.7-26.70.00-34 / 35 (IMO I) . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Kolbenschmidt 1.90.7-26.70.00-36 / -37 (IMO II) . . . . . . . . . . . . . . . . . . . . . . . . . 94 Use of the pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Weight tolerance when replacing connecting rod / piston . . . . . . . . . . . . . . . . . . 97 Wear limits of the ring grooves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Piston, piston pin, small-end bush wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Gas oil and heavy fuel operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Attention! Barring with piston removed (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Shank division tightening instruction (RM 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Shank division tightening instruction (VM 32). . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Tightening instruction for marine type connecting rods (VM 32 C, RM 32 E). . . 101 Differences between marine type connecting rods and standard connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Upper shank division . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Piston pin and small-end bush wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Evaluation of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Small-end bush. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Tightening instruction for big-end bearing nuts (RM 32 + VM 32) . . . . . . . . . . . 105 Big-end bearing nut tightening instruction (marine type connecting rod) (VM 32 C, RM 32 E) . . . . . . . . . . . . . . . . . . . . . . 106 Note for using connecting rod bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

3/15

m

Engineer’s Handbook Contents

M32

c2

Big-end bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Reference dimensions of the big-end bearings after proper tightening . . . . . . . 108 Screw plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Weight tolerance when replacing connecting rod / piston . . . . . . . . . . . . . . . . . 109 Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Permissible wedge shapes, canyons, scores, pockets . . . . . . . . . . . . . . . . . . . 110 Fretting formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Nominal dimensions and wear limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Check of the contact surface and rework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Contact surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Replacement criterion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Flame ring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Anti-polishing ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Evaluation of bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Tightening instruction (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Measuring the gap (RM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Tightening instruction (VM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Measuring the gap (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Bearing clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Thrust washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Limit dimensions of the main bearing shells. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Crank web deflection (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Headless screws and screw plugs in the crankshaft . . . . . . . . . . . . . . . . . . . . . 127 Balance weight equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Contact pattern of the balance weight surface . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Tightening instruction for balance weight installation (RM) . . . . . . . . . . . . . . . . 129 Tightening instruction for balance weight installation (RM 32 E) . . . . . . . . . . . . 129 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

4/15

m

Engineer’s Handbook Contents

M32

c2

Tightening instruction for balance weight installation (VM with normal stroke) . 130 Tightening instruction for balance weight installation (VM with 460 mm stroke - IMO II). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Vibration damper removal with device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Vibration damper installation without power take-off . . . . . . . . . . . . . . . . . . . . . 133 Vibration damper installation with power take-off (RM) . . . . . . . . . . . . . . . . . . . 134 Vibration damper installation with power take-off (VM) . . . . . . . . . . . . . . . . . . . 136 Allowable crankshaft refinishing dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Surface hardness of the crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Pump gear on the crankshaft (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Cam formation on crank pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Crankshaft seal and flywheel hub installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Crankshaft seal 1.90.7-73.40.00-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Flywheel hub 1.90.7-73.40.00-02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Crankshaft seal 1.90.7-73.40.00-03 / -04 (RM) . . . . . . . . . . . . . . . . . . . . . . . . . 146 Crankshaft seal 1.91.7-73.40.00-02 / -03 (VM) . . . . . . . . . . . . . . . . . . . . . . . . . 146 Dismounting and mounting of flywheel hub and crankshaft gear . . . . . . . . . . . . 148 Timing gear train (M 32 and VM 32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Gear on crankshaft 1.90.7-25.30.00-02 (RM). . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Gear on crankshaft 1.90.7-25.30.00-03 (RM). . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Gear on crankshaft 1.90.7-99.25.30-01 (RM). . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Gear on crankshaft (all other RM and VM engines) . . . . . . . . . . . . . . . . . . . . . . 150 Intermediate gear installation 1.90.7-51.40.00- 01/02 (RM) . . . . . . . . . . . . . . . . 151 Intermediate gear installation 1.90.7-51.40.00-02 (RM) . . . . . . . . . . . . . . . . . . . 152 Wear limits for intermediate gear (M 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Intermediate gear installation 1.91.7-51.40.00-01 (VM) . . . . . . . . . . . . . . . . . . . 153 Intermediate gear installation 1.91.7-51.40.00-02 (VM) . . . . . . . . . . . . . . . . . . . 154 Intermediate gear installation 1.91.7-51.40.00-03 (VM) . . . . . . . . . . . . . . . . . . . 155 Installation of crankshaft gear (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Camshaft gear installation (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 Lubricating oil nozzles for timing gear train (RM and VM) . . . . . . . . . . . . . . . . . 156 Removal and installation of the gear for pump drive . . . . . . . . . . . . . . . . . . . . . 158 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

5/15

m

Engineer’s Handbook Contents

M32

c2

Pump gear support installation and removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Timing gear train (M 32 C and VM 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Timing wheel installation for Common Rail engines. . . . . . . . . . . . . . . . . . . . . . 160 Crankshaft gear installation (RM 32 C and VM 32 C) . . . . . . . . . . . . . . . . . . . . 160 Intermediate gear installation (RM 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Lubricating oil nozzles for timing gear train (RM 32 C). . . . . . . . . . . . . . . . . . . . 161 Camshaft gear installation (RM 32 C and VM 32 C) . . . . . . . . . . . . . . . . . . . . . 162 Intermediate gear installation (VM 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Lubricating oil nozzles for timing gear train (VM 32 C). . . . . . . . . . . . . . . . . . . . 163 Timing gear train (M 32 E and VM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Camshaft gear installation (RM 32 E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Governor drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Old design (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 New design (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Backlash and end clearance (M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Camshaft bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Bearing evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Camshaft bearing 1.90.7-31.91.01-30 (RM 32) . . . . . . . . . . . . . . . . . . . . . . . . . 169 Camshaft normal bearing 1.90.7-31.91.01-32 with locating screws . . . . . . . . . . 170 Normal camshaft bearing 1.90.7-31.91.01-32 with hexagon socket head cap screws (RM 32 C) . . . . . . . . . . . . . . . . . . . . . . . 171 Camshaft bearing (RM 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Camshaft bearing (VM 32 and VM 32 C), banks A and B . . . . . . . . . . . . . . . . . 173 Camshaft bearing (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Camshaft assembly - RM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Assembly of camshaft sections (separate bearing journals / RM) . . . . . . . . . . . 176 Assembly of camshaft sections (integrated bearing journals / RM) . . . . . . . . . . 177 Camshaft assembly - RM32C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 Camshaft assembly - 6 M 32 C and 9 M 32 C . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

6/15

m

Engineer’s Handbook Contents

M32

c2

Camshaft assembly 8 M 32 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Camshaft assembly 6 M 32 E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Camshaft assembly 8 M 32 E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Camshaft assembly 9 M 32 E. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Camshaft assembly RM 32 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Camshaft assembly - VM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 Arrangement for 12 M 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Arrangement for 16 M 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186 Camshaft assembly VM 32 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Camshaft assembly - 12 M 32 C, bank A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Camshaft assembly - 12 M 32 C, bank B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Camshaft assembly - 16 M 32 C, bank A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Camshaft assembly - 16 M 32 C, bank B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Gear wheel on camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Vibration damper installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 Vibration damper removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 Installation of additional masses (9 M 32 CCR) . . . . . . . . . . . . . . . . . . . . . . . . . 194 Installation of additional masses (6/8 M 32 CCR) . . . . . . . . . . . . . . . . . . . . . . . 195 Starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Installation (new design) - RM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Adjusting instruction (new design) - RM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 Installation (old design). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Adjusting instruction (old design) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197 Pipes on the starting air distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Lower valve drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Lower valve drive: Installation (RM 32, RM 32 C, and RM 32 E with FCT) . . . . 199 Assembly of gear wheel with clamping collar (RM 32, RM 32 C, and RM 32 E with FCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Installation of limit switch bracket (RM 32, RM 32 C, and RM 32 E with FCT). . 200 Position switch (FCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Adjustment of start of fuel delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Adjusting unit: Blocking screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Adjusting unit: Assembly - RM 32 C (early variant 1.90.7-44.81.00-01). . . . . . . 203 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

7/15

m

Engineer’s Handbook Contents

M32

c2

Adjusting unit: Installation for M 32 C (new variants 1.90.7-44.81.00-02/-03/-04/-05) . . . . . . . . . . . . . . . . . . . . . . . . . . 205 Adjusting unit: Installation for M 32 E (variants 3200.7-44.81.00-01/-02). . . . . . 205 Adjusting unit: Installation for VM 32 C (variant 1.91.7-44.81.00-01) . . . . . . . . . 209 Bearing brackets for eccentric cam follower shafts (non FCT). . . . . . . . . . . . . . 212 Bearing brackets with shims. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 Cam follower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Push-rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 Injection pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Fastening of the pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215 Adjustment and determination of injection pump spacer plate thickness . . . . . . 216 Adjustment of start of fuel delivery (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217 Adjustment of start of fuel delivery for engines without eccentric . . . . . . . . . . . . 218 Adjustment of start of fuel delivery for engines with eccentrics on the cam follower shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 Stop cylinder at the injection pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Common rail components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 Safety note - observe before carrying out any work! . . . . . . . . . . . . . . . . . . . . . 223 Installation of the high-pressure pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 High-pressure pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Rail installation according to EV 1.90.7-85.28.00-01 . . . . . . . . . . . . . . . . . . . . . 231 Rail installation according to EV 1.90.7-85.28.00-02 . . . . . . . . . . . . . . . . . . . . . 234 Circulation valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 Combi valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 Flow limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 Intermediate shafts (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 Bearing shells of the intermediate shafts (RM). . . . . . . . . . . . . . . . . . . . . . . . . . 244 Bearing and gear wheel on the gear shaft (RM). . . . . . . . . . . . . . . . . . . . . . . . . 246 Timing wheel on camshaft gear wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

8/15

m

Engineer’s Handbook Contents

M32

c2

IMO adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 General note regarding the IMO certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Engine adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 Engine adjustment (non IMO and IMO I) RM 32 CCR 480 kW/cyl. and 500 kW/cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Engine adjustment IMO II CCR 480/500 kW/cyl. (RM) . . . . . . . . . . . . . . . . . . 262 IMO adjustment: Check (M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264 IMO adjustment: Marking of the flywheel (M 32 C) . . . . . . . . . . . . . . . . . . . . . . 264 CCR: Check of the position of the timing wheel on the camshaft. . . . . . . . . . . . 266 CCR: Check of pick-up position adjustment at the crankshaft. . . . . . . . . . . . . . 266 IMO adjustment: Check (M 32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266 IMO adjustment: Marking of the flywheel (M 32) . . . . . . . . . . . . . . . . . . . . . . . . 266 IMO adjustment of start of fuel delivery, variant with shims (M 32 C) . . . . . . . . 267 IMO adjustment of start of fuel delivery, variant with FCT . . . . . . . . . . . . . . . . . 269 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271 Starting fuel limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Governor arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Lubricating oil nozzles for gear wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 Fuel rack position transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Master starting valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275 Oil sump - installation of normal oil pan with drain . . . . . . . . . . . . . . . . . . . . . . . 276 Oil sump - installation of deep oil pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276 Oil sump - Installation of oil pan for resiliently mounted engines (RM). . . . . . . . 277 Lubricating oil pipes (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 Lubricating oil pipes (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 Supply and disposal pipes at the free end (stationary VM - CPGS). . . . . . . . . . 281 Brackets for supply and disposal pipes at the free end . . . . . . . . . . . . . . . . . . . 281 Lubricating oil, cooling water, and fuel leakage pipes (VM 32 C, flat oil pan) . . 282 Fuel filter pipe, nozzle leakage pipe - crude oil engine (VM 32). . . . . . . . . . . . . 283 Fuel filter pipe (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284 Fuel pipe - crude oil engine (RM 32 C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Double stop pipe (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

9/15

m

Engineer’s Handbook Contents

M32

c2

Fuel leakage pipe - crude oil engine (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285 Fuel leakage pipe - crude oil engine (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287 Fuel distributing and collecting pipe: End flanges . . . . . . . . . . . . . . . . . . . . . . . 288 Fuel distributing and collecting pipe (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . 290 Fuel distributing and collecting pipe (RM 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . 291 Pipe assembly, fuel supply (VM 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292 Media guide (RM 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293 Plate at normal bearing of the crankshaft (VM 32 C) . . . . . . . . . . . . . . . . . . . . . 293 Cooling water pipe (RM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294 Cooling water pipe (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295 Cooling water pipe (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296 Lashing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298 Barring gear RM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Barring gear RM 32 + RM 32 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299 Barring gear VM 32 C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Barring gear VM 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302 Big-end bearing temperature monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303 Brackets for main bearing temperature monitoring . . . . . . . . . . . . . . . . . . . . . . 304 Level probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Pressure transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Pressure switches on the genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305 Installation of thermocouples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Adjustment of the speed pick-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306 Speed pick-up bracket (M 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Installation of the crankcase oil mist detector. . . . . . . . . . . . . . . . . . . . . . . . . . . 307 Pump covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Oil filter, oil safety strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308 Brackets for TC and RTD switch boxes (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . 309 Brackets for lateral switch boxes (RM 32 E). . . . . . . . . . . . . . . . . . . . . . . . . . . . 309 Headless screw for duplex fuel filter cover plate . . . . . . . . . . . . . . . . . . . . . . . . 310

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

10/15

m

Engineer’s Handbook Contents

M32

c2

Pump support with attached pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Pump support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311 Cover on pump support (RM 32 E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312 Lubricating oil connections for cooling water pumps, HT and LT circuit (VM 32 C). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313 Cooling water pumps: Gear wheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . 314 Lubricating oil pumps, suction and pressure pump . . . . . . . . . . . . . . . . . . . . . . 314 Lubricating oil pump: Gear wheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Fuel feed pump (RM 32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315 Fuel feed pump drive (RM 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316 Cooling water pump drive backlash (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . 316 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Flywheel installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Flywheel installation (RM 32 CCR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Flywheel installation (VM 32 CCR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 Coupling adapter ring on flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Flexible flange connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321 Couplings TEF 50.000/50W-ST, TEF 63.000/50W-ST, TEF 80.000/50W-ST . 321 Vulkan RATO-S 1G391W, series 2200, 1G39100032 . . . . . . . . . . . . . . . . . . . . 322 Vulkan RATO-DS A3415, series 2200, 1A3410A023. . . . . . . . . . . . . . . . . . . . . 323 Vulkan RATO-DS A33D0, series 2200, 1A33D0A033 . . . . . . . . . . . . . . . . . . . . 324 Vulkan RATO-DS A34DZ/D1-D6, series 2200, 1A34D0A016 . . . . . . . . . . . . . . 326 Vulkan RATO-DS A34DO/D1-D6, series 2200, 1A34D0A027 . . . . . . . . . . . . . . 326 Vulkan RATO-DS A34DO

series 2200, 1A34D0 . . . . . . . . . . . . . . . . . . 326

Vulkan RATO-DS A34D5,

series 2200, 1A34D0A016 . . . . . . . . . . . . . . 326

Vulkan RATO-DS A34D5,

series 2200, 1A34D0A019 . . . . . . . . . . . . . . 326

Vulkan RATO-DS A34D5,

series 2200, 1A34D002A2 . . . . . . . . . . . . . . 326

Vulkan RATO-S G392W, series 2100, 1G39200058 . . . . . . . . . . . . . . . . . . . . . 328 Vulkan RATO-S G342Q, series 2100, 1G34200062 . . . . . . . . . . . . . . . . . . . . . 328 Vulkan RATO-DS A31D5, series 2400, 1A31D5A042 . . . . . . . . . . . . . . . . . . . . 330 Vulkan RATO-DS A33D0, series 2200, 1A33D0A049 . . . . . . . . . . . . . . . . . . . . 332 Vulkan RATO-DS A33D0, series 2200, 1A33D0 . . . . . . . . . . . . . . . . . . . . . . . . 332 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

11/15

m

Engineer’s Handbook Contents

M32

c2

Vulkan RATO-DS A33D0, series 2200, 1A33D0A0XX with additional mass . . . 334 Vulkan RATO-R G401J, series 2200, 1G4010R009 . . . . . . . . . . . . . . . . . . . . . 336 Vulkan RATO-R G401J, series 2200, 1G39100036. . . . . . . . . . . . . . . . . . . . . . 338 Charge air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Charge air duct drain pipe (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Differential pressure gauge on charge air cooler (VM). . . . . . . . . . . . . . . . . . . . 340 Sealing caps in the charge air cooler casing . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Installation of charge air cooler casing (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . 341 Installation of charge air cooler casing, driving end (6 M 32 C) . . . . . . . . . . . . . 343 Installation of charge air cooler casing, free end (6 M 32 C) . . . . . . . . . . . . . . . 344 Installation of charge air cooler casing for TPL67, driving end and free end (8 M 32 C and 9 M 32 C) . . . . . . . . . . . . . . . . . . . . . . 345 Installation of charge air cooler casing for TPL65, driving end and free end (8 M 32 C with single-pipe charging) . . . . . . . . . . . . . 347 Installation of charge air cooler casing, driving end and free end (RM 32 E) . . . 349 Installation of charge air cooler, driving end and free end, IMO I and WB1 (RM) 350 Installation of charge air cooler GEA -13 / - 44, driving and free end, IMO II (6 M 32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352 Installation of charge air cooler GEA -20, driving end and free end (VM 32 C). 353 Installation of charge air cooler Vestas -74, free end (RM 32 E) . . . . . . . . . . . . 354 Installation of charge air cooler GEA -79, driving end (RM 32 E). . . . . . . . . . . . 355 Tightening torques for charge air cooler GEA -78 / -79 (RM 32 E) . . . . . . . . . . 356 Air injection (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357 Compressor bypass valve (RM 32 E). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358 Control of the compressor bypass valve (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . 359 Air blow-off device (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361 Air stop valves (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362 Air inlet casing to charge air cooler (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Air inlet casing to charge air cooler (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363 Air passage (RM) (1.90.7-72.41.00-*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364 Air passage (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365 Air passage, driving end and free end (VM) (1.91.7-72.41.00-01 / -02), (3401.7-72.41.00-01). . . . . . . . . . . . . . . . . . . . . . . . 366 Coverings at the air inlet casing (1.9*.7-72.81.00-*). . . . . . . . . . . . . . . . . . . . . . 367

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

12/15

m

Engineer’s Handbook Contents

M32

c2

Turbocharger installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 Tightening torques and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 Drain pipe, driving end and free end (RM 32 E) HFO . . . . . . . . . . . . . . . . . . . . 375 Turbocharger bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376 Lubricating oil pipes at the turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377 Installation of turbocharger NA295, DE (driving end) and FE (free end) (6 M 32)377 Installation of turbocharger NA355, DE and FE (8 M 32 and 9 M 32) . . . . . . . . 377 Installation of turbocharger NA297, DE and FE (6 M 32 C) . . . . . . . . . . . . . . . . 378 Installation of turbocharger NA357, DE and FE, (8 M 32 C and 9 M 32 C) . . . . 380 Installation of turbocharger TPS61, DE and FE (6 M 32 C) . . . . . . . . . . . . . . . . 382 Installation of turbocharger TPL65-A, DE (8 M32 C) . . . . . . . . . . . . . . . . . . . . . 383 Installation of turbocharger A145, DE and FE (6 M 32 C) . . . . . . . . . . . . . . . . . 386 Installation of turbocharger TPL67-C, DE and FE (8 M 32 C, 9 M 32 C) . . . . . . 389 Installation of turbocharger NA297, FE (12 M 32 C) . . . . . . . . . . . . . . . . . . . . . 393 Installation of turbocharger NA297 FE with air stop valves (12 M 32 C) . . . . . . 398 Installation of turbocharger NA297,FE, stationary applications with HFO (12 M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . 399 Installation of turbocharger TPL65, DE and FE (VM 32 C) . . . . . . . . . . . . . . . . 400 Installation of turbocharger TPL65, DE and FE (VM 32 C) . . . . . . . . . . . . . . . . 402 Installation of turbocharger TPL65 with air stop valves (VM 32 C). . . . . . . . . . . 406 Installation of turbocharger TPL65 with flange on the air inlet casing (VM 32 C) 407 Installation of turbocharger TPS61 (12 M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . 410 Installation of NT1-10 turbocharger (6M32E) . . . . . . . . . . . . . . . . . . . . . . . . . . 414 Installation NT1-12 turbocharger (8M32E and 9M32E) . . . . . . . . . . . . . . . . . . . 415 Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 Expansion joint installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416 Single-pipe charging (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417 Pulse charging (RM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 Exhaust nozzle on the turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419 RM 32 E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 Wastegate installation (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421 Installation of wastegate control (RM 32 E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

13/15

m

Engineer’s Handbook Contents

M32

c2

Exhaust tubes with integral insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424 Fixing screws (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 VM 32 with turbocharger at free end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 6 M 32 with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 8 M 32 with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 9 M 32 with turbocharger at driving end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426 Exhaust cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 Exhaust tubes with integral insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427 Installation sequence for 6 M 32 C (FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428 Installation sequence for 6 M 32 C (free end), special design for AP Möller . . . 430 Installation sequence for 6 M 32 C (DE), ABB TPS61, single-pipe charging (old)432 Installation sequence for 6 M 32 C (DE), ABB A145 and ABB TPS61, single-pipe charging (new) . . . . . . . . . . . . . . . . . . 435 Installation sequence for 6 M 32 E (free end), Napier NT10A, pulse charging . 438 Assembly sequence for 8 M 32 C (DE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442 Installation sequence for 8 M 32 C (FE), ABB TPL67, single-pipe charging . . . 443 Installation sequence for 8 M 32 C (FE), ABB TPL67, pulse charging. . . . . . . . 444 Installation sequence for 8 M 32 C (FE), ABB TPL65, single-pipe charging . . . 446 Installation sequence for 8 M 32 C (free end), special design for AP Möller . . . 448 Installation sequence for 8 M 32 E (FE), Napier NT12A, single-pipe charging . 449 Installation sequence for 9 M 32 C (DE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452 Installation sequence for 9 M 32 C (FE), single-pipe charging. . . . . . . . . . . . . . 453 Installation sequence for 9 M 32 C (FE), pulse charging (var. 12) . . . . . . . . . . . 454 Installation sequence for 9 M 32 C (FE), pulse charging (var. 13) . . . . . . . . . . . 455 Installation sequence for 12 M 32 C (DE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456 Installation sequence 12 M 32 C (FE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459 Diesel Generator Set. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 Engine and generator fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461 Additional tightening torques for 16 M 32 C . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464 Installation of PTO coupling hub (VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465 Installation of PTO coupling hub (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466 Alignment instruction for diesel generator sets. . . . . . . . . . . . . . . . . . . . . . . . . . 467 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

14/15

m

Engineer’s Handbook Contents

M32

c2

Resilient mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 Installation (RM and VM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473 Locking device to be used in case of damage . . . . . . . . . . . . . . . . . . . . . . . . . . 474 Installation of the conical elements (M 32 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . 475 Installation of the conical elements (M 32 C, M 32 E) . . . . . . . . . . . . . . . . . . . . 480

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

15/15

m

Engineer’s Handbook General Notes

M 32

c2

General Notes Cylinder arrangement according to DIN

M 32

VM 32

Engines starting with engine No. 38xxx are M 32 C engines. If any data differs from the basic version, this will be indicated separately.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

16

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

Engine Data / Engine Operating Data M 32

M 32 Bore (RM and VM)

320 mm

Stroke RM 32 .................................................... VM 32 ....................................................

420 mm 480 mm

Speed RM 32 .................................................... VM 32 ....................................................

600 rpm 750 rpm

Power output (RM and VM)

500 kW/cyl.

Lubricating oil temperature at engine inlet

60 - 65 °C

Lubricating oil temperature rise

6 - 12 °C

Fresh water circulation cooling Temperature at engine outlet .................... 80 - 90 °C Temperature rise ..................................... 4 - 6 °C (at rated power) Pressure .................................................. 2.5 - 5.0 bar Charge air temperature Engine inlet ........................................... IMO I engines ....................................... Distillate fuel ...................................

35 - 40 °C 32 °C 35 - 40 °C

Lubricating oil pressure at the last main bearing ................

4 - 5 bar (at rated engine speed)

Fuel pressure before injection pumps MDO operation ......................................... HFO operation ..........................................

3 - 5 bar 4 - 5 bar

Nozzle cooling

1.5 - 3.0 bar

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

17

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C Prop

RM 32 C Prop Continuous rated power

450 kW/cyl.

Engine speed

600 rpm

Minimum operating speed

360 rpm

Mean effective pressure

23.3 bar

Ignition pressure

200 bar

Turbocharger type 6 M 32 C (IMO320605) ............................ NA297 8 M 32 C (IMO320805) ............................. NA357 9 M 32 C (IMO320905) ............................. NA357 Fuel Nozzle cooling

via lubricating oil system

Fuel consumption at constant propeller speed and 100 % .................................................

181 g/kWh

Fuel filter: Mesh size of MDO fine filter .................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Lubricating oil Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Lubricating oil temperature at engine inlet

60 - 65 °C

Operating pressure at the engine

4 - 5 bar

Content of circulation tank / dry sump 6 M 32 C (IMO320605) ............................ 8 M 32 C (IMO320805) ............................. 9 M 32 C (IMO320905) .............................

4.1 m3 5.4 m3 6.1 m3

Lubricating oil filter: Mesh size of duplex filter ...................... Mesh size of automatic filter .................

0.08 mm 0.03 mm

Cooling water Min./max. FW pressure at engine inlet

4.5 / 6.0 bar

FW temperature downstream of the engine 80 - 90 °C Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

18

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

Content of the expansion tank 6 M 32 C (IMO320605) ............................ 8 M 32 C (IMO320805) ............................ 9 M 32 C (IMO320905) .............................

0.35 m3 0.45 m3 0.55 m3

Water content in engine 6 M 32 C (IMO320605) ............................. 8 M 32 C (IMO320805) ............................ 9 M 32 C (IMO320905) .............................

0.70 m3 0.95 m3 1.05 m3

Two-circuit system: FW temperature at charge air cooler inlet

38 °C

Two-circuit system: Required FW volume for charge air cooler 6 M 32 C (IMO320605) ............................. 8 M 32 C (IMO320805) ............................. 9 M 32 C (IMO320905) .............................

40 m3/h 60 m3/h 60 m3/h

c2

Air Air requirement (ta = 20 °C) 6 M 32 C (IMO320605) ............................. 8 M 32 C (IMO320805) ............................ 9 M 32 C (IMO320905) .............................

16150 m3/h 21250 m3/h 24950 m3/h

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Charge air pressure

3.1 bar

Max. permissible crankcase pressure,

15 mmWC

Exhaust gas NOx emission (Marpol 73/78, Annex VI, Cycle E2, D2)

11.9 g/kWh

Max. exhaust gas resistance after turbine

0.03 bar

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 6 M 32 C (IMO320605) ............................. 8 M 32 C (IMO320805) ............................ 9 M 32 C (IMO320905) .............................

310 °C (tolerance: 10 %) 310 °C (tolerance: 10 %) 295 °C (tolerance: 10 %)

Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 6 M 32 C (IMO320605) ............................. 8 M 32 C (IMO320805) ............................. 9 M 32 C (IMO320905) .............................

19620 kg/h (tolerance: 10 %) 26265 kg/h (tolerance: 10 %) 30840 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

19

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C IMO II

RM 32 C IMO II Continuous rated power of the engine according to ISO 3046/1

500 kW/cylinder

Engine speed

600 rpm

Minimum operating speed

360 rpm

Ignition pressure

200 bar

Mean effective pressure

25.9 bar

Turbocharger type 6 M 32 C (IMO320608) ............................. ABB A145 8 M 32 C (IMO320808) ............................. ABB TPL 67 9 M 32 C (IMO320908) ............................. ABB TPL 67 Fuel Nozzle cooling

via lubricating oil system

Fuel consumption at 100 %

177 g/kWh

Fuel filter: Mesh size of MDO fine filter .................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Cooling water Content of expansion tank 6 M 32 C (IMO320608) ............................. 0.35 m3 8 M 32 C (IMO320808) ............................. 0.45 m3 9 M 32 C (IMO320908) ............................. 0.55 m3 Water content of the engine 6 M 32 C (IMO320608) ............................. 0.70 m3 8 M 32 C (IMO320808) ............................. 0.95 m3 9 M 32 C (IMO320908) ............................. 1.05 m3 FW temperature downstream of the engine

80 - 90 °C

FW pressure at engine inlet

4.5 - 6.0 bar

Two-circuit system: FW temperature at charge air cooler inlet

38 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

20

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C IMO II Two-circuit system: Required fresh water quantity for charge air cooler 6 M 32 C (IMO320608) ............................. 40 m3/h 8 M 32 C (IMO320808) ............................. 60 m3/h 9 M 32 C (IMO320908) ............................. 60 m3/h Air Charge air pressure

3.8 bar

Max. permissible crankcase pressure, nom. diam. of vent pipe

15 mmWC 80 mm

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Air requirement (ta = 20 °C) 6 M 32 C (IMO320608) ............................. 17150 m3/h 8 M 32 C (IMO320808) ............................. 23350 m3/h 9 M 32 C (IMO320908) ............................. 26250 m3/h Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Content of circulation tank / dry sump 6 M 32 C (IMO320608) ............................. 4.1m3 8 M 32 C (IMO320808) ............................. 5.4m3 9 M 32 C (IMO320908) ............................. 6.1m3 Lubricating oil temperature before engine

60 - 65 °C

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm Exhaust gas

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2) Max. exhaust gas resistance after turbine

9.8 g/kWh 0.03 bar

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

21

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C IMO II Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 6 M 32 C (IMO320608) ............................ 303 °C (tolerance: 10 %) 8 M 32 C (IMO320808) ............................. 315 °C (tolerance: 10 %) 9 M 32 C (IMO320908) ............................. 310 °C (tolerance: 10 %) Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 6 M 32 C (IMO320608) ............................. 21132 kg/h (tolerance: 10 %) 8 M 32 C (IMO320808) ............................. 28860 kg/h (tolerance: 10 %) 9 M 32 C (IMO320908) ............................. 32445 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

22

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C IMO II short stroke

VM 32 C IMO II short stroke Continuous rated power of the engine according to ISO 3046/1 12 M 32 C (IMO321205) .......................... 480 and 500 kW/cylinder 16 M 32 C (IMO321605) ........................... 480 and 500 kW/cylinder Rated engine speed 480 kW/cyl. ........................................... 500 kW/cyl. ...........................................

720 rpm 750 rpm

Minimum operating speed (all engines)

450 rpm

Mean effective pressure

23.7 bar

Ignition pressure

200 bar

Turbocharger type

ABB TPL65 Fuel

Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % 12 M 32 C (480 kW/cyl.) ........................... 12 M 32 C (500 kW/cyl.) ........................... 16 M 32 C (480 kW/cyl.) ........................... 16 M 32 C (500 kW/cyl.) ...........................

181 g/kWh 182 g/kWh 182 g/kWh 184 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Cooling water Content of expansion tank 12 M 32 C ................................................ 16 M 32 C ................................................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 C ................................................ 16 M 32 C ................................................

1.4 m3 1.9 m3

FW temperature downstream of the engine

80 - 90 °C

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

23

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C IMO II short stroke Two-circuit system: FW temperature at charge air cooler inlet

38 °C

Two-circuit system: Required fresh water quantity for charge air cooler 12 M 32 C ................................................ 16 M 32 C ................................................

80 m3/h 100 m3/h

Air Charge air pressure VM 32 C (480 kW/cyl.) ............................. VM 32 C (500 kW/cyl.) .............................

3.2 bar 3.4 bar

Max. permissible crankcase pressure, Vent pipe DN

15 mmWC 125 mm

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Air requirement (ta = 20 °C) 12 M 32 C (480 kW/cyl.) ........................... 12 M 32 C (500 kW/cyl.) ........................... 16 M 32 C (480 kW/cyl.) ........................... 16 M 32 C (500 kW/cyl.) ...........................

34425 m3/h 36210 m3/h 45895 m3/h 48280 m3/h

Lubricating oil Lubricating oil operating pressure at engine Content of circulation tank / dry sump 12 M 32 C (480 kW/cyl.) ........................... 12 M 32 C (500 kW/cyl.) ........................... 16 M 32 C (480 kW/cyl.) ........................... 16 M 32 C (500 kW/cyl.) ...........................

4 - 5 bar

7.60 m3 8.00 m3 10.0 m3 10.8 m3

Lubricating oil temperature before engine

60 - 65 °C

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

24

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C IMO II short stroke Exhaust gas NOx emission (Marpol 73/78 Annex VI Cycle E2, D2) VM 32 C (480 kW/cyl.) ............................. VM 32 C (500 kW/cyl.) ............................. Max. exhaust gas resistance after turbine

9.8 g/kWh 9.1 g/kWh 0.03 bar

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 12 M 32 C (480 kW/cyl.) ........................... 12 M 32 C (500 kW/cyl.) ........................... 16 M 32 C (480 kW/cyl.) ........................... 16 M 32 C (500 kW/cyl.) ...........................

317 °C (tolerance: 10 %) 310 °C (tolerance: 10 %) 311 °C (tolerance: 10 %) 305 °C (tolerance: 10 %)

Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 12 M 32 C (480 kW/cyl.) ........................... 12 M 32 C (500 kW/cyl.) ........................... 16 M 32 C (480 kW/cyl.) ........................... 16 M 32 C (500 kW/cyl.) ...........................

42545 kg/h (tolerance: 10 %) 44755 kg/h (tolerance: 10 %) 56725 kg/h (tolerance: 10 %) 59670 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

25

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C IMO II long stroke

VM 32 C IMO II long stroke Continuous rated power of the engine according to ISO 3046/1 12 M 32 C (IMO321206) ........................... 16 M 32 C (IMO321606) ...........................

500 kW/cylinder 500 kW/cylinder

Rated engine speed

720 and 750 rpm

Minimum operating speed (all engines)

450 rpm

Mean effective pressure VM 32 C (720 rpm) ................................ VM 32 C (750 rpm) ................................

22.5 bar 21.6 bar

Ignition pressure

200 bar

Turbocharger type

ABB TPL65 Fuel

Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % VM 32 C (720 rpm) ............................... VM 32 C (750 rpm) ...............................

178 g/kWh 179 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Cooling water Content of expansion tank 12 M 32 C ................................................ 16 M 32 C ................................................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 C ................................................ 16 M 32 C ................................................

1.4 m3 1.9 m3

FW temperature downstream of the engine

80 - 90 °C

Min./max. FW pressure at engine inlet

2.5 bar

Two-circuit system: FW temperature at charge air cooler inlet 38 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

26

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C IMO II long stroke Two-circuit system: Required fresh water quantity for charge air cooler 12 M 32 C ................................................ 16 M 32 C ................................................

80 m3/h 100 m3/h

Air Charge air pressure 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

3.25 bar 3.40 bar 3.30 bar 3.50 bar

Max. permissible crankcase pressure Vent pipe DN

15 mmWC 125 mm

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Air requirement (ta = 20 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

34730 m3/h 34700 m3/h 48000 m3/h 47500 m3/h

Lubricating oil Lubricating oil operating pressure at engine Content of circulation tank / dry sump 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

4 - 5 bar

7.60 m3 8.00 m3 10.0 m3 10.8 m3

Lubricating oil temperature before engine

60 - 65 °C

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm Exhaust gas

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2)

9 g/kWh

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

27

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C IMO II long stroke Max. exhaust gas resistance after turbine

0.03 bar

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

304 °C (tolerance: 10 %) 297 °C (tolerance: 10 %) 294 °C (tolerance: 10 %) 291 °C (tolerance: 10 %)

Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

42800 kg/h (tolerance: 10 %) 42768 kg/h (tolerance: 10 %) 59116 kg/h (tolerance: 10 %) 58492 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

28

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 E IMO II

RM 32 E IMO II Continuous rated power of the engine accor- 550 kW/cylinder ding to ISO 3046/1 Engine speed

720 and 750 rpm

Minimum operating speed

360 rpm

Mean effective pressure RM 32 E (720 rpm) ................................. RM 32 E (750 rpm) .................................

24.78 bar 23.78 bar

Ignition pressure

225 bar

Turbocharger type 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

Napier NT10 Napier NT12 Napier NT12

Fuel Nozzle cooling

via lubricating oil system

Fuel consumption at 100 %

179 g/kWh

Fuel filter: Mesh size of MDO fine filter .................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Cooling water Content of expansion tank 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

0.35 m3 0.45 m3 0.55 m3

Water content of the engine 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

0.70 m3 0.95 m3 1.05 m3

FW temperature downstream of the engine

80 - 90 °C

Min./max. FW pressure at engine inlet

2,5 / 6,0 bar

Two-circuit system: FW temperature at charge air cooler inlet

38 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

29

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 E IMO II Two-circuit system: Required fresh water quantity for charge air cooler 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

40 m3/h 60 m3/h 60 m3/h

Air Charge air pressure

4.1 bar

Max. permissible crankcase pressure, nom. diam. of vent pipe

15 mmWCmmwc 80 mm

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Air requirement (ta = 20 °C) 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

19167 m3/h 25555 m3/h 28750 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Content of circulation tank / dry sump 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

4.1m3 5.4m3 6.1m3

Lubricating oil temperature before engine

60 - 65 °C

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm Exhaust gas

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2)

9.6 g/kWh

Max. exhaust gas resistance after turbine

0.03 bar

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

304 °C (tolerance: 10 %) 310 °C (tolerance: 10 %) 305 °C (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

30

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 E IMO II Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 6 M 32 E ................................................... 8 M 32 E ................................................... 9 M 32 E ...................................................

23691 kg/h (tolerance: 10 %) 31585 kg/h (tolerance: 10 %) 35535 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

31

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 E IMO II HFO

VM 32 E IMO II HFO Continuous rated power of the engine according to ISO 3046/1

530 kW/cylinder

Rated engine speed

720 and 750 rpm

Minimum operating speed (all engines)

450 rpm

Mean effective pressure VM 32 E (720 rpm) ................................ VM 32 E (750 rpm) ................................

23.80 bar 22.88 bar

Ignition pressure

215 bar

Turbocharger type

ABB TPL65 Fuel

Nozzle cooling

via lubricating oil system

Fuel consumption at 100 %

180 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Cooling water Content of expansion tank 12 M 32 E ................................................ 16 M 32 E ................................................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 E ................................................ 16 M 32 E ................................................

1.4 m3 1.9 m3

FW temperature downstream of the engine

80 - 90 °C

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

Two-circuit system: FW temperature at charge air cooler inlet

38 °C

Two-circuit system: Required fresh water quantity for charge air cooler 12 M 32 E ................................................ 16 M 32 E ................................................

80 m3/h 100 m3/h

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

32

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 E IMO II HFO Air Charge air pressure VM 32 E (720 rpm) ................................. VM 32 E (750 rpm) .................................

3.44 bar 3.46 bar

Max. permissible crankcase pressure Vent pipe DN

15 mmWC 125 mm

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Air requirement (ta = 20 °C) 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

35940 m3/h 36675 m3/h 47925 m3/h 48900 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Content of circulation tank / dry sump 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

7.60 m3 8.00 m3 10.0 m3 10.8 m3

Lubricating oil temperature before engine

60 - 65 °C

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm Exhaust gas

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2)

9 g/kWh

Max. exhaust gas resistance after turbine

0.03 bar

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

332 °C (tolerance: 10 %) 324 °C (tolerance: 10 %) 331 °C (tolerance: 10 %) 325 °C (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

33

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 E IMO II HFO Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

44425 kg/h (tolerance: 10 %) 45331 kg/h (tolerance: 10 %) 59233 kg/h (tolerance: 10 %) 60440 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

34

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 E IMO II MDO

VM 32 E IMO II MDO Continuous rated power of the engine according to ISO 3046/1

560 kW/cylinder

Rated engine speed

720 and 750 rpm

Minimum operating speed (all engines)

450 rpm

Mean effective pressure VM 32 E (720 rpm) ................................ VM 32 E (750 rpm) ................................

25.20 bar 24.19 bar

Ignition pressure

215 bar

Turbocharger type

ABB TPL65 Fuel

Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

180 g/kWh 180 g/kWh 181 g/kWh 182 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm

Cooling water Content of expansion tank 12 M 32 E ................................................ 16 M 32 E ................................................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 E ................................................ 16 M 32 E ................................................

1.4 m3 1.9 m3

FW temperature downstream of the engine

80 - 90 °C

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

Two-circuit system: FW temperature at charge air cooler inlet

38 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

35

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 E IMO II MDO Two-circuit system: Required fresh water quantity for charge air cooler 12 M 32 E ................................................ 16 M 32 E ................................................

80 m3/h 100 m3/h

Air Charge air pressure VM 32 E (720 rpm) ................................. VM 32 E (750 rpm) .................................

3.72 bar 3.74 bar

Max. permissible crankcase pressure Vent pipe DN

15 mmWC 125 mm

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3 N.C.

Air requirement (ta = 20 °C) 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

37740 m3/h 38415 m3/h 50325 m3/h 51220 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Content of circulation tank / dry sump 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

7.60 m3 8.00 m3 10.0 m3 10.8 m3

Lubricating oil temperature before engine

60 - 65 °C

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm Exhaust gas

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2)

9 g/kWh

Max. exhaust gas resistance after turbine

0.03 bar

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

36

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 E IMO II MDO Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

334 °C (tolerance: 10 %) 326 °C (tolerance: 10 %) 333 °C (tolerance: 10 %) 324 °C (tolerance: 10 %)

Exhaust gas mass 25 °C intake temp., rel. air humidity 60 % 12 M 32 E (720 rpm) ............................... 12 M 32 E (750 rpm) ............................... 16 M 32 E (720 rpm) ............................... 16 M 32 E (750 rpm) ...............................

46650 kg/h (tolerance: 10 %) 47482 kg/h (tolerance: 10 %) 62200 kg/h (tolerance: 10 %) 63310 kg/h (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

37

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C EPG

RM 32 C EPG Continuous rating of the engine according to ISO 3046/1 6 M 32 C (IMO320602) ............................. 8 M 32 C (IMO320802) ............................. 9 M 32 C (IMO320902) .............................

380 kW/cylinder 480 kW/cylinder 480 kW/cylinder

Engine speed

600 rpm

Compression ratio

15.5 : 1

Minimum operating speed

180 rpm

Mean effective pressure

24.9 bar

Compression pressure

160 bar

Ignition pressure

190 bar

Start of fuel delivery

7° bef. TDC

Start of injection

2° bef. TDC

Turbocharger type 6 M 32 C (IMO320602) ............................. 8 M 32 C (IMO320802) ............................. 9 M 32 C (IMO320902) .............................

NA297 NA357 NA357

Fuel Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % 6 M 32 C (IMO320602) ............................. 8 M 32 C (IMO320802) ............................. 9 M 32 C (IMO320902) .............................

179 g/kWh 178 g/kWh 178 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm Air

Charge air pressure 6 M 32 C (IMO320602) ............................. 8 M 32 C (IMO320802) ............................. 9 M 32 C (IMO320902) .............................

3.12 bar 3.10 bar 3.10 bar

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

38

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C EPG Max. permissible crankcase pressure

25 mmWC

Intake vacuum upstream of compressor

max. permissible: 150 mmWC

Air requirement (ta = 20 °C) 6 M 32 C (IMO320602) ............................. 8 M 32 C (IMO320802) ............................. 9 M 32 C (IMO320902) .............................

16800 m3/h 22000 m3/h 25300 m3/h

Compressor end temperature (ta = 25 °C) 6 M 32 C (IMO320602) ............................. 8 M 32 C (IMO320802) ............................. 9 M 32 C (IMO320902) .............................

211 °C 209 °C 210 °C

Compressor end temperature (ta = 45 °C) 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

243 °C 242 °C 242 °C

Cooling water Content of expansion tank 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

0.35 m3 0.45 m3 0.55 m3

Water content of the engine 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

0.70 m3 0.95 m3 1.05 m3

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

FW temperature at charge air cooler inlet

38 °C

FW temperature downstream of the engine

80 - 90 °C

Required FW volume for charge air cooling 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

70 m3/h 80 m3/h 90 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Temperature upstream of the engine

60 - 65 °C

Mesh size of duplex filter

0.08 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

39

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C EPG Mesh size of automatic filter

0.03 mm

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Lubricating oil circulation tank / dry sump Content 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

4.0 m3 5.3 m3 5.9 m3

Exhaust gas Max. exhaust gas resistance after turbine

0.03 bar

NOx (diesel)

1.93 g/m3 (15 % O2)

NOx (diesel)

13.6 g/kWh

NOx (HFO)

2.12 g/m3 (15 % O2)

NOx (HFO)

14.96 g/kWh

CO

0.06 g/m3 (15 % O2)

CO

0.7 g/kWh

HC

0.1 g/m3 (15 % O2)

HC

0.78 g/kWh

Exhaust gas mass at 100 % (ta = 25 °C) 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

20200 kg/h 26500 kg/h 30000 kg/h

Exhaust gas mass at 100 % (ta = 45 °C) 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

19400 kg/h 25200 kg/h 28600 kg/h

Exhaust gas temperature at 100 % (ta = 25 °C) 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

322 °C 350 °C 330 °C

Exhaust gas temperature at 100 % (ta = 45 °C) 6 M 32 C (IMO320602) ................................ 8 M 32 C (IMO320802) ................................ 9 M 32 C (IMO320902) ................................

341 °C 371 °C 350 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

40

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C EPG WB II

RM 32 C EPG WB II Continuous rated power of the engine according to ISO 3046/1

480 kW/cylinder

Engine speed

600 rpm

Compression ratio

15.5 : 1

Minimum operating speed

180 rpm

Mean effective pressure

24.9 bar

Compression pressure

160 bar

Ignition pressure

190 bar

Start of fuel delivery

5.5° bef. TDC

Start of injection

1.5° bef. TDC

Turbocharger type 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

ABB TPS61 ABB TPL65 ABB TPL67

Fuel Nozzle cooling

via lubricating oil system

Fuel consumption at 100 %

177 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm Air

Charge air pressure

3.51 bar

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3

Max. permissible crankcase pressure

25 mmWC

Intake vacuum upstream of compressor

max. permissible: 150 mmWC

Air requirement (ta = 20 °C) 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

16020 m3/h 22450 m3/h 26065 m3/h

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

41

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C EPG WB II Compressor end temperature (ta = 25 °C)

222 °C

Compressor end temperature (ta = 45 °C)

256 °C

Cooling water Content of expansion tank 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

0.35 m3 0.45 m3 0.55 m3

Water content of the engine 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

0.70 m3 0.95 m3 1.05 m3

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

FW temperature at charge air cooler inlet

38 °C

FW temperature downstream of the engine

80 - 90 °C

Required FW volume for charge air cooling 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

70 m3/h 80 m3/h 90 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Temperature upstream of the engine

60 - 65 °C

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Lubricating oil circulation tank / dry sump Content 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

4.0 m3 5.3 m3 5.9 m3

Exhaust gas Max. exhaust gas resistance after turbine

0.03 bar

NOx (diesel)

1.42 g/m3 (15 % O2)

NOx (diesel)

9.46 g/kWh

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

42

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

RM 32 C EPG WB II NOx (HFO)

1.54 g/m3 (15 % O2)

NOx (HFO)

10.22 g/kWh

CO

0.048 g/m3 (15 % O2)

CO

0.34 g/kWh

HC

0.21 g/m3 (15 % O2)

HC

0.49 g/kWh

Exhaust gas mass at 100 % (ta = 25 °C) 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

19800 kg/h 27750 kg/h 32200 kg/h

Exhaust gas mass at 100 % (ta = 45 °C) 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

18680 kg/h 26180 kg/h 30380 kg/h

Exhaust gas temperature at 100 % (ta = 25 °C) 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

297 °C 320 °C 300 °C

Exhaust gas temperature at 100 % (ta = 45 °C) 6 M 32 C (IMO320610) ................................ 8 M 32 C (IMO320810) ................................ 9 M 32 C (IMO320910) ................................

315 °C 339 °C 318 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

43

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG

VM 32 C EPG Continuous rated power of the engine according to ISO 3046/1

480 kW/cylinder

Engine speed

720 and 750 rpm

Compression ratio

14.2 : 1

Minimum operating speed Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

240 rpm 250 rpm

Mean effective pressure Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

23.7 bar 22.8 bar

Compression pressure

150 bar

Ignition pressure

198 bar

Start of fuel delivery

14° bef. TDC

Turbocharger type 12 M 32 C (IMO321203) ............................. 16 M 32 C (IMO321603) .............................

Napier NA297 ABB TPL65

Fuel Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

176 g/kWh 177 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm Air

Charge air pressure 12 M 32 C (IMO321203) ........................... 16 M 32 C (IMO321603) ...........................

2.9 bar 2.8 bar

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3

Max. permissible crankcase pressure

25 mmWC

Intake vacuum upstream of compressor

max. permissible: 150 mmWC

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

44

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG Air requirement (ta = 20 °C) 12 M 32 C (IMO321203) ............................. 16 M 32 C (IMO321603) .............................

36000 m3/h 46700 m3/h

Compressor end temperature (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

202 °C 203 °C 195 °C 196 °C

Compressor end temperature (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

234 °C 236 °C 227 °C 228 °C

Cooling water Content of expansion tank 12 M 32 C (IMO321203) ............................. 16 M 32 C (IMO321603) .............................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 C (IMO321203) ............................. 16 M 32 C (IMO321603) .............................

1.4 m3 1.9 m3

Required pressure at the distributing pipe

2 - 2.5 bar

FW temperature at charge air cooler inlet

38 °C

FW temperature downstream of the engine

80 - 90 °C

Required FW volume for charge air cooling 90 m3/h Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Temperature upstream of the engine

60 - 65 °C

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.034 mm

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Lubricating oil circulation tank / dry sump Content 12 M 32 C (IMO321203) ............................. 16 M 32 C (IMO321603) .............................

8.0 m3 10.8 m3

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

45

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG Exhaust gas Max. exhaust gas resistance after turbine

0.03 bar

NOx (diesel) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.98 g/m3 (15 % O2) 1.99 g/m3 (15 % O2)

NOx (diesel) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

11.77 g/kWh 13.63 g/kWh

NOx (HFO) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

2.42 g/m3 (15 % O2) 2.44 g/m3 (15 % O2)

NOx (HFO) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

12.71 g/kWh 15.20 g/kWh

CO

0.07 g/m3 (15 % O2)

CO

0.56 g/kWh

HC

0.13 g/m3 (15 % O2)

HC

1.17 g/kWh

Exhaust gas mass at 100 % (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

38722 kg/h 39312 kg/h 57139 kg/h 57984 kg/h

Exhaust gas mass at 100 % (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

37175 kg/h 37740 kg/h 54853 kg/h 55665 kg/h

Exhaust gas temperature at cylinder 12 M 32 C (IMO321203) ............................. 16 M 32 C (IMO321603) .............................

380 °C 430 °C

Exhaust gas temperature after turbine 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C .................................................

305 °C 300 °C 325 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

46

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II

VM 32 C EPG WB II Continuous rated power of the engine according to ISO 3046/1

480 kW/cylinder

Engine speed

720 and 750 rpm

Compression ratio

17.8 : 1

Minimum operating speed Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

420 rpm 450 rpm

Mean effective pressure Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

21.60 bar 20.73 bar

Ignition pressure

200 bar

Turbocharger type

ABB TPL65 Fuel

Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

177 g/kWh 178 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm Air

Charge air pressure 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

3.20 bar 3.35 bar 3.30 bar 3.50 bar

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3

Max. permissible crankcase pressure

15 mmWC

Intake vacuum upstream of compressor

max. permissible: 150 mmWC

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

47

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II Air requirement (ta = 20 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

33025 m3/h 33605 m3/h 45920 m3/h 45430 m3/h

Compressor end temperature (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

211 °C 217 °C 215 °C 222 °C

Compressor end temperature (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

244 °C 250 °C 248 °C 255 °C

Cooling water Content of expansion tank 12 M 32 C ................................................. 16 M 32 C .................................................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 C ................................................. 16 M 32 C .................................................

1.4 m3 1.9 m3

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

FW temperature at charge air cooler inlet

38 °C

FW temperature downstream of the engine

80 - 90 °C

Required FW volume for charge air cooling 12 M 32 C ................................................. 16 M 32 C .................................................

80 m3/h 100 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Temperature upstream of the engine

60 - 65 °C

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

48

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II Lubricating oil circulation tank / dry sump Content 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

7.6 m3 8.0 m3 10.0 m3 10.8 m3

Exhaust gas Max. exhaust gas resistance after turbine

0.03 bar

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2)

9 g/kWh

NOx (diesel) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.26 g/m3 (15 % O2) 1.22 g/m3 (15 % O2)

NOx (diesel) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

9.41 g/kWh 9.08 g/kWh

NOx (HFO) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.39 g/m3 (15 % O2) 1.33 g/m3 (15 % O2)

NOx (HFO) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

10.35 g/kWh 9.99 g/kWh

CO Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

0.05 g/m3 (15 % O2) 0.055 g/m 3 (15 % O2)

CO Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

0.32 g/kWh 0.36 g/kWh

HC

0.11 g/m3 (15 % O2)

HC Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.07 g/kWh 1.10 g/kWh

Exhaust gas mass at 100 % (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

40820 kg/h 41535 kg/h 56750 kg/h 56150 kg/h

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

49

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II Exhaust gas mass at 100 % (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

38510 kg/h 39185 kg/h 53350 kg/h 52780 kg/h

Exhaust gas temperature at 100 % (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

310 °C 300 °C 320 °C 315 °C

Exhaust gas temperature at 100 % (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

330 °C 318 °C 340 °C 334 °C

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

315 °C (tolerance: 10 %) 305 °C (tolerance: 10 %) 294 °C (tolerance: 10 %) 291 °C (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

50

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II 500 kW/cyl.

VM 32 C EPG WB II 500 kW/cyl. Continuous rated power of the engine according to ISO 3046/1

500 kW/cylinder

Engine speed

720 and 750 rpm

Compression ratio

17.8 : 1

Minimum operating speed Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

420 rpm 450 rpm

Mean effective pressure Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

22.5 bar 21.6 bar

Ignition pressure

200 bar

Turbocharger type

ABB TPL65 Fuel

Nozzle cooling

via lubricating oil system

Fuel consumption at 100 % Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

177 g/kWh 178 g/kWh

Fuel filter: Mesh size of MDO fine filter ................. Mesh size of HFO automatic filter ......... Mesh size of HFO fine filter ..................

0.025 mm 0.010 mm 0.034 mm Air

Charge air pressure 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

3.25 bar 3.40 bar 3.30 bar 3.50 bar

Min./max. starting air pressure

10 bar / 30 bar

Air consumption per start (warm engine)

1.2 m3

Max. permissible crankcase pressure

15 mmWC

Intake vacuum upstream of compressor

max. permissible: 150 mmWC

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

51

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II 500 kW/cyl. Air requirement (ta = 20 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

34730 m3/h 34700 m3/h 48000 m3/h 47500 m3/h

Compressor end temperature (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

213 °C 218 °C 215 °C 222 °C

Compressor end temperature (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

246 °C 252 °C 248 °C 256 °C

Cooling water Content of expansion tank 12 M 32 C .................................................. 16 M 32 C ..................................................

0.7 m3 1.0 m3

Water content of the engine 12 M 32 C .................................................. 16 M 32 C ..................................................

1.4 m3 1.9 m3

Min./max. FW pressure at engine inlet

2.5 / 6.0 bar

FW temperature at charge air cooler inlet

38 °C

FW temperature downstream of the engine

80 - 90 °C

Required FW volume for charge air cooling 12 M 32 C .................................................. 16 M 32 C ..................................................

80 m3/h 100 m3/h

Lubricating oil Lubricating oil operating pressure at engine

4 - 5 bar

Temperature upstream of the engine

60 - 65 °C

Mesh size of duplex filter

0.08 mm

Mesh size of automatic filter

0.03 mm

Lubricating oil consumption at full load

0.6 ± 0.3 g/kWh

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

52

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II 500 kW/cyl. Lubricating oil circulation tank / dry sump Content 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

7.6 m3 8.0 m3 10.0 m3 10.8 m3

Exhaust gas Max. exhaust gas resistance after turbine

0.03 bar

NOx emission (Marpol 73/78 Annex VI Cycle E2, D2)

9 g/kWh

NOx (diesel) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.26 g/m3 (15 % O2) 1.22 g/m3 (15 % O2)

NOx (diesel) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

9.41 g/kWh 9.08 g/kWh

NOx (HFO) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.39 g/m3 (15 % O2) 1.33 g/m3 (15 % O2)

NOx (HFO) Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

10.35 g/kWh 9.99 g/kWh

CO Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

0.05 g/m3 (15 % O2) 0.055 g/m3 (15 % O2)

CO Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

0.32 g/kWh 0.36 g/kWh

HC

0.11 g/m3 (15 % O2)

HC Rated speed 720 rpm ......................... Rated speed 750 rpm .........................

1.07 g/kWh 1.10 g/kWh

Exhaust gas mass at 100 % (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

40800 kg/h 42678 kg/h 59116 kg/h 58492 kg/h

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

53

m

Engineer’s Handbook Engine Data / Engine Operating Data

M 32

c2

VM 32 C EPG WB II 500 kW/cyl. Exhaust gas mass at 100 % (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

40800 kg/h 40265 kg/h 55770 kg/h 55200 kg/h

Exhaust gas temperature at 100 % (ta = 25 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

304 °C 297 °C 294 °C 291 °C

Exhaust gas temperature at 100 % (ta = 45 °C) 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

322 °C 315 °C 312 °C 309 °C

Exhaust gas temperature after turbine 25 °C intake temp., rel. air humidity 60 % 12 M 32 C (720 rpm) ............................... 12 M 32 C (750 rpm) ............................... 16 M 32 C (720 rpm) ............................... 16 M 32 C (750 rpm) ...............................

304 °C (tolerance: 10 %) 297 °C (tolerance: 10 %) 294 °C (tolerance: 10 %) 291 °C (tolerance: 10 %)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

54

m

Engineer’s Handbook Firing Orders / Valve Timing

M 32

c2

Firing Orders / Valve Timing Firing orders 6 M 32 / 6 M 32 E

8 M 32 / 8 M 32 E

9 M 32

9 M 32E

12 M 32

16 M 32

clockwise

1-3-5-6-4-2

counter-clockwise

1-2-4-6-5-3

clockwise

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

counter-clockwise

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

clockwise

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

counter-clockwise

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

clockwise

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

counter-clockwise

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

clockwise

1-3-5-6-4-2

counter-clockwise

1-2-4-6-5-3

clockwise

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

counter-clockwise

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

Valve timing The indicated values are applicable for 75 mm roller diameter and 0.4 mm roller clearance RM 32 Exhaust opens: 60° CA before BDC Inlet opens: 53° CA before TDC

Exhaust closes: Inlet closes:

53° CA after TDC 40° CA after BDC

VM 32 Exhaust opens: 60° CA before BDC Inlet opens: 55° CA before TDC

Exhaust closes: Inlet closes:

55° CA after TDC 45° CA after BDC

RM 32 IMO I Exhaust opens: 40° CA before BDC Inlet opens: 45° CA before TDC

Exhaust closes: Inlet closes:

45° CA after TDC 5° CA after BDC

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

55

m

Engineer’s Handbook Firing Orders / Valve Timing

M 32

c2

VM 32 IMO I Exhaust opens: 45° CA before BDC Inlet opens: 45° CA before TDC

Exhaust closes: Inlet closes:

45° CA after TDC 15° CA after BDC

8 M 32 IMO I 480 kW/cyl. Exhaust opens: 40° CA before BDC Inlet opens: 45° CA before TDC

Exhaust closes: Inlet closes:

45° CA after TDC 5° CA after BDC

8 + 32 M 1 IMO 440 kW/cyl. Exhaust opens: 60° CA before BDC Inlet opens: 38° CA before TDC

Exhaust closes: Inlet closes:

53° CA after TDC 40° CA after BDC

RM 32 C IMO II (also CCR) Exhaust opens: 40° CA before BDC Exhaust closes: Inlet opens: 47.5° CA before TDC Inlet closes:

47.5° CA after TDC 19.9° CA before BDC

VM 32 C IMO II Exhaust opens: 40° CA before BDC Inlet opens: 50° CA before TDC

Exhaust closes: Inlet closes:

50° CA after TDC 10° CA before BDC

8 M 32 with FCT Full load: Exhaust opens: 40° CA before BDC Exhaust closes: 50° CA after TDC Inlet opens: 50° CA before TDC Inlet closes: 5° CA after BDC

Part load: Exhaust opens: Exhaust closes: Inlet opens: Inlet closes:

57° CA before BDC 33° CA after TDC 33° CA before TDC 22° CA after BDC

RM 32 C IMO II with FCT (also CCR) FCT position NORMAL: Exhaust opens: 40° CA before BDC Exhaust closes: 47.5° CA after TDC Inlet opens: 47.5° CA before TDC Inlet closes: 20° CA before BDC

FCT position EARLY: Exhaust opens: 40° CA before BDC Exhaust closes: 47.5° CA after TDC Inlet opens: 30.5° CA before TDC Inlet closes: 3° CA before BDC

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

56

m

Engineer’s Handbook Firing Orders / Valve Timing

M 32

VM 32 C IMO II with FCT FCT position NORMAL: Exhaust opens: 40° CA before BDC Exhaust closes: 50° CA after TDC Inlet opens: 50° CA before TDC Inlet closes: 10° CA before BDC

c2

FCT position EARLY: Exhaust opens: 40° CA before BDC Exhaust closes: 50° CA after TDC Inlet opens: 33° CA before TDC Inlet closes: 7° CA after BDC

6 + 9 M 32 IMO I, DNV Clean Design Exhaust opens: 40° CA before BDC Exhaust closes: Inlet opens: 45° CA before TDC Inlet closes:

45° CA after TDC 10° CA before BDC

6 + 9 M 32 MEK 440 kW/cyl. Exhaust opens: 60° CA before BDC Inlet opens: 53° CA before TDC

Exhaust closes: Inlet closes:

53° CA after TDC 40° CA after BDC

RM 32 CCR Exhaust opens: 40° CA before BDC Inlet opens: 45° CA before TDC

Exhaust closes: Inlet closes:

45° CA after TDC 5° CA after BDC

VM 32 C IMO I, DNV Clean Design Exhaust opens: 45° CA before BDC Inlet opens: 45° CA before TDC

Exhaust closes: Inlet closes:

45° CA after TDC 5° CA before BDC

VM 32, VM 32C EPG Exhaust opens: 45° CA before BDC Inlet opens: 55° CA before TDC

Exhaust closes: Inlet closes:

45° CA after TDC 15° CA after BDC

RM 32 CCR (IMO II) 480 kW/cyl. and 500 kW/cyl. Exhaust opens: 40° before BDC Exhaust closes: Inlet opens: 47.5° before TDC Inlet closes:

47.5° after TDC 20° before BDC

6 + 9 M 32 IMO 480 kW/cyl. (fixed-pitch propeller) Exhaust opens: 40° CA before BDC Exhaust closes: Inlet opens: 50° CA before TDC Inlet closes:

50° CA after TDC 5° CA after BDC

6 + 8 M 32 E 550 kW/cyl. Exhaust opens: 45° CA before BDC Inlet opens: 45° CA before TDC

45° CA after TDC 15° CA before BDC

Exhaust closes: Inlet closes:

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

57

m

Engineer’s Handbook Firing Orders / Valve Timing

M 32

6 + 8 M 32 E 550 kW/cyl. with FCT FCT position NORMAL: Exhaust opens: 45° CA before BDC Exhaust closes: 45° CA after TDC Inlet opens: 45° CA before TDC Inlet closes: 15° CA before BDC

c2

FCT position EARLY: Exhaust opens: 45° CA before BDC Exhaust closes: 45° CA after TDC Inlet opens: 28° CA before TDC Inlet closes: 2° CA after BDC

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

58

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Dimensions and Weights

Designation

Length mm

Width mm

Height mm

Weight kg

Engine block: (without studs, with bearing caps and bearing bolts) 6 M 32

3,972

1,550

1,885

11,800

8 M 32

5,032

1,550

1,885

14,600

9 M 32

5,562

1,550

1,885

16,450

12 M 32

4,891

2,415

2,150

22,600

16 M 32

6,241

2,415

2,150

27,500

Crankshaft with balance weights: 6 M 32

3,920

4,795

8 M 32

4,980

6,020

9 M 32 (12 balance weights)

5,510

6,170

12 M 32

4,839

6,236

16 M 32

6,189

8,450

Crankshaft without balance weights: 6 M 32 C

3,920

3,175

6 M 32 E

3,920

3,031

8 M 32 C

4,980

3,920 or 4,400

8 M 32 E

4,980

3,910

9 M 32 C

5,510

4,299 to 4,550

9 M 32 E

5,510

4,320

12 M 32 C

4,839

3,750 to 4,320

16 M 32 C

6,189

4,990 to 5,580

Oil pan: 6 M 32

4,069

1,158

474

777

8 M 32

5,129

1,158

474

957

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

59

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Length mm

Width mm

Height mm

Weight kg

9 M 32

5,659

1,158

474

1,045

12 M 32

4,986

1,338

453

985

16 M 32

6,336

1,338

453

1,213

0.00.6-41.80.00-01 (GEA)

1486

530

676

450

0.00.6-41.80.00-02 (GEA)

1486

530

676

450

0.00.6-41.80.00-12 (GEA)

1262

530

676

360

0.00.6-41.80.00-13 (GEA)

1160

530

676

400

0.00.6-41.80.00-16 (GEA)

2099

536

716

1100

0.00.6-41.80.00-20 (GEA)

2099

536

716

1200

0.00.6-41.80.00-38 (Vestas)

1280

720

870

949

0.00.6-41.80.00-43 (GEA)

1262

530

676

n.s.

0.00.6-41.80.00-44 (GEA)

1262

530

676

401

0.00.6-41.80.00-69 (Vestas)

1282

720

870

678

0.00.6-41.80.00-74 (Vestas)

1283

500

693

495

0.00.6-41.80.00-78 (GEA)

1281

510

694

485

0.00.6-41.80.00-79 (GEA)

1281

510

694

484

6 M 32

200

Ø 900

811

8 M 32

200

Ø 1000

1,022

9 M 32

200

Ø 900

806

Ø 800 Ø 800 Ø 800

290 350 275

200

Ø 1025

1,080

6 M 32

62

Ø 330

29

8 M 32

62

Ø 330

29

9 M 32

85

Ø 400

62

Designation

Charge air cooler:

Crankshaft vibration damper:

VM 32 0.00.6-63.13.00-38 0.00.6-63.13.00-39 0.00.6-63.13.00-44 16 M 32 Camshaft vibration damper:

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

60

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Width mm

Height mm

Weight kg

62

Ø 330

29

Driving end

32.85

Ø 408

4.0

To crankshaft bearing 2

23.85

Ø 457

4.0

Cylinder liner

Ø 433

908 - 982

246 - 280

Crankshaft bearing M 32

122

Ø 318

10.7

Crankshaft bearing VM 32

122

Ø 358

9.45

23.85

Ø 410

3.0

Designation

Length mm

12 M 32 16 M 32 Thrust washer VM 32:

Thrust washer M 32 Automatic filter Boll & Kirch type 6.48 DN 125

544

415

852

205

Balance weight

650

98

348

128.3

660

98

325

124.1

623

98

326

128.6

1,045

108

351

198

1,075

108

380

217

880

110

385

199

1,034

105

336.5

198

944

114

348

217

841.5

114

380

199

910 to 1,045

1,008 to 1,238

836 to 875

792 to 1,130

2,238

1,140

1,940

Balance weight RM 32 E

Balance weight VM 32

Charge air cooler casing RM 32 Charge air cooler casing VM 32 Charge air cooler casing RM 32 E 3200.7-72.87.01-01 (free end)

approx. 1,511

923

889

1,030

3200.7-72.87.01-02 (driving end)

approx. 1,503

923

approx. 929

1,156

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

61

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Designation

Length mm

Width mm

Height mm

Inlet casing 6 M 32

Weight kg 220

Inlet casing 8+9 M 32

240 to 320

Inlet casing 6 M 32 C (driving end)

218 to 287

Inlet casing 6 M 32 C (free end)

328

Inlet casing VM at TPL65

960 to 986

Inlet casing VM at NA297

975

Turbocharger bracket VM 32 (driving end)

1,108

1,960

1,135

1,800

Turbocharger bracket VM 32 (-02)

1,010

1,962

1,305

1,600

FCT adjusting unit VM 32

365

Gear on crankshaft Camshaft section

133 440

Ø 460

82

Ø 282

59.1

Camshaft bearing

60

Ø 240

2.8

Camshaft end bearing

124

Ø 288

7.2

Bearing journal

90

Ø 225

22

Bearing journal VM 32

135

Ø 225

33

Bearing journal VM 32 (A)

204

Ø 225

51

Bearing journal VM 32 (B)

233

Ø 225

59

End bearing journal

252

Ø 225

62

End bearing journal VM 32 (A)

335

Ø 225

98

End bearing journal VM 32 (B)

364

Ø 225

107

Camshaft gear RM 32

110

Ø 900

335

Camshaft gear RM 32 (tilt application)

110

Ø 900

485

Camshaft gear (complete with hub)

100

Ø 900

487

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

62

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Designation

Length mm

Width mm

Height mm

CCR high-pressure pumps with gear casing 1.90.7-64.80.00-06

Weight kg

392

CCR gear

110

Ø 900

470

Gear, pump drive

45

Ø 486

28

Pump gear support RM 32

104

Ø 448

90

177.5

Ø 448

171

Intermediate ring 6 M 32 C

90

Ø 448

80

Pump gear support VM 32 C

138

Ø 448

127

Intermediate gear M 32

120

Ø 450

126.1

Intermediate gear VM 32

120

Ø 556

205

Pump gear support 6 M 32 C + VM

Intermediate gear shaft M 32

370

Ø 122

31.2

Intermediate gear shaft VM 32

342

Ø 125

25

Cover f. timing gear casing (RM 32 E) 1.90.7-51.15.01-02

1035

252

153

34

Cylinder head with inlet and exhaust valves

846 or 854

539

395

345

Cylinder head without inlet and exhaust valves with guides

846 or 854

539

395

300

203

Ø 75

Rocker arm shaft

267

Cooling collar Piston pin Small-end bush 1.90.7-28.10.03-01 / -04 / -05 1.90.7-28.10.03-08

134 to 153

264

Ø 150

33.3

Ø 153 Ø 153

168 168

4.2 4.3

Ø 320

Piston, composite Piston with connecting rod

7

500

1,568

115.4 393

Connecting rod M 32

1,351

236

Connecting rod VM 32

1,382

241

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

63

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Width mm

Height mm

Weight kg

Connecting rod small end M 32

150

330

38

Connecting rod small end VM 32

150

350

41

Designation

Length mm

Ø 293

Big-end bearing (RM and VM) Pump mounting plate 1,130

1,115

195

1,275

1,355

340

1,208

1,160

253

Flywheel rim RM 32

170

Ø 1,439

1,396 to 1,414

Flywheel rim VM 32

170

Ø 1,439

1,342 to 1,404

1.90.7-63.10.00-02

Flywheel hub

278

Ø 680

371

Turbocharger: Napier NA 295

590

Napier NA 355

700

Napier NA 297

777

Napier NA 357

1427

ABB TPL65 or TPL65-A

890

1545

870

1230

ABB TPL67 or TPL67-C

1120

1820

890

1330

ABB TPS61

725

1566

850

680

ABB A145

740

1570

900

750

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

64

m

c2

Engineer’s Handbook Dimensions and Weights

M 32

Oil filling quantities for wet sump pans

Engine

Min. oil level (dipstick)

Max. oil level (dipstick)

Min. oil level alarm (sensor)

Max. oil level alarm (sensor)

6 M 32

2300 l

not applicable

8 M 32

2900 l

not applicable

9 M 32

2750 l

3190 l

1350 l

not applicable

Oil filling quantities for diesel generator sets on base frames Engine

Min. oil level (dipstick)

Max. oil level (dipstick)

Min. oil level alarm

Max. oil level alarm

6 M 32

3170 l

3920 l

2380 l

4420 l

8 M 32

3600 l

4450 l

2700 l

4960 l

9 M 32

4490 l

5560 l

3370 l

6250 l

7200 l

10890 l

12 M 32 16 M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

65

m

Engineer’s Handbook Engine Block

M 32

c2

Engine Block Covering, crankcase doors, caps Slightly grease only flat gaskets before inserting them. For caps without gasket use Dirko universal sealing compound No. 610.020 (grey). Insert stud bolts DIN 976 - M16 - B - 8.8 and studs DIN 835 - M16 - 8.8 with ⇒ M = 40 Nm Dry, without lubricant Insert studs DIN 939 M20 - 8.8 with ⇒ M = 150 Nm Molykote

Main bearing studs See chapter “Main Bearings”

Lubricating oil nozzles for timing gear train See chapter “Timing Gear Train”, section “Lubricating oil nozzles for timing gear train”

Tightening torques for screw plugs See “General Part” of the Engineer’s Handbook, chapter “General Assembly Instructions”, section “Tightening torques for screw plugs”

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

66

m

c2

Engineer’s Handbook Engine Block

M 32

Crankcase door with relief valve Tighten screws (1) at relief valve 162 EVA with

⇒

M = 24.5

Nm.

Tighten screws (2) at relief valve 150 EVS with

⇒

M = 25

Nm

Tighten screws (3) at relief valve 150 EVO with Molykote

⇒

M = 25

Nm

Tighten screws (3) at relief valve 150 EVN with

⇒

M = 24.5

Nm

Tighten screws (4) at relief valve 150 EVO with Molykote

⇒

M = 25

Nm

In case of relief valves with protecting caps (5): Before mounting the O-ring (16) cover the M12 thread (Y) and Ø12 shank of guide bolt (6). Lubricate the guide at X with Molykote Paste G and check the valve for ease of movement. Tighten screws (7) at relief valve FBD135* (8) from the inside with ⇒ M = 25 Nm Loctite 243 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

67

m

c2

Engineer’s Handbook Engine Block

M 32

* Manufacturer: Taizhou Saite Flow Control Co. Ltd, China

Cover for timing gear train (RM 32 E) Insert studs M16x45 (15) with Molykote G Rapid Plus Tighten nuts M16 (14) with Molykote G Rapid Plus

⇒

M = 40

⇒

M = 130 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

68

m

c2

Engineer’s Handbook Engine Block

M 32

Installation of bearing bushes Cool the bearing bush (1) with liquid nitrogen down to and insert it so as to be flush with the engine block.

⇒

-195 °C

Cool the bearing bush (2) with liquid nitrogen down to and insert it so as to be flush with the engine block.

⇒

-195 °C

Reference dimension of the bush after pressing-in, Ø

⇒ 120 + 0.048 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

69

m

c2

Engineer’s Handbook Cylinder Head

M 32

Cylinder Head Removing and installing the cylinder head Removal: Before loosening the cylinder head nuts remove the complete rocker arm bracket, because otherwise the sleeve of the hydraulic tool will not fit between the rocker arms. After that, screw the nuts onto the studs for rocker arm bracket fastening again to avoid damaging their threads by the chains of the hoist. Installation: Insert the studs into the engine block with a torque of ⇒ Molykote (M 32 + VM 32) Oil (M 32 C + VM 32 C) Do not damage the stamps and numbers when inserting the studs.

M = 250

Nm

RM and VM up to 500 kW/cyl.* 1. Pretighten the round nuts with a pin so as to be finger tight. 2. Stretch all six studs jointly with ⇒ P = 850 - 25 bar and tighten the round nuts with a pin. In doing so, pay attention to ease of movement. Molykote The pressure must remain constant when the pump is not actuated, otherwise there will be a tightening fault. Hydr. tightening device: 1.90.7-92.03.00-01 Piston area: 66 cm2 (* except (to date): Engines of BC Ferries) RM 550 kW/cyl. and VM 530/560 kW/cyl. 1. Pretighten the round nuts with a pin so as to be finger tight. 2. Stretch all six studs jointly with ⇒ P = 900 - 25 bar and tighten the round nuts with a pin. In doing so, pay attention to ease of movement. Molykote The pressure must remain constant when the pump is not actuated, otherwise there will be a tightening fault. Hydr. tightening device: 1.90.7-92.03.00-01 Piston area: 66 cm2

Check: Decrease the pressure by 50 bar. Loosening of the round nuts by means of a pin must not be possible any more. If the cylinder head nuts cannot be loosened at the prescribed pressure, the pressure can be increased by 50 bar. Do not increase the pressure any further, because this may stretch the thread and, therefore, jam the nuts. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

70

m

Engineer’s Handbook Cylinder Head

M 32

c2

Check for leaks at the cylinder head At control bore (1) leaks between cylinder head, anti-polishing ring, and cooling collar can be identified.

Lifting the cylinder head M16 threads (2) are used for receiving the cylinder head lifting device

Differences between M 32 and M 32 C Some changes have been implemented on the M 32 C/ VM 32 C cylinder head. The most important changes are the following: 1. The cast-on exhaust gas flange 2. The guide bolts are freeze fitted. 3. The rocker arm shaft is straight. 4. The valve cover has changed. 5. There is only one spring per valve. It is possible to use M 32 C cylinder heads on M 32 engines.However, consultation with Customer Service is required.

Rocker arm bracket (M 32) Each time the cylinder head is removed, check parallel pin (3) for damage and replace it if necessary. Insert studs (1) with Oil

⇒

M = 150 Nm

Tighten nuts (2) with Molykote

⇒

M = 300 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

71

m

c2

Engineer’s Handbook Cylinder Head

M 32

Rocker arm bracket (M 32 C) Insert 4 studs (3) with Oil

⇒

M = 150 Nm

Tighten 4 nuts (4) with Molykote

⇒

M = 300 Nm

Each time the cylinder head is removed, check parallel pin (5) for damage and replace it if necessary.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

72

m

c2

Engineer’s Handbook Cylinder Head

M 32

Rocker arms When freeze fitting new ball pins pay attention to an accurate position (1) to ensure proper oil supply. (Cool down to -195 °C with nitrogen). Before pressing-in coat the bushes lightly with oil, do not use Molykote. When pressing-in the bushes pay attention to the position of the joint and the holes. Reference dimension Ø

Reference dimensions for the bushes Straight rocker arm for “banana-shaped” rocker arm shaft (inlet and exhaust): Ø reference dimension after pressing-in

⇒ 74.99 + 0.112 mm

Slanting rocker arm for straight rocker arm shaft (inlet and exhaust): Ø reference dimension after pressing-in

⇒ 74.99 + 0.12

mm

After pressing-in the bushes shall recede by

⇒ 0.20 - 0.30

mm

Radial clearance Clearance in new condition

⇒

0.02 - 0.15

mm

Limit clearance

⇒

0.25

mm

Valve clearance On a warm engine (shut down for at least 15 minutes) Inlet

⇒

0.40 + 0.10

mm

Exhaust

⇒

1.10 + 0.10

mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

73

m

c2

Engineer’s Handbook Cylinder Head

M 32

Adjustment of the valve bridges with respect to the valve spindles Adjust clearance “S” on a warm engine (shut down for at least 15 minutes). 1. Open the indicator valves. Bar the piston of the cylinder to be adjusted to ignition TDC. Inlet and exhaust valves are closed, rocker arms are relieved. 2. Relieve the valve bridge from the load caused by the rocker arm. Increase clearance S between rocker arm and valve bridge and/or fold back the rocker arm. 3. Loosen locknut (3) of the valve bridge and unscrew adjusting screw (2) so as to obtain zero-clearance contact at X. 4. At this position of the valve bridge screw in the adjusting screw (2) so as to obtain zeroclearance contact at Y. Do not tilt the valve bridge. 5. Hold adjusting screw (2) and tighten locknut (3) with

⇒

M = 150 Nm

6. Check for zero clearance at X and Y with a 0.02 mm feeler gauge. After that, adjust the valve clearance S in accordance with the relevant instructions. 7. Tighten nut (4) with and check clearance S once more.

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 250 Nm

74

m

c2

Engineer’s Handbook Cylinder Head

M 32

Valve guides Drive out the old valve guides by means of removal drift 9.2181A. Cool the valve guides down to -195 °C and insert them into the cylinder head. Measure the diameter of the valve stem in the guided area. Measure the guide in transverse direction of the engine. See also section “Oversize steps for valve seat inserts and valve guides” for further information. Normal clearance Inlet

⇒

0.11 - 0.17

mm

Exhaust

⇒

0.18 - 0.24

mm

Limit clearance Inlet M 32 C

⇒

0.25

mm

Inlet RM 32 + VM 32

⇒

0.3

mm

Exhaust

⇒

0.35

mm

Sealing caps When installing the sealing caps, make sure that the sealing surfaces of the caps and the corresponding holes are clean and free of grease. Coat the sealing surfaces with Loctite 270. Use the provided drive-in mandrel for installation. The sealing cap edges must be located 1.5 + 0.5 mm deep in the cylinder head.

Screw plugs Tighten screw plugs G1/2A with High-temperature paste

⇒

M = 60

Nm

Tighten screw plugs DIN 906 M10x1 with Molykote

⇒

M = 20

Nm

Tighten screw plugs DIN 908 M10x1 with Hylomar * Caution! For variant 1.90.7-21.07.00-27 (CCR) tighten this screw plug with Hylomar Caution! One of these screw plugs is located in the indicator hole. Tighten this screw everywhere with High-temperature paste

⇒

M = 30

Nm

⇒

M = 20

Nm

⇒

M = 30

Nm

Tighten screw plugs M33x2 with Hylomar

⇒

M = 200

Nm

Tighten screw plugs M42x2 with Hylomar *

⇒

M = 300

Nm

Tighten screw plugs M52x2 with Hylomar *

⇒

M = 400

Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

75

m

Engineer’s Handbook Cylinder Head

M 32

c2

* For HFO engines insert the screw plugs (52), (94), (95) and (97) that are indicated below with a light coat of oil. For tightening torques of screw plugs not indicated here, see “General Part” of the Engineer’s Handbooks, chapter “General Assembly Instructions”, section “Tightening torques for screw plugs”

O-rings Apply a thin coat of Petro Gel Amber to the O-rings and insert them into the cylinder heads untwisted.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

76

m

c2

Engineer’s Handbook Cylinder Head

M 32

Fuel injector (M 32 C) Tighten the nozzle nut (1) with Oil

⇒

M = 350 Nm

Screw in studs (2) with Oil

⇒

M = 40

Tighten the sleeve (3) for the fuel injector with Apply Loctite 510 to thread and sealing face.

⇒

M = 300 Nm

⇒

M = 60

Pretighten nuts (4) evenly by hand (without tool). Ensure flush fit of the flange to the nozzle holder and tighten in 2 steps with Molykote

Nm

Nm

O-ring 58 x 3.55 Viton

O-ring 58 x 3.55 Perbunan

Apply Loctite 510 to sealing face and thread here

No sealing ring here

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

77

m

c2

Engineer’s Handbook Cylinder Head

M 32

Fuel injector (M 32) Tighten the sleeve for the fuel injector with Loctite 510

⇒

M = 300 Nm

Tighten the nozzle nut (1) with Oil

⇒

M = 350 Nm

Insert studs (2) with Oil

⇒

M = 40 Nm

O-ring 58 x 3.55 Viton O-ring 58 x 3.55 Perbunan

Old design

Apply Loctite 510 to thread and sealing surface here

New design

Short

Long studs 2

Fuel injector - old design Caution! Insert the injector into the cylinder head without sealing ring. Insert studs (2) (see Fig. above) with Oil Pretighten nuts evenly by hand (without tool). Ensure flush fit of the flange to the nozzle holder and finally tighten in 2 steps with Molykote

⇒

M = 40 Nm

⇒

M = 40 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

78

m

Engineer’s Handbook Cylinder Head

M 32

c2

Removing and installing the fuel injector For removal screw threaded rod (1) with nut (2) onto setscrew (3). Then place the fixture with locking device (4) onto the threaded rod and studs and loosen the injector by turning nut (5). Clean the seat in the screwed-in sleeve with cleaning tool (6). When inserting the injector pay attention to the position of fixing pin (7). Mount the flange with spring dowel pin (8) towards exhaust gas side and with ring lug downwards.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

79

m

c2

Engineer’s Handbook Cylinder Head

M 32

Starting valve Tighten self-locking nut (1) with ⇒ M = 50 Nm Oil for HFO engines Molykote for non-HFO engines Tightening instruction also applies to the dummy valve at the B-bank of the VM 32. Reference dimension from top edge of nut to top edge of valve spindle ⇒ ≤ 7.5mm Cool the starting valve seat insert (2) with liquid nitrogen down to -195 °C and insert it into the cylinder head. No air gap is admissible at the lower contact surface of the starting valve seat insert. Grinding-in of starting valve seat inserts with the related valve spindle by hand using 10-15 µ grinding paste.

Reference dimension < 7.5 mm Reference dimension

< 7.5 mm

B-bank, VM 32

RM 32 and VM 32

Fuel injector delivery pipe Pre-tighten both sides with then tighten with Oil

⇒ ⇒

M = 80 Nm M = 150 ± 10Nm

Alternatively, tighten finger-tight and a further

⇒

25°

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

80

m

c2

Engineer’s Handbook Cylinder Head

M 32

Indicator valve and relief valve (RM 32 and VM 32) Insert studs (1) with ⇒ M = 50 Nm Molykote Pretighten nuts (2) so as to be finger tight. Then tighten alternately in 2 steps with ⇒ Dw = 30° Molykote Insert indicator valve (3) and relief valve (4) with high-temperature thread paste (such as Dag S 5080 Dt. Acheson).

Guide bolts for the valve bridges with thread Tighten the guide bolts with Loctite 243 without thread Cool the guide bolts down to with liquid nitrogen and insert them into the cylinder head.

⇒

M = 500 Nm

⇒

T = -195 °C

Valve bridges Cool thrust pieces (2) and (3) down to -195 °C with liquid nitrogen for inserting them. Insert and check expander (8) according to the instructions of the manufacturer and with the tools and tests specified by the manufacturer.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

81

m

c2

Engineer’s Handbook Cylinder Head

M 32

Valve rotators MDO operation:

On inlet and exhaust valves

HFO operation:

On inlet and exhaust valves

Regrinding hard-faced valve stems First, check whether the seat face is nitrided or hard faced. See below: Nitrided valve spindles. Using a syringe, evenly apply small dots ofdiamond paste (grain 10-15 µ) to the seat face of a new or refinished valve cone. Thereafter, for reasons of dilution and to increase the grip, spray the entire seat insert surface with a thinner (F25) belonging to the diamond paste. Insert the oiled valve stem into the guide bush. Fasten the device on the valve head and slightly grind valve cone and seat by hand for a short time applying a moderate pressure, turning the device to and fro. The percentage contact area made visible through the smooth grinding process shall, over the entire circumference, not exceed 30 % - 50 % of the seat width starting from the outside diameter. If a contact pattern as described above is not reached, remachining of both sealing surfaces is required. After machining, check both seats by means of an illuminated magnifying glass. Do not refinish the fillet. Round off the outside edge with a stone after machining. Measure height (Z) and angle (Y) of the hard facing. Desired values for Y and Z see table below: Inlet valve spindle

Exhaust valve spindle

Angle Y

Dim. Z

Angle Y

Dim. Z

29° 54’ ±3’ (HFO) or nitrided spindles (19° 54’ ±3’)

min. 1 mm

29° 54’ ±3’

min. 1.5 mm

Nitrided valve spindles Only check nitrided valve spindles with blue paste. It is by no means allowable to remachine valve spindles with nitrided seat! This would damage the nitriding layer and render the valve spindles unusable. Nitrided valve spindles can be identified by their changed marking: Instead of the hyphen, the letter “N” is inserted between engine code and variant. Example: 34N70 (nitrided) instead of 34-70 (hard faced). Nitrided valve spindles require valve seats that are different from those of hard-faced valve spindles! Therefore, do not change the combinations. A changeover from hard-faced to nitrided valve spindles thus also requires a change of the valve seats. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

82

m

c2

Engineer’s Handbook Cylinder Head

M 32

Checking inlet and exhaust valve spindles

Measuring distance:

⇒

389.80 mm

Eccentricity on the valve stem when measured over the above measuring distance and with supporting points at A and B shall not exceed

⇒

0.04

mm

Radial runout of the valve cone shall not exceed

⇒

0.03

mm

A valve spindle cannot be used any further when there is corrosive material erosion of of the head diameter.

⇒

>2%

Max. admissible projection of the valve spindle (check every 1,500 hours) see also below

⇒

> 3.0 - 3.5 mm

Valve spindles cannot be used any further when: 1. The valve seat face is damaged (cracks, blow-by) 2. There is severe pitting on the bottom side of the valve head (formation of so-called “paving stones) 3. There are corrosion pits and mechanical damage in the area of valve stem, stem transition, and valve head. 4. The limit for refinishing has been exceeded. 5. There is burnout S due to high-temperature corrosion on the bottom of the valve head exceeding 1.5 mm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

83

m

Engineer’s Handbook Cylinder Head

M 32

c2

Valve projection Due to valve and valve seat wear the valves are “growing” out of the cylinder head. Therefore, in order to determine possible premature wear upon • commissioning • installation of new or overhauled cylinder heads, and • replacement of valve spindles and seats • and every 1,500 operating hours thereafter measure the valve heights by means of a depth gauge and enter the measured values on the “Valve Projection” measuring sheet. The warning threshold/limit for valve projection on engines operated with distillate fuels is 3.0 mm - 4.0 mm. Valve seat inserts HFO engines: - Ultra-fine machining of the inlet and exhaust valve seats (seat inserts) with special tool. - Grinding-in of the inlet and exhaust valves with grinding paste (grain 10 - 15µ). - Check the contact surface: 30 - 50 % of the seat width on the outside. Non-HFO engines, exhaust valve seats: - Ultra-fine machining of the valve seats (seat inserts) with special tool. - Grinding-in of the valves with grinding paste (grain 10 - 15µ). - Check the contact surface: 30 - 50 % of the seat width on the outside. Non-HFO engines, inlet valve seats: - Ultra-fine machining of the valve seats (seat inserts) with special tool. - Caution! Do not use grinding paste on inlet valves! - Check the valve seat by means of blue paste: Contact on the outside, continuously all around. When refinishing the valve seats, make sure the dimensions stated in the sketches are observed. Dimension Ø X for the rework =107 + 0.2 mm. At a no material removal is permissible.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

84

m

c2

Engineer’s Handbook Cylinder Head

M 32

Inserting inlet and exhaust valve seats

In case of a first-time replacement of the seat inserts without rework thoroughly check the surface of the holes. Axial score marks and corrosion residues are not permissible. 1. Cool valve seat inserts down to -195 °C. 2. Insert the valve seat inserts. 3. When the valve seat inserts are firmly inserted, press them on with the pressing device. Tighten nut (1) of the pressing device with

⇒

Alternative procedure: Press valve seat inserts on with the hydraulic device applying⇒ 4. Check: For inlet valve seat inserts no air gap (2) is permissible between valve seat insert and cylinder head. For exhaust valve seat inserts an air gap (3) of is permissible.

⇒

M = 150 Nm F = 80

kN

0.6 + 0.5 mm

5. Pressure test of the cooling water chambers: 10 bar at 8 minutes. For non-HFO engines use water with ESSO Rustban 310 corrosion preventative. For HFO-engines use water with anticorrosion oil.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

85

m

c2

Engineer’s Handbook Cylinder Head

M 32

Oversize steps for valve seat inserts and valve guides INLET VALVE SEAT INSERTS for HFO (30° seat angle) Oversize to nom. dim.

Hole size

(if required)

Valve seat insert

mm

Ø D1 + 0.02

a1 + 0.2

Ø mm - 0.02

Variant

0.0

(112)

(50)

(112.13)

-09

0.5

112.5

50.2

112.63

-16

1.0

113

50.2

113.13

-17

1.5

113.5

50.2

113.63

-18

1.90.7-21.51.02-XX Notes

Oversize step for manufacture

INLET VALVE SEAT INSERTS for MDO (20° seat angle) Oversize to nom. dim.

Hole size

(if required)

Valve seat insert

mm

Ø D1 + 0.02

a1 + 0.2

Ø mm - 0.02

Variant

0.0

(112)

(50)

(112.13)

-10

0.5

112.5

50.2

112.63

-13

1.0

113

50.2

113.13

-14

1.5

113.5

50.2

113.63

-15

1.90.7-21.51.02-XX Notes

5



D

Oversize step for manufacture

…'

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

86

m

c2

Engineer’s Handbook Cylinder Head

M 32

EXHAUST VALVE SEAT INSERTS Hole sizes in the cyl. head

(if required)

Valve seat insert

1.90.7-21.51.03-XX

Ø D2 + 0.02

Ø D3 + 0.2

Ø D4 + 0.02

b1 + 0.2

Ø mm - 0.01

Variant

117

106.2

105

43

117.14

-29

117.5

106.7

105.5

43.2

117.64

-30

118

107.2

106

43.2

118.14

-31

118.5

107.7

106.5

43.2

118.64

-32

Notes

Oversize step for manufacture

5

5



E





ƒ

' ฀' '

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

87

m

c2

Engineer’s Handbook Cylinder Head

M 32

VALVE GUIDES Hole sizes in the cyl. head

Guide bush

1.90.7-21.23.01-XX

Ø d1 +0.025

Ø d2

Ø mm r6

Guide bush Drawing No.

(44)

(45)

(44)

-01 (exhaust) -02 (inlet)

44.5

45.5

44.5

-03 (exhaust) -04 (inlet)

45

46

45

-05 (exhaust) -06 (inlet)

45.5

46.5

45.5

-07 (exhaust) -08 (inlet)

Notes

Oversize step for manufacture

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

88

m

Engineer’s Handbook Cylinder Head

M 32

c2

Valve cover Mount the threaded bush (6) with palm grip (15) against the stopper and secure with Loctite 270. Observe the mounting position of the disc springs (9). Pay attention to the position of sealing ring (2).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

89

m

Engineer’s Handbook Piston

M 32

c2

Piston

Caution! Barring with piston removed (VM) On VM 32 there is a risk of collision of the connecting rods when barring the engine with piston removed. After removal of only one piston of a crank pin the engine cannot be barred any more by 360°. During barring there is a risk of shank division collision. Therefore, when barring always make sure that the shank divisions do not touch each other! If necessary, change the direction of rotation.

Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 Insert studs with into the piston crown.

⇒

Pretighten nuts crosswise with ⇒ Apply Molykote paste G-n Plus to threads and contact surfaces

M = 10 Nm M = 30 Nm

⇒

Dw = 250°

Check the screw-in torque of the studs with

⇒

M = 10 Nm

Pretighten nuts crosswise with

⇒

M = 30 Nm

After that, finally tighten the nuts with

⇒

Dw = 160°

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

⇒

M = 90 Nm

Tighten nuts with Loosen the nuts again.

Caution: Replace studs upon reassembly if the projecting length from crown contact surface exceeds 205.5 mm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

90

m

c2

Engineer’s Handbook Piston

M 32

Mahle 1.90.7-26.70.00-08 / 09 / 12 / 13 / 16 / 17 / 18 / 22 / 23 / 24 / 26 / 27 / 28 / 29 / 30 ⇒

M = 10

Nm

M = 100

Nm

Check the screw-in torque of the studs in the piston crown with ⇒

M = 10

Nm

Pretighten nuts crosswise with

⇒

M = 35

Nm

After that, finally tighten the nuts with

⇒

Dw = 90°

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

⇒

M = 100

Insert studs with into the piston crown.

Tighten nuts crosswise with ⇒ Apply Molykote Paste G-n Plus to threads and contact surfaces Loosen the nuts again.

Nm

Caution: The torque for checking does not correspond to the proper tightening torques and is no substitute for the mounting instructions. Caution: Replace studs upon reassembly if the projecting length from crown contact surface exceeds 129.5 mm.

Removal of Mahle 1.90.7-26.70.00-01 / 02 / 05 / 07 / 09 / 13 / 16 / 18 / 22 / 23 / 24 If for removal of the pistons the bolts at the shank division of the connecting rods are loosened, the connecting rod must be fixed at the balance weights. As the 8 M 32 and 9 M 32 engines (before engine No. 38723) are not equipped with a full set of balance weights, there are different retainers in the tool kit. The engines are equipped with anti-polishing rings located in the upper section of the cylinder liner. These rings must be removed before piston removal because their diameter is smaller than the diameter of the cylinder liner.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

91

m

c2

Engineer’s Handbook Piston

M 32

Mahle 1.90.7-26.70.00-19 / 20 / 21 / 31 Lubricate thread and contact surface of the stud with Molykote paste G-n Plus. Tighten the stud with ⇒ M = 300 Nm Loosen the stud again. Pretighten the stud with Continue to tighten the stud by Check: When applying a torque of further turning of the stud must not be possible.

⇒ ⇒ ⇒

M = 50 Nm Dw = 140° M = 300 Nm

Caution: The torque for checking does not correspond to the proper tightening torques and is no substitute for the mounting instructions. Caution: Replace studs upon reassembly if the projecting length from crown contact surface exceeds 146 mm. Weight to be kept: With mounted stud: Without stud

⇒ ⇒

131.9 ± 0.66 100.6 ± 0.57

kg kg

Mahle 1.90.7-26.70.00-25 Lubricate thread and head contact surface of the studs with Molykote paste G-n Plus. Insert studs with into the piston crown. Loosen the stud again. Pretighten the stud with Continue to turn the stud by Check: When applying a torque of further turning of the stud must not be possible.

⇒

M = 300 Nm

⇒ ⇒

M = 35 Nm Dw = 140°

⇒

M = 300 Nm

Caution: The torque for checking does not correspond to the proper tightening torques. Caution: Replace studs upon reassembly if the projecting length from crown contact surface exceeds 146 mm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

92

m

c2

Engineer’s Handbook Piston

M 32

MWH 1.90.7-26.70.00-06 Insert fixing pin (heavy-type dowel pin) into the piston crown. Coat the thread in the piston crown with engine lubricating oil. Coat the thread of the piston screw with graphite paste. Screw piston screws into the crown without jolts by applying a torque of ⇒ M = 50 Nm Spray piston crown and skirt with anticorrosion oil.

Mounting of the sliding piece in the piston skirt Insert the circlip into the piston skirt. Provide the sliding piece with supporting rings and compression spring. Insert the sliding piece from below, slide it on 25 mm against the spring pressure and hold it. Mount the circlip on the sliding piece. Grease the sealing ring and insert it into the piston skirt untwisted. Place the piston skirt on the crown. Grease thrust pieces as well as threads and contact surfaces of the nuts with graphite paste (Molykote paste HSC or Copaslip). Put on thrust pieces and nuts and tighten crosswise with Check the tightening torque of M = 50 Nm of the piston screws in the crown. Pretighten nuts crosswise with

⇒

M = 90

Nm

⇒

M = 25

Nm

After that, finally tighten the nuts with

⇒

Dw = 90°

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

⇒

M = 300 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

93

m

c2

Engineer’s Handbook Piston

M 32

Kolbenschmidt 1.90.7-26.70.00-34 / 35 (IMO I) Clearance between piston crown and skirt in new condition (nuts not tightened): Screw the studs into the piston crown with Lubricate thread and contact surface of the nuts with Molykote paste G-n Plus. Tighten nuts crosswise with Loosen the nuts again. Check proper fit of the studs in the crown with Tighten nuts crosswise with After that, continue to turn the nuts crosswise by

⇒

S = 0.30 - 0.34 mm

⇒

M = 50

⇒

M = 105 Nm

⇒ ⇒ ⇒

M = 50 Nm M = 20 Nm M = 120°

Check: When applying ⇒ in tightening direction the nuts must not turn any further.

Kolbenschmidt 1.90.7-26.70.00-36 / -37 (IMO II) Clearance between piston crown and skirt in new condition (nuts not tightened) Variant -36 Variant -37

M = 70

Nm

Nm

⇒ ⇒

S = 0.30 - 0.34 mm S = 0.38 - 0.42 mm

⇒

M = 50 Nm

⇒

M = 130 Nm

Loosen the nuts again. Check proper fit of the studs in the crown with Tighten nuts crosswise with

⇒ ⇒

M = 50 Nm M = 20 Nm

After that, continue to turn the nuts crosswise by

⇒

M = 90°

Screw the studs into the piston crown with Lubricate thread and contact surface of the nuts with Molykote paste G-n Plus. Tighten nuts crosswise with

Check: When applying ⇒ in tightening direction the nuts must not turn any further.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 85 Nm

94

m

c2

Engineer’s Handbook Piston

M 32

Use of the pistons The data of this table is not binding and intended to provide an overview only. Piston

RM 32

VM 32

Fuel

Max. power

IMO

Max. power

IMO

1.90.7-26.70.00-01

440

-

-

-

HFO

1.90.7-26.70.00-02

480

1

480

1

HFO

1.90.7-26.70.00-03

480

1

480

1

HFO

1.90.7-26.70.00-04

480

1

-

-

HFO

1.90.7-26.70.00-05

480

1

480

1

HFO

1.90.7-26.70.00-06

480

1

-

-

HFO

1.90.7-26.70.00-07

480

1

480

-

HFO

1.90.7-26.70.00-08

480

1

480

-

HFO

1.90.7-26.70.00-09

-

-

480

1

HFO

1.90.7-26.70.00-10

480

1

480

-

MDO

1.90.7-26.70.00-11

480

1

480

-

HFO

1.90.7-26.70.00-12

480

1

480

-

MDO

1.90.7-26.70.00-13

480

1

480

-

HFO

1.90.7-26.70.00-14

480

1

-

-

HFO

1.90.7-26.70.00-15

480

1

480

-

MDO

1.90.7-26.70.00-16

-

-

500

1

HFO

1.90.7-26.70.00-17

500

1

500

1

MDO

1.90.7-26.70.00-18

500

1

500

-

HFO

1.90.7-26.70.00-19

500

2

500

1+2

HFO

1.90.7-26.70.00-20

500

1

500

-

HFO + MDO

1.90.7-26.70.00-21

500

1

500

-

HFO

1.90.7-26.70.00-22

-

-

500

1

HFO

1.90.7-26.70.00-23

500

1

500

-

HFO + MDO

1.90.7-26.70.00-24

500

1

500

-

HFO

1.90.7-26.70.00-25

500

1

500

-

HFO

1.90.7-26.70.00-26

-

-

500

1

HFO

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

95

m

c2

Engineer’s Handbook Piston

M 32

Piston

RM 32

VM 32

Fuel

Max. power

IMO

Max. power

IMO

1.90.7-26.70.00-27

500

1

500

-

HFO

1.90.7-26.70.00-28

-

-

500

1

HFO

1.90.7-26.70.00-29

500

1

500

-

HFO

1.90.7-26.70.00-30

440

-

-

-

HFO

1.90.7-26.70.00-31

550

2

560

1+2

HFO + MDO

1.90.7-26.70.00-32

500

-

500

-

HFO

1.90.7-26.70.00-34

500

1

500

-

HFO

1.90.7-26.70.00-35

500

1

500

-

HFO + MDO

1.90.7-26.70.00-36

550

2

560

1+2

HFO

1.90.7-26.70.00-37

550

2

560

1+2

HFO + MDO

Removal If for removal of the pistons the bolts at the shank division of the connecting rods are loosened, the connecting rod must be fixed at the balance weights. As the 8 M 32 and 9 M 32 engines (prior to engine No. 38723) are not equipped with a full set of balance weights, the tool kit includes different retainers. The engines are equipped differently. The first engines were not equipped with an antipolishing ring (also referred to as flame ring). All subsequent engines are provided with an anti-polishing ring that is inserted in the upper part of the cylinder liner. The anti-polishing ring is smaller in diameter than the cylinder liner and must be removed before extracting the piston. Installation Arrange the ring joints alternately in the longitudinal axis of the engine and displaced by 120°. Oil pistons and piston rings well. Install the piston rings with the marking pointing upwards. Install the piston mounting device and tighten the clamping screw so that it can still be moved around the piston. Check this by turning the piston mounting device.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

96

m

c2

Engineer’s Handbook Piston

M 32

Weight tolerance when replacing connecting rod / piston In order to avoid any unbalance, the masses of piston / connecting rod must not differ excessively between the individual cylinder units. For tolerance data please refer to chapter “Connecting Rod”, section “Weight tolerance when replacing connecting rod / piston”.

Wear limits of the ring grooves (standard piston ring equipment) Groove

Piston ring height hR Nominal dimension

Groove height hN2 Wear limit

Limit clearance hN2 - hR

1

8 mm

8.45 mm*

0.5 mm*

2

6 mm

6.45 mm

0.5 mm

3

10 mm

10.20 mm

0.3 mm

* Values are applicable for HFO and MDO

hN1 = dimension in new condition hN2 = wear dimension

Wear limits of the ring grooves (Piston 1.90.7-26.70.00-01 / -02 / -05 / -07) Groove

Piston ring height hR Nominal dimension

Groove height hN2 Wear limit

Limit clearance hN2 - hR

1

8 mm

8.45 mm

0.5 mm

2/3

6 mm

6.45 mm

0.5 mm

4

10 mm

10.20 mm

0.3 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

97

m

c2

Engineer’s Handbook Piston

M 32

Piston, piston pin, small-end bush wear limits Min. clearance (new)

Max. clearance (new)

Limit clearance (wear)

Piston bosses A Piston pin C

0.06 mm

0.09 mm

0.15 mm

Small-end bush B Piston pin C

0.14 mm

0.24 mm

0.26 mm

Piston boss distance D Small-end bush width X

0.50 mm

1.10 mm

1.30 mm

Difference between

Measure the piston bosses A on both sides approx. 10 - 20 mm behind the circlip groove. To determine the end clearance use dimensions D and X

For further information on measuring and replacing the small-end bush, see chapter “Connecting Rod”, section “Small-end bush”. Gas oil and heavy fuel operation Ring groove

Ring

Drawing No.

1

Rectangular ring

1.90.7-26.17.01-01

2+3

Rectangular ring

1.90.7-26.17.01-02 *1

4

Bevelled-edge oil control ring

0.00.6-35.41.02-26 *2

*1 = *2 =

alternatively 1.90.7-26.17.01-03 old variant 0.00.6-35.41.01-23.3

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

98

m

c2

Engineer’s Handbook Connecting Rod

M 32

Connecting rod

Attention! Barring with piston removed (VM) On VM 32 there is a risk of collision of the connecting rods when barring the engine with piston removed. After removal of only one piston of a crank pin the engine cannot be barred any more by 360°. During barring there is a risk of shank division collision. Therefore, when barring always make sure that the shank divisions do not touch each other! If necessary, change the direction of rotation.

Shank division tightening instruction (RM 32) There are two connecting rod designs: The new design includes connecting rod bolts with a head and a threaded end, the old design has connecting rod bolts with two threaded ends and nuts at both ends. There are different shank division tightening instructions applicable to these designs. Shank division tightening instruction for old design: Measure unstretched bolt length Tighten the stud bolts crosswise with ⇒ Apply Molykote G Rapid plus to threads and contact surfaces

M = 230 + 25

Nm

Measure stretched bolt length and determine total elongation. Tightening is correct when total elongation

⇒

L = 0.27 - 0.30 mm

Shank division tightening instruction for new design: Mechanically tighten the stud bolts with ⇒ Apply Molykote G Rapid plus to threads and contact surfaces

M = 50

Nm

Mark zero position of the stud bolts to be able to check the torque angle later on. Tighten the stud bolts crosswise mechanically with

⇒

M = 230

Nm

Alternatively, tighten them with

⇒

P = 320

bar

Check: Tightening should correspond to a torque angle of approx. ⇒ (visual check).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Dw = 50° + 30°

99

m

c2

Engineer’s Handbook Connecting Rod

M 32

Shank division tightening instruction (VM 32) Tighten the stud bolts with ⇒ Apply Molykote G Rapid plus to threads and contact surfaces

M = 50

Nm

M = 230

Nm

P = 320

bar

Mark zero position of the stud bolts to be able to check the torque angle later on. Tighten the stud bolts crosswise mechanically with ⇒ Note: If 250 Nm are applied at (1), 230 Nm will be reached at (2). Alternatively, tighten them with

⇒

Check: Tightening should correspond to a torque angle of approx. ⇒ (visual check).

Dw = 50° + 30°

The figure below shows how to apply the tool for tightening the shank division bolts.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

100

m

Engineer’s Handbook Connecting Rod

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

101

m

Engineer’s Handbook Connecting Rod

M 32

c2

Differences between marine type connecting rods and standard connecting rods The following figures show the differences between a marine type connecting rod and a standard connecting rod:

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

102

m

Engineer’s Handbook Connecting Rod

M 32

c2

RM 32 - VM 32 - M 32 C Upper shank division For loosening and tightening bolts (2) with a torque wrench there is a wrench holding device to be fastened to the screws of the crankcase cover. Attention: Do not bar the engine while this support is mounted! Note: The connecting rods are marked with the respective cylinder number, do not interchange them! Top and bottom parts of the connecting rods may be interchanged in exceptional cases and upon consultation with the Technical Customer Service Support.

Piston pin and small-end bush wear limits The wear limits of piston pin and small-end bush are indicated in chapter “Piston”, section “Piston, piston pin, small-end bush wear limits”.

Evaluation of bearings Refer to the General Part of the Engineer’s Handbook for the evaluation of bearings.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

103

m

c2

Engineer’s Handbook Connecting Rod

M 32

Small-end bush Evaluation: The decisive criteria for assessing the small-end bush are basically the clearance limits indicated in chapter “Piston”, section “Piston, piston pin, small-end bush wear limits”. A small-end bush shall only be replaced when: > A clearance limit has been reached or > The clearance limit will probably be exceeded before the next overhaul or > There is mechanical damage such as severe score marks, crumbling or deep cavitation pits or > The small-end bush has reached an operating time of 60,000 hours. Removal: Attention: Small-end bushes on VM32 and VM32C delivered prior to 2005 may not be replaced. This work shall only be carried out by Caterpillar Kiel ([email protected]). In all other cases, the following applies: Do not press the small-end bush out of the connecting rod! Make the bush stress-free by sawing or milling at the point marked (1). Installation: Attention: Small-end bushes on VM32 and VM32C delivered prior to 2005 may not be replaced. This work shall only be carried out by Caterpillar Kiel ([email protected]). In all other cases, the following applies: Cool the small-end bush down to < -160 °C and push it into the small end. In doing so, make sure the oil holes are correctly positioned. Lateral projection must be the same on both sides. After reaching normal temperature, measure the small-end bush. The reference dimension after freeze fitting is Ø



150.144 + 0.076 mm

Attention: Oversize bushes may only be used after consultation with Technical Customer Service Support and by submitting photos and measuring values of the small-end bores.

Techn. revision: Feb.2018 Caterpillar confidential: yellow © 2018 Caterpillar Motoren GmbH & Co. KG - All rights reserved

104

m

c2

Engineer’s Handbook Connecting Rod

M 32

Tightening instruction for big-end bearing nuts (RM 32 + VM 32) There are two connecting rod bolt designs: The bolts of new design have a head and a threaded end, the bolts of old design have two threaded ends and nuts at both ends. There are different tightening instructions applicable to the two designs.

Big-end bearing nut tightening instruction for the old design: Measure unstretched bolt length. Tighten the round nuts with Molykote (hydraulic cylinder with 66 cm2 piston area)

⇒

P = 1200 + 25 bar

Decrease the pressure by 50 bar. Loosening of the round nuts must not be possible any more. Measure stretched bolt length and determine total elongation. Tightening is correct when total elongation ⇒

L = 1.5 - 1.6

mm

Big-end bearing nut tightening instruction for the new design: Observe the note for using connecting rod bolts (see below)! Mechanically pretighten the round nut at the pin side (operating side) with Then finally tighten both round nuts with Molykote (Use hydraulic cylinder with 66 cm2 piston area and hydraulic element, No. 0.9213 C)

⇒

M = 100 + 30 Nm

⇒

P = 1200 + 25 bar

Check: Decrease the pressure by 50 bar. Loosening of the round nuts must not be possible any more. Check the torque angle by means of the holes at the outer edge of the nuts: 5 holes minus half the hole distance = 225° - 22° Removal If the nuts cannot be loosened at the prescribed pressure, a pressure increase by 50 bar is possible. Do not increase the pressure any further, because otherwise the thread will get stretched, and this may cause jamming of the nut.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

105

m

c2

Engineer’s Handbook Connecting Rod

M 32

Tightening instruction for marine type connecting rods (VM 32 C, RM 32 E) Applies to connecting rods with lower shank division (variants 1.91.7-28.10.00-17, -18 -19) Note: In RM 32 E variant -18 is used. Tighten the stud bolts with Molykote



M = 100

Nm

For RM 32 E, see Operating Instructions, chapter “Maintenance”, Job Card A5.05.02.04.02.nn. For VM 32 C, see Operating Instructions, chapter “Maintenance”, Job Card A5.05.02.04.01.nn.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

106

m

Engineer’s Handbook Connecting Rod

M 32

c2

RM 32 - VM 32 - M 32 C Note for using connecting rod bolts For connecting rods with straight oil hole only use connecting rod bolts with the collar at 10 mm distance.

Straight oil hole

For connecting rods with oblique oil hole both types of connecting rod bolts may be used.

Oblique oil hole

If the connecting rod bolt with the collar at 20 mm distance were used in combination with the connecting rod with straight oil hole, the collar would block part of the oil hole. Big-end bearing For data on bearing evaluation see General Part of the Engineer’s Handbook. For fixation in the connecting rod and the big-end bearing cap the upper and lower shells of old design are provided with locating lugs. These lugs are oriented towards the operating side. In case of big-end bearing shells of newer design, only the lower shells have two lugs for fixation in the big-end bearing cap. Here the marking of both bearing shells must point towards operating side. Any lateral projection of the upper bearing shell must be identical on both sides.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

107

m

c2

Engineer’s Handbook Connecting Rod

M 32

Reference dimensions of the big-end bearings after proper tightening (Dimensions are applicable with fitted bearing shell measured in the bearing inside diameter with completely assembled connecting rod). Do not measure in the joint area of the bearing shells. Measure dimension B 5 degrees (or 30 mm on the circumference) away from the joints of the bearing shells in clockwise direction. For marine type connecting rod: Do not measure dimension A as shown below, but at right angle with respect to dimension B (5 degrees or 30 mm away from the centre axis). Crankshafts with 420 / 480 mm stroke New condition Big-end bearing bolts tightened to specification

Permissible reference dimensions of connecting rods that have already been in service, valid for installation of new big-end bearings Big-end bearing bolts tightened to specification Deformation in transverse direction

Deformation in direction of rod

Dim. A (mm)

Dim. B (mm)

Dim. A min. (mm)

Dim. B max. (mm)

Dim. A max. (mm)

Dim. B min. (mm)

280.25 + 0.05

A + 0.04 + 0.02

280.23

A + 0.13

280.33

A+ 0.03

Crankshafts with 460 mm stroke New condition Big-end bearing bolts tightened to specification

Permissible reference dimensions of connecting rods that have already been in service, valid for installation of new big-end bearings Big-end bearing bolts tightened to specification Deformation in transverse direction

Deformation in direction of rod

Dim. A (mm)

Dim. B (mm)

Dim. A min. (mm)

Dim. B max. (mm)

Dim. A max. (mm)

Dim. B min. (mm)

290.26 + 0.05

A + 0.04 + 0.02

290.24

A + 0.13

290.34

A+ 0.03

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

108

m

Engineer’s Handbook Connecting Rod

M 32

c2

Screw plugs Lubricate the screw plugs M22x1.5 (1) (see Fig. above) with Loctite 270 and screw into the connecting rod with 60 Nm.By means of a cross chisel apply three powerful strokes to the thread of the connecting rod, each staggered by 120° around the circumference. Apply the cutting edge of the chisel perpendicular to the thread and cause a significant deformation to the thread. Marking The connecting rod is marked with the engine number and the cylinder number. The big-end bearing cap is marked with the cylinder number only. The big-end bearing shell is marked with the cylinder number. All markings are on the operating side. Weight tolerance when replacing connecting rod / piston In order to avoid any unbalance, the masses of piston / connecting rod must not differ excessively between the individual cylinder units. To determine the mass per cylinder unit weigh the piston together with the connecting rod (without piston rings and without big-end bearing). Permissible weight deviation within the set for one RM 32: 2500 g Permissible weight deviation within the set for one VM 32: 2000 g When installing piston and connecting rod distribute them in such a way that the weights are increasing in the following cylinder sequence: 6 M 32:

5 2 1 6 4 3

8 M 32:

6 3 5 1 8 2 7 4

9 M 32:

1 9 8 2 7 3 6 4 5

12 M 32: 5A 5B 2A 2B 1A 1B 6A 6B 4A 4B 3A 3B 16 M 32: 6A 6B 3A 3B 1A 1B 8A 8B 7A 7B 2A 2B 4A 4B 5A 5B

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

109

m

c2

Engineer’s Handbook Cylinder Liner

M 32

Cylinder liner Permissible wedge shapes, canyons, scores, pockets Wedge (Wedge-shaped indentation over the entire circumference, originating from TDC of 1st piston ring and extending downward): Height ⇒ > 8.00 mm Depth * ⇒ > 0.03 mm Canyons (Individual deep blow-by grooves in the area of the 1st piston ring (TDC)): Max. number ⇒ 3 Length ⇒ > 8.00 mm Total width ⇒ > 4.00 mm Score marks (Severe vertical, linear friction marks running through the TDC area of the 1st piston ring): Number (In combination with other symptoms) ⇒ 3 Number (If score marks only are identified) ⇒ 19 (max.) Length ⇒ > 180.00 mm Depth ⇒ > 0.5 mm Pockets (Areal, irregular indentations): Number Length Width ** Depth *

⇒ ⇒ ⇒ ⇒

3 > 90.00 > 30.00 > 0.02

mm mm mm

Striping (Dark discoloration of the running surface with friction marks): (s-): Faintly visible striping, honing structure preserved ⇒ No action (s): Clearly visible striping, honing structure preserved ⇒ No action (s+): Impermissible, pronounced striping, honing structure locally destroyed ⇒ Action: Replace cylinder liner and ring package. If piston crown and anti-polishing ring are showing palpable material erosion, replace these components as well. Fretting formation (Unsightly but uncritical bearing pattern on the upper / lower fit): A rework of the fits or change of the cylinder liner is necessary if fretting occurs on more than 50 % of the surface of one of the main load areas with local material erosion > 0.5 mm and over the entire height of the respective fit. Remove slight friction rust with fine emery cloth and carefully smooth material build-up of uncritical friction rust marks. For illustrations about fretting formation please refer to the next page. * Probe radius r ≥ 3 mm ** In circumferential direction

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

110

m

c2

Engineer’s Handbook Cylinder Liner

M 32

Fretting formation: Figure showing the main load areas on the liner fits Main load area of the cylinder liner fits

Engine axis

Cylinder bore in engine block upper and lower liner fit respectively

Main load area

Uncritical

Radial fit, developed view.

Main load area

Engine axis

Engine axis

Schematic representation of critical and uncritical fretting marks

If more than 50 % of the surface of the main load area and local material erosion > 0.5 mm, then critical = rework of engine block and/or liner change required

Example photos of fretting marks on radial fits: Conditions see above!

Uncritical:

Critical:

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

111

m

c2

Engineer’s Handbook Cylinder Liner

M 32

RM 32 - VM 32 - M 32 C Pocket Wedge shape

Score mark

TDC 1st ring Canyon

Installation During installation make sure that marking (1) of the cylinder liner coincides with marking (2) of the cooling collar. Apply a thin coat of Petro Gel Amber to the O-rings and insert them into the grooves untwisted. Attention: On RM 32 engines and the B-side of VM 32 engines the marking points towards the driving end. On the A-side the cooling collar is turned by 180°, the marking on the cooling collar points towards the free end. Install the cylinder liner here with the marking pointing towards the free end. A wrongly inserted liner may cause extensive damage. Nominal dimensions and wear limits Nominal dimension of cylinder liner Ø dimension in new condition ⇒ Wear dimension of bore (entire cylinder running surface) ⇒ Nominal dimension of anti-polishing (calibration) ring New dimension (cleaned and in installed condition) ⇒

320.00 - 320.057 mm 320.50 mm

319.257 - 319.200 mm

Wear limit for anti-polishing ring Wall thickness must not be less than

⇒

7

mm

Wear limits for cylinder liner in the TDC area Wear limit

⇒

1.00

mm

Max. ovality

⇒

0.30

mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

112

m

c2

Engineer’s Handbook Cylinder Liner

M 32

VM 32 Check of the contact surface and rework Corrosion and friction rust in combination with frequent removal of the cylinder liner from the engine block may cause the cylinder liner to break off at point X. For this reason the following pages provide information on how to assess the condition of the cylinder liner and carry out a rework, if required.

Contact surfaces Schematic installation situation:

Cylinder liner

Cooling collar

Contact surface cylinder liner

Axial contact surfaces cylinder liner/ engine block Engine block

X

Contact surface engine block

Upper radial fit of the cylinder liner

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

113

m

c2

Engineer’s Handbook Cylinder Liner

M 32

VM 32 Evaluation chart for contact surfaces Figure 3 (Applies to engine block & cylinder liner)

Evaluation of the contact surfaces

Conspicuous areas of corrosive / abrasive attack of max. 10 % of the total contact surface up to a width of 7 mm proceeding from the inside diameter of the contact surface.

Conspicuous areas such as shown in fig. 1 are considered to be of no concern.

ma x.

m ax .7

Description of the contact surfaces of engine block and cylinder liner

7m m

Figure 2 (Applies to engine block & cylinder liner)

m m

Figure 1 (Applies to engine block & cylinder liner)

Conspicuous contact patterns of corrosive / abrasive attack of max. 25 % of the total contact surface up to a width of 7 mm proceeding from the inside diameter of the contact surface.

Critical contact patterns of corrosive / abrasive attack of more than 25 % of the total contact surface and / or more than a width of 7 mm proceeding from the inside diameter of the contact surface.

Material erosion is clearly palpable, but not more than 0.2 mm can be measured. Over the entire circumference of the contact surface there is still a continuous ridge of a min. width of 7 mm.

Material erosion is clearly palpable and more than 0.2 mm can be measured and / or Over the entire circumference of the contact surface there is no continuous ridge of a min. width of 7 mm. Critical contact patterns of the contact surfaces of cylinder liner and / or engine block as shown in fig. 3 must be immediately reworked.

Conspicuous contact patterns of the contact surfaces of cylinder liner and / or engine block as shown in fig. 2 are of no concern but require careful documentation and follow up.

Cylinder liners that have reached the wear limit of the contact surfaces (0.3 mm) must be replaced.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

114

m

c2

Engineer’s Handbook Cylinder Liner

M 32

VM 32 Contact surfaces: Required action

Rework

Figure 1 (Conspicuous areas) No

Figure 2 (Conspicuous contact patterns) No

Additional checks required

No

No

Follow upinspection

Normal maintenance interval

Reduced maintenance interval Another check of the same and one additional contact surface per bank is required at the next opportunity, however, latest during the next 7,500 hours maintenance. Before installing the cylinder liner clean the contact surfaces and smooth any possible material build-up.

Installation instructions

Before installing the cylinder liner clean the contact surfaces and smooth any possible material build-up.

Figure 3 (Critical contact patterns) Yes In this case, rework the damaged contact surface(s) immediately. Attention: All rework must to be carried out by an authorized CAT/MaK dealer. Yes Check the contact surfaces of all cylinders and rework if required. Normal maintenance interval

Before installing the cylinder liner clean the reworked contact surfaces.

VM 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

115

m

c2

Engineer’s Handbook Cylinder Liner

M 32

Determination of the rework variant Rework / new parts Variant 1 Engine block Contact surface

Variant 2

X

Variant 3

X

Variant 4

X

X

Engine block Upper fit

X X

Engine block Lower fit Cylinder liner Contact surface

Variant 5

X X

X

X

X

Cylinder liner Series production (part that has already been in use or new part)

X

X

Cylinder liner Special variant (new part)

X

Drawings needed for a rework Drawings Spacer ring

Alternative block manufacture

Variant 1

1.90.7-16.10.02-06/-07/-08

1.90.7-99.11.00-07

Variant 2

1.90.7-16.10.02-06/-07/-08

1.90.7-99.11.00-08

Variant 3

1.90.7-16.10.02-06/-07/-08

1.90.7-99.11.00-09 VM: 1.91.7-99.11.11-36 RM: 1.90.7-99.11.11-12

Variant 4

1.90.7-16.10.02-06/-07/-08

1.90.7-99.11.00-10 VM: 1.91.7-99.11.11-36 RM: 1.90.7-99.11.11-12

Cylinder liner rework

Cylinder liner New version

1.90.7-99.16.11-08

1.90.7-99.16.11-08

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

116

m

c2

Engineer’s Handbook Cylinder Liner

M 32

Drawings Spacer ring Variant 5

1.90.7-16.10.02-06/-07/-08

Alternative block manufacture

Cylinder liner rework

1.90.7-99.11.00-06 VM: 1.91.7-99.11.11-35 RM: 1.90.7-99.11.11-42

Cylinder liner New version VM: 1.90.799.16.11-07 RM: 1.90.799.16.11-10

Engineering drawings can be ordered via Parts Operations. Recommended rework tools can be enquired via Customer Support Service.

Replacement criterion The basis for deciding whether or not to replace a cylinder liner are the identified running characteristics of the piston rings. If no excessive wear and no traces of burning are visible on the running surface, the cylinder liner is suitable for further use.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

117

m

Engineer’s Handbook Cylinder Liner

M 32

c2

RM 32 - VM 32 - M 32 C Flame ring Engines 37002 to 37014 and 37019 to 37025 are equipped with a flame ring. This ring rests on the cylinder liner. Its diameter is smaller than that of the cylinder liner and it, therefore, must be removed before extracting the piston. The ring can be pressed out of its position by means of the tool shown below.

RM 32 - VM 32 Anti-polishing ring The diameter of this ring is smaller than that of the cylinder liner.It is located in the upper section of the cylinder liner. Remove this ring by means of device (1) shown below.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

118

m

Engineer’s Handbook Main Bearings

M 32

c2

Main bearings Evaluation of bearings For data on bearing evaluation see General Part of the Engineer’s Handbook. Tightening instruction (RM) At the locating bearing screw in the lateral bolts (3) with an O-ring sized 30 x 3.55. The bearing guide grooves are located on the right-hand side (operating side). 1. Insert studs (1) with ⇒ Molykote Do not damage the stamps and numbers when inserting the studs.

M = 500 Nm

2. Tighten round nuts (2) evenly by hand.

3. Insert studs (3) with ⇒ M = 150 Molykote Do not damage the stamps and numbers when inserting the studs.

Nm

4. Tighten round nuts (4) evenly by hand. 5. Tighten round nuts (4) on the operating side with ⇒ P = 150 + 50 bar Then tighten both round nuts (4) with ⇒ P = 650 ± 20 bar 2 Piston area of the hydraulic device = 66.0 cm Tighten both round nuts of one bearing block in one operation. Use the hydraulic device in accordance with drawing number 1.90.7-92.03.00-01. 6. Tighten round nuts (2) with ⇒ P = 1150 ± 20 bar 2 Piston area of the hydraulic device = 95.0 cm Tighten both round nuts of one bearing block in one operation. Use the hydraulic device in accordance with drawing number 1.90.7-92.03.00-01.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

119

m

c2

Engineer’s Handbook Main Bearings

M 32

Check (RM) Decrease the pressure by 50 bar. Loosening of the round nuts by means of a pin must not be possible any more. During the tightening process the pressure must remain constant when the pump is not operated, otherwise there will be a tightening fault. If the nuts of the lateral and main bearing bolts cannot be loosened at the prescribed pressure, a pressure increase by P = 50 bar is possible. Tighten M6 screws for fastening of the washers (at the inside of the through hole for stud (3)) with Molykote

⇒

M=7

Nm

Measuring the gap (RM) Remove round nuts (4) and studs (3) of the main bearing. Loosen round nuts (4) of the adjacent main bearing blocks. Loosen both round nuts (4) of one bearing block in one operation. Loosen both main bearing nuts (2) of the main bearing in one operation. Use the hydraulic device in accordance with drawing 1.90.7-92.03.00-01. Tighten main bearing nuts (2) alternately and evenly by hand until the joint faces of the bearing shells just touch each other. Determine the projecting length of the bearing shell by measuring the gap between engine block and main bearing cap on operating side and exhaust side. Gap total of operating and exhaust side (on new main bearing shells)

⇒

1.00 - 1.25 mm

After longer operation the gap totals for main bearings must not be less than

⇒

0.80

mm

Tighten all bolts and nuts again according to the instructions (see above.).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

120

m

c2

Engineer’s Handbook Main Bearings

M 32

Tightening instruction (VM) At the locating bearing screw in the lateral bolts (2) with an O-ring sized 30 x 3.55. The bearing guide grooves are located on bank B. 1. Insert studs (1) with ⇒ M = 500 Molykote Do not damage the stamps and numbers when inserting the studs.

Nm

2. Tighten round nuts (3) evenly by hand. 3. Insert studs (2) with ⇒ M = 150 Molykote Do not damage the stamps and numbers when inserting the studs.

Nm

4. Tighten round nuts (4) evenly by hand. 5. Tighten round nuts (4) on the B side with ⇒ P = 150 + 50 bar Then tighten both round nuts (4) with ⇒ P = 680 - 25 bar 2 Piston area of the hydraulic device = 66.0 cm Tighten both round nuts of one bearing block in one operation. Use the hydraulic device in accordance with drawing number 1.91.7-92.03.00-01. 6. Tighten round nuts (3) for VM 32 with

⇒

P = 1025 - 25 bar

Tighten round nuts (3) for VM 32 C with ⇒ P = 1000 bar 2 Piston area of the hydraulic device = 145.0 cm Tighten both main bearing nuts of one bearing block in one operation. Use the hydraulic device in accordance with drawing number 1.91.7-92.03.00-01.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

121

m

c2

Engineer’s Handbook Main Bearings

M 32

Check (VM) Decrease the pressure by 50 bar. Loosening of the round nuts by means of a pin must not be possible any more. During the tightening process the pressure must remain constant when the pump is not operated, otherwise there will be a tightening fault. If the nuts of the lateral and main bearing bolts cannot be loosened at the prescribed pressure, a pressure increase by P = 50 bar is possible.

View of the free end Bank B

Bank A

Measuring the gap (VM) Remove round nuts (4) and studs (2). Loosen round nuts (4) of the adjacent main bearing blocks. Loosen both round nuts (4) of one bearing block in one operation. Loosen both main bearing nuts (3) in one operation. Use the hydraulic device in accordance with drawing number 1.91.7-92.03.00-01. Tighten both main bearing nuts (3) alternately and evenly by hand until the joint faces of the bearing shells just touch each other. Determine the projecting length of the bearing shell by measuring the gap between engine block and main bearing cap on the A and B bank sides. Gap total of bank A and bank B (on new main bearing shells)

⇒

1.00 - 1.20 mm

After longer operation the gap totals for main bearings must not be less than

⇒

0.90 mm

Tighten all bolts and nuts again according to the instructions (see above). Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

122

m

c2

Engineer’s Handbook Main Bearings

M 32

RM 32 - VM 32 - M 32 C Marking Bearing caps and bearing shells are marked on the operating side with the respective cylinder numbers, starting from the driving end. Do not interchange these parts! Locating and normal bearings are identical. For axial fixation at bearing 1 (locating bearing) install thrust washers. Fasten the lower parts of the thrust washers (1) with spring dowel pins (2) on the bearing cap (3). Insert the upper parts in the engine block without pins. Bearing clearances End clearance RM 32 S = S1 + S2

⇒

0.30 - 0.50 mm

Limit clearance RM 32

⇒

0.80

End clearance VM 32 S = S1 + S2

⇒

0.30 - 0.60 mm

Limit clearance VM 32

⇒

0.90

mm

mm

Bearing No. stamped here

The locating lug is on the operating side

Thrust washers On the VM 32 the thrust washers have different thicknesses. Install the thicker thrust washer (32.85 mm) at the driving end and the thinner thrust washer (23.85 mm) in the direction of main bearing 2. Fasten the lower parts on the bearing cap with spring dowel pins, as on the RM 32. Insert the upper parts without pins.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

123

m

c2

Engineer’s Handbook Main Bearings

M 32

Limit dimensions of the main bearing shells The first measurement of the main bearing shells is carried out on the bearing subjected to the highest load. The bearings subjected to highest load (starting from driving end) are: 6 M 32: Bearing 4 8 M 32: Bearing 5 9 M 32: Bearing 6 Measure the wall thickness in the main load area at measuring points (X). Dimension in new condition RM 32

⇒

8.870 -0.015 mm

Limit dimension RM 32

⇒

8.81

mm

If the limit value is reached, also check all other main bearings.

X

For VM 32 a surface and wear evaluation of the main bearing shells at the bearings subjected to the highest load must be carried out (see Section “Bearings” in the General Part of the Engineer’s Handbook). The bearings subjected to highest load (starting from driving end) are: 12 M 32: Bearings 4 and 6 16 M 32: Bearings 5 and 7

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

124

m

c2

Engineer’s Handbook Main Bearings

M 32

Removal and installation of main bearing shells Removal 1. Bar the connecting rod of an adjacent cylinder pair to position 1: Position 1 = for engines with counter-clockwise rotation: 40° CA (crank angle) before BDC of bank B / 40° CA after BDC of bank A for engines with clockwise rotation: 40° CA after BDC of bank B / 40° CA before BDC of bank A 2. Loosen the lateral bolts of the corresponding main bearing. 3. In position 2, place the device under the corresponding main bearing cap. Caution! Install table (2) on bearing bracket (3) with 2 screws (18) only after introducing the tool. 4. Place hydraulic jacks 1.00.7-92.13.00-24 and supporting rings 1.00.7-92.03.02-16 onto table (2). 5. Move device to position 1. 6. Screw threaded sleeves 1.00.7-92.03.10-05 onto main bearing studs of the bearing. 7. Loosen round nuts (1) according to the instructions of drawing 1.91.7-92.03.00-01. 8. Unscrew the threaded sleeves. 9. Move device to position 2. Remove hydraulic jacks and supporting rings from table (2). 10. Move device to position 1 and unscrew round nuts (1). 11. Move device to position 2. In case of jammed caps fasten table (2) with screws (17) to main bearing. Caution! Screws (17) must be tightened as far as they will go. Additionally, loosen the lateral bolts of the adjacent main bearing caps. 12. Remove lower main bearing shell. 13. Introduce dog (11) into crankshaft oil hole. 14. Bar the engine so that the upper main bearing shell slides out.

Position 1

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

125

m

c2

Engineer’s Handbook Main Bearings

M 32

Installation 1. Installation takes place in reverse removal order. Additionally, however, use guiding device (4) for mounting the upper main bearing shell. 2. First, introduce the upper main bearing shell by hand as far as possible. M 32 E: Upper bearing shell guided in the oil groove of the engine block. Lower bearing shell guided in the milled clearance of the bearing cap. 3. Place guiding device (4) into the main bearing cap lowered to position 2. 4. Carefully raise device until bearing shell is at limit stop (position 3). In doing so, pay attention to correct position of the groove (with respect to the lug of the bearing shell) and lateral limit stop. Fasten the device finger tight by means of round nut (1) (on one side only). 5. Bar the engine to slide in the upper bearing shell. After that, move device to position 2. 6. Remove guiding device from table (2). Remove dog (11) from crankshaft oil hole. 7. The remaining steps are to be carried out in accordance with the removal instructions, only in reverse order.

Position 3 Position 2

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

126

m

c2

Engineer’s Handbook Crankshaft

M 32

Crankshaft

Crank web deflection (RM and VM) Cylinders not subjected to any external load (generally applies to all cylinders, also to cylinder 1 if flywheel hub and flywheel are not yet installed, as well as to the last cylinder if the secondary PTO shaft incl. bearing in pump mounting plate is not yet connected). Limit value: ⇒ 0.06 to - 0.09 mm Cylinders subjected to additional load (normally cylinder 1, on account of the flywheel) and last cylinder if power is taken off at the free end. Limit value:

⇒

0.06 to - 0.13

mm

Headless screws and screw plugs in the crankshaft M24 headless screws (1) in the crank webs: Degrease the threads and insert the headless screws with Loctite 270. (For RM 32 E: tighten the headless screw with 100 Nm.) After that, secure the headless screw in all cases with a center punch. Screw plugs (1) in the crank webs: Degrease the threads and insert the screw plugs with Loctite 270. After that, tighten with 150 Nm. RM 32 E: Tighten the screw plugs with sealing ring (2) in the crankshaft with 30 Nm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

127

m

c2

Engineer’s Handbook Crankshaft

M 32

Balance weight equipment 12 M 32 16 M 32 6 M 32 9 M 32 C** 8 M 32 Crank pin 1 Crank pin 2 Crank pin 3 Crank pin 4 Crank pin 5 Crank pin 6 Crank pin 7 Crank pin 8

12 balance weights 16 balance weights 12 balance weights 18 balance weights (from 38723, see below) 12 balance weights 2 pcs. 1 pc., left side* 1 pc., right side* 2 pcs. 2 pcs. 1 pc., left side* 1 pc., right side* 2 pcs.

9 M 32** Crank pin 1 Crank pin 2 Crank pin 3 Crank pin 4 Crank pin 5 Crank pin 6 Crank pin 7 Crank pin 8 Crank pin 9

12 balance weights 2 pcs. 1 pc., left side* none 2 pcs. 2 pcs. 2 pcs. none 1 pc. right side* 2 pcs.

* = seen from operating side ** = On all 9 M 32 C engines starting with engine number 38723 (May 2009) and all engines with retrofitted crankshaft variant -06, the crankshafts are equipped with 18 instead of 12 balance weights. Due to the differing balance weight configurations, there are different supports for the connecting rods when extracting a piston.

Contact pattern of the balance weight surface Contact area absolutely required Contact area permissible only in combination with No material build-up permissible

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

128

m

c2

Engineer’s Handbook Crankshaft

M 32

Tightening instruction for balance weight installation (RM) Note: These values do not apply to RM 32 E 1. Screw in the studs with ⇒ Molykote 2. Tighten one stud with ⇒ 3. Tighten the second stud with ⇒ Decrease the pressure by 50 bar. Loosening of the round nuts must not be possible any more. 4. Tighten the stud from step 2 with ⇒

M = 150

Nm

P = 380 bar P = 650 - 25 bar P = 650 - 25 bar

Decrease the pressure by 50 bar. Loosening of the round nut must not be possible any more. Piston area = 66 cm2 Hydraulic tightening device as per drawing number 1.90.7-92.03.00-01 Stud: M36, length: 412 mm Alternative tightening instruction Stretch both studs on one balance weight simultaneously with

⇒

P = 650 - 25 bar

Tightening instruction for balance weight installation (RM 32 E) 1. Screw in the studs with Molykote 2. Tighten stud 1 with 3. Tighten stud 2 with 4. Tighten stud 1 with

⇒

M = 150

⇒ ⇒ ⇒

F = 400 kN F = 810 + 15 kN F = 810 + 15 kN

Nm

Note: 400 kN = 525 bar and 810 + 15 kN = 1065 + 20 bar with a piston area of 76 cm2 each. Hydraulic tightening device 1.9213 X as per drawing 3200.7-92.03.00-XX. 5. Check the torque angle by using the holes at the outer edge of the nut: 2 holes plus half the hole distance = 90° + 22.5° 6. Decrease the pressure by 50 bar. Loosening of the round nuts must not be possible any more. Alternative tightening instruction Stretch both studs on one balance weight simultaneously with the tightening device.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

129

m

c2

Engineer’s Handbook Crankshaft

M 32

Tightening instruction for balance weight installation (VM with normal stroke) Note: Orient the threaded hole (if existing) in the side face of the balance weight towards the cylinder centre. 1. Screw in the studs with ⇒ Molykote 2. Tighten the first stud with ⇒ 3. Tighten the second stud with ⇒ Decrease the pressure by 50 bar. Loosening of the nut must not be possible any more. 4. Tighten the stud from step 2 with ⇒ Decrease the pressure by 50 bar. Loosening of the nut must not be possible any more. Piston area = 145 cm2 Hydraulic tightening device as per drawing 1.91.7-92.03.00-XX Alternative tightening instruction 1. Tighten both studs on one balance weight simultaneously with ⇒ 2. Decrease the pressure by 50 bar. Loosening of the nuts must not be possible any more.

M = 150

Nm

P = 375 bar P = 750 + 25 bar P = 750 + 25 bar

P = 750 + 25 bar

Tightening instruction for balance weight installation (VM with 460 mm stroke - IMO II) 1. Screw in the studs with ⇒ Molykote 2. Tighten the first stud with ⇒ 3. Tighten the second stud with ⇒ Decrease the pressure by 50 bar. Loosening of the round nut must not be possible any more. 4. Tighten the stud from step 2 with ⇒ Decrease the pressure by 50 bar. Loosening of the round nut must not be possible any more. Effective piston area = 45 cm2

M = 150

Nm

P = 430 bar P = 860 + 25 bar P = 860 + 25 bar

Alternative tightening instruction Stretch both studs on one balance weight simultaneously according to the tightening instruction.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

130

m

c2

Engineer’s Handbook Crankshaft

M 32

Vibration damper Note: Maintenance intervals and replacement deadlines are specified in the maintenance plan of the operating instructions. Observe the instructions of Geislinger for installing the screws! Clean the contact surfaces of all parts (free of oil and grease). Apply Molykote 1000 to the thread and Loctite 275 (for damper D 90/46: Loctite 243) to both sides of the disc springs. Tighten screws (1) with the torque indicated in the table below. If no tightening torque is indicated, tighten the screws with the stated pre-torque (if no pre-torque is indicated, tighten the screws until the disc spring is seated flatly). After that, continue to tighten by the indicated torque angle. Damper (engine)

Tightening torque

Screws

D 100/18/1

(M 32)

D 80/19

(6 M 32)

M14 - 8.8

D 100/18/3

(8-9 M 32)

M24 - 10.9

D 80/20

(12 M 32)

M16 - 8.8

226 Nm

D 80/21

(16 M 32)

M16 - 8.8

226 Nm

Pre-torque + torque angle

No data, see Geislinger instruction 142 Nm 65° (+10%)

D 80/26 (6 M 32 + 6 M 32 E)

135 Nm (+10%)

D 100/18/4

(8/9 M 32)

980 Nm (+10%)

125 Nm (+10%) and 65° (+5°)

D 100/32

(8 M 32 CCR)

980 Nm (+10%)

125 Nm (+10%) and 76° (+5°)

D 90/46

(16 M 32 C)

843 Nm (+10%)

160 Nm (+10%) and 36° (+5°)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

131

m

Engineer’s Handbook Crankshaft

M 32

c2

Vibration damper removal with device 1. Fasten the left bracket (4) and right bracket (5) for the rail (1 + 2). 2. Assemble the split rail (1 + 2) in the engine, fix with pin (2.3) and suspend in holders (4) and (5). 3. Screw the carrier bracket (8) to the vibration damper and fasten the link of the carriage (7) to the carrier bracket with pin. 4. Tension the rail by means of the eye bolts on the suspension, also tension the rope of the winch (6) by means of the crank. 5. Loosen the fixing screws of the vibration damper and remove the vibration damper from the shaft journal. In doing so, follow up with the complete rail. 6. After that, pull the rail until there is sufficient clearance between the vibration damper and the shaft journal. 7. Extract the vibration damper by means of the winch (6) and secure the carriage (7) with a safety bolt (1.3). 8. Pull the lifting belt (9.2) into the hole of the vibration damper and attach to the lifting beam (9.1). 9. Attach the lifting beam to the crane hook and tension the lifting belt. Loosen the carrier bracket (8) from the carriage. Put the vibration damper onto a suitable base support.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

132

m

c2

Engineer’s Handbook Crankshaft

M 32

Vibration damper installation without power take-off Pretighten the stud bolts (1) with After that, finally tighten with Molykote

⇒ ⇒

M = 400 Nm Dw = 60°

Stud bolts M30, width across flats 46 6 M 32 = 12 pcs. 8 M 32 = 16 pcs. 9 M 32 = 18 pcs. 12 M 32 = 20 pcs. 16 M 32 = 20 pcs. Tighten the tack bolts (2) and bolts (3) for the pump gear support with Molykote Tack bolt M16 x 130, DIN 931 Bolt M16 x 110 Tighten all M16 bolts with Molykote Tighten all M12 bolts with Molykote

⇒

M = 130 Nm

⇒

M = 130 Nm

⇒

M = 60

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

133

m

c2

Engineer’s Handbook Crankshaft

M 32

Vibration damper installation with power take-off (RM) Attention! In case of power take-off at the free end of the engine, pay particular attention to crank web deflection of the last cylinder. Pretighten the stud bolts (1) with After that, finally tighten with Molykote

⇒ ⇒

M = 660 Nm Dw = 60°

For installing the vibration damper 20 stud bolts M30 W 46 each are to be used for 6/8/9 M 32. Tighten 2 bolts (2) (M16 x 110) with Molykote

⇒

M = 130 Nm

Tighten 2 bolts (3) (M16 x 130) with Molykote

⇒

M = 130 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

134

m

c2

Engineer’s Handbook Crankshaft

M 32

Installation sequence for RM 32: 1. Tighten vibration damper (5) with 2 bolts (M16x140 8.8) with 130 Nm. 2. (Only if there is an intermediate ring (see figure below)): Install intermediate ring (9) with two hexagon bolts M16x100-8.8 on vibration damper (5). Tighten bolt with 130 Nm 3. (Only if there is an intermediate ring (see figure below)): Check intermediate ring (9) and crankshaft for run-out (max. 0.03 mm). 4. Install PTO shaft (7), gear (6) and stud bolts (1) at the crankshaft. 5. Measure crank web deflection at the last cylinder. 6. Check run-out between gear (6) and crankshaft (max. 0.03 mm) and between PTO shaft (7) and crankshaft (max. 0.15 mm). 7. Install lower bearing casing (8) with bearing shells. Push the lower bearing casing upwards until the bearing fits closely on the shaft without any clearance. 8. Lift the bearing casing by half the crank web deflection value of TDC to BDC. 9. Tighten the fitted bolt (10) with extension sleeve so as to be finger tight (approx. 30 Nm). 10. Position the casing laterally so that the clearance is the same at the left and right side. 11. Tighten the bolts (10) and (11) of the lower bearing casing with 60 Nm. 12. Install the upper bearing casing and pin it to the lower casing. Tighten all bolts of the upper bearing casing with 60 Nm. 13. Check the shaft for perfect running. 14. Pin the bearing casing to the engine block. Finally tighten bolts (12) with Molykote

⇒

M = 80

Finally tighten bolts (13) with Molykote

⇒

M = 350 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

135

m

Engineer’s Handbook Crankshaft

M 32

c2

Vibration damper installation with power take-off (VM) Attention! In case of power take-off at the free end of the engine, pay particular attention to crank web deflection of the last cylinder. Before assembly degrease flange surfaces B and apply a thin coat of DIRKO HT sealing compound. Keep the non hatched areas A free of sealing compound. Keep the groove (Ø 513.7 mm) and the surface within the groove free of sealing compound.

Installation sequence for VM 32: Insert the oil nozzle into the cap with oil prior to assembly and check for clearance fit. Tighten vibration damper (5) with 2 bolts (M16x140 8.8) with 130 Nm. Install PTO shaft (7), gear (6) and stud bolts (1) at the crankshaft. Measure crank web deflection at the last cylinder. Check run-out between gear (6) and crankshaft (max. 0.03 mm) and between PTO shaft (7) and crankshaft (max. 0.15 mm). 5. Install lower bearing casing (8) with bearing shells. Push the lower bearing casing upwards until the bearing fits closely on the shaft without any clearance. 6. Lift the bearing casing by half the crank web deflection value of TDC to BDC. 7. Tighten the fitted bolt (17) with extension sleeve so as to be finger tight (approx. 30 Nm). 8. Position the casing laterally so that the clearance is the same at the left and right side. 9. Tighten the bolts (3) and (17) of the lower bearing casing with 130 Nm. 10. Install the upper bearing casing and pin it to the lower casing. Tighten all bolts (3) of the upper bearing casing with 130 Nm. 11. Check the shaft for perfect running. 12. Pin the bearing casing to the engine block.

1. 2. 3. 4.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

136

m

c2

Engineer’s Handbook Crankshaft

M 32

⇒ ⇒

Pretighten the stud bolts (1) with After that, continue to tighten by Molykote

M = 400 Nm Dw = 60°

Insert bolts (2) and (4) with Molykote and tighten them with the corresponding standard torques.

Allowable crankshaft refinishing dimensions Main bearing journal

Crank pin

300 mm

280 mm

1. undersize step

299.5 mm

279.5 mm

2. undersize step

299 mm

279 mm

3. undersize step

---

278 mm

4. undersize step

298 mm

277 mm

5. undersize step

---

---

6. undersize step

297 mm

---

RM 32 C Journal/pin diameter

Tolerance for all values is h6.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

137

m

c2

Engineer’s Handbook Crankshaft

M 32

Main bearing journal

Crank pin

300 mm

290 mm

1. undersize step

299.5 mm

289.5 mm

2. undersize step

299 mm

289 mm

3. undersize step

---

288 mm

4. undersize step

298 mm

287 mm

5. undersize step

---

---

6. undersize step

297 mm

---

RM 32 E Journal/pin diameter

Tolerance for all values is h6.

Main bearing journal

Crank pin

340 mm

280 mm

1. undersize step

339.5 mm

279.5 mm

2. undersize step

339 mm

279 mm

3. undersize step

---

278 mm

4. undersize step

338 mm

277 mm

5. undersize step

---

---

6. undersize step

337 mm

---

VM 32 C stroke 420 mm Journal/pin diameter

Tolerance for all values is h6.

Main bearing journal

Crank pin

340 mm

290 mm

1. undersize step

339.5 mm

289.5 mm

2. undersize step

339 mm

289 mm

3. undersize step

---

288 mm

4. undersize step

338 mm

287 mm

5. undersize step

---

---

6. undersize step

337 mm

---

VM 32 C stroke 460 mm Journal/pin diameter

Tolerance for all values is h6. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

138

m

c2

Engineer’s Handbook Crankshaft

M 32

Surface hardness of the crankshaft Engine

Hardness (HB) Drawing number

Min.

Max.

1.93.7-25.10.01-03

235

280

1.93.7-25.10.01-04

250

295

1.94.7-25.10.01-01

235

280

1.94.7-25.10.01-03

235

280

1.94.7-25.10.01-04

250

295

1.99.7-25.10.01-02

235

280

1.99.7-25.10.01-03

235

280

1.99.7-25.10.01-04

250

295

1.99.7-25.10.01-06

250

295

6 M 32 E

3206.7-25.10.01-01

270

330

8 M 32 E

3208.7-25.10.01-01

270

330

9 M 32 E

3209.7-25.10.01-01

270

330

1.96.7-25.10.01-03

255

300

1.96.7-25.10.01-05

260

320

1.96.7-25.10.01-06

275

335

1.98.7-25.10.01-03

255

300

1.98.7-25.10.01-05

265

325

1.98.7-25.10.01-06

280

340

6 M 32

8 M 32

9 M 32

12 M 32

16 M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

139

m

c2

Engineer’s Handbook Crankshaft

M 32

Pump gear on the crankshaft (RM 32 E) Pretighten the stud bolts (3) with After that, finally tighten with Molykote G Rapid Plus

⇒ ⇒

M = 400 Nm Dw = 60°

Insert bolts (5) with Molykote and tighten them with the corresponding standard torques.

 





Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

140

m

Engineer’s Handbook Crankshaft

M 32

c2

Cam formation on crank pins In the area of the oil groove of big-end bearing shell variant -25 the bearing absorbs less load than at the outer bearing surfaces. This may lead to less crank pin wear in the running area of the groove and cam formation in this area. A cam is a central elevation on the lateral surface of the crank pin. This problem may occur on all RM 32 and VM 32 engines equipped with big-end bearing variant -25. Each time when changing a bearing it is, therefore, required to carry out a straightness measurement at different points of the lateral surface of the crank pins. Please also refer to job card D5.05. 02.05.50.00. Stock number of the measuring device: 1001-0919-00-00 Procedure: 1. Bar the crankshaft to TDC position so that reference point 1 is at the top. 2. Clean the crank pin at the point to be measured and fasten the complete measuring device with the rubber belt (2) in upright position on the crank pin. Measure from the operating side, in case of VM 32 from bank B. The two adjusting screws (1) are pointing towards the operator and must rest on the crank pin. 3. Push the measuring slide completely towards the right (free end) and set the dial gauge to zero. 4. Push the measuring slide completely towards the left (driving end) and reset the dial gauge to zero by turning the left adjusting screw. 5. Push the measuring slide completely towards the right (free end) and set the dial gauge to zero once again by turning the right adjusting screw.

1

2

Repeat steps 4 and 5 until the dial gauge indicates zero on both sides. 6. Move the measuring slide slowly towards the left until the dial gauge indicates the highest point. Take note of the determined value.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

141

m

Engineer’s Handbook Crankshaft

M 32

c2

7. Push the measuring slide until reaching the left limit stop and then slowly move it towards the right until the dial gauge indicates the highest point. Take note of the determined value. 8. Compare both measuring values (in the ideal case both values are the same). Enter the higher value on the measuring sheet. 9. Continue turning the measuring device in counter-clockwise direction (seen from the driving end) up to the next measuring point on the crank pin. Continue barring the engine correspondingly so that the new measuring point is at the top. 10. Repeat the measurements for all indicated points. After completion of the measurements send the completely filled in measuring sheet to the following e-mail address: [email protected]

Supplementary measurement: If measuring values > 0.025 are identified at measuring points 2 to 8, additionally measure the diameters of the affected crank pins. Measure the crank pin according to the following figure by means of an external micrometer. A measurement is only permissible by trained personnel and on a cold engine. Measurement is carried out on lines A and B, from TDC to BDC each time, and staggered by 90° from 90° to 270°. Enter the measuring values on a measuring sheet and transmit this to Caterpillar Kiel for evaluation. Based on the measuring values it will be determined whether a local refinishing of the cam is allowable.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

142

m

Engineer’s Handbook Crankshaft

M 32

c2

Evaluation: If a crank pin shows an elevation of more than 15µm above 0 at any location, the permissible tolerance is exceeded and the crank pin should be refinished, see below: “Recommendation”. If a mean value was formed when measuring (see item 6), subtract this mean value from the measured maximum value. If the result is more than 15µm, the permissible tolerance is exceeded and the crank pin should be refinished, see below: “Recommendation”. Attention! In case of a measurable cam of less than 15µm the engine shall be run in carefully upon re-commissioning!

Recommendation: If the permissible tolerance is exceeded on a crank pin, the pin should be ground down to the next undersize step depending on the actual condition of the shaft. Contact the Caterpillar REParts-Center in Kiel in such a case: [email protected] If such a measure is carried out, note this down on the respective measuring sheet and at the appropriate points of the engine documentation.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

143

m

Engineer’s Handbook Crankshaft Seal and Flywheel Hub Installation

M 32

c2

Crankshaft seal and flywheel hub installation RM 32 Crankshaft seal 1.90.7-73.40.00-01 Variant 1.90.7-73.40.00-01 is used on engines Nos. 37001 and 37003, cost unit 261014. Engine 37003 is operated with engine 37008 as twin-engine propulsion plant.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

144

m

c2

Engineer’s Handbook Crankshaft Seal and Flywheel Hub Installation

M 32

Flywheel hub 1.90.7-73.40.00-02 Caution! The following work shall only be executed by qualified MaK personnel! Contact Parts Operations in Kiel to hire the required tools and qualified professionals. Insert spring dowel pins (1) into gear on crankshaft. Align the end plate so as to be centered to the crankshaft and flush with the bottom edge of the engine block. ⇒

Tighten screws (2) with Molykote

M = 130

Nm

Lubricate the crankshaft cone with hydraulic oil. Guide the flywheel hub over the crankshaft and push it onto the crankshaft cone until contact is reached. Install the tightening device. In doing so, fix the flywheel hub on the locating pin of the tightening device.In this position the projecting spring dowel pins at the gear on crankshaft are aligned to the corresponding receiving bores on the flywheel hub. Prerequisite is TDC position of cylinder 1. Press the flywheel hub into final position with the tightening device and oil press fit. Oil pressure

⇒

P = 1350

Tighten the nut at the device with The slide-on distance is

⇒ ⇒

M = 1350 Nm M = 30 - 3.5 mm

Tighten the screws for the oil thrower (3) with Molykote

⇒

M = 50

bar

Nm

Loosen the device at the earliest 12 hours after releasing the oil press fit. Start the engine at the earliest 72 hours after removing the holding device. 16 pcs. 16 pcs.

hexagon head bolts hexagon head screws

M10 x 50 M16 x 45

DIN 931 ISO 4017

10.9 8.8 -A3C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

145

m

c2

Engineer’s Handbook Crankshaft Seal and Flywheel Hub Installation

M 32

Crankshaft seal 1.90.7-73.40.00-03 / -04 (RM) Crankshaft seal 1.91.7-73.40.00-02 / -03 (VM) Caution! The following work shall only be executed by qualified MaK personnel! Contact Parts Operations in Kiel to hire the required tools and qualified professionals. Tighten screws (2) with Molykote

⇒

M = 215 Nm

Screw flange ring (1) and crankshaft gear (3) onto the flywheel hub. Pretighten screws (4) with Molykote

⇒

M = 50

Nm

Tighten screws (8) with Molykote

⇒

M = 50

Nm

End clearance at 7 is different for RM and VM

Align and install the cover plate (5) so as to be centered to the crankshaft and flush with the bottom edge of the engine block. Tighten screws (6) with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 130 Nm

146

m

c2

Engineer’s Handbook Crankshaft Seal and Flywheel Hub Installation

M 32

Lubricate the crankshaft cone with hydraulic oil H36 DIN 51524. Guide the flywheel hub with the crankshaft gear over the crankshaft and push it onto the crankshaft cone until contact is reached. Install the tightening device; in doing so, fix the flywheel hub on the locating pin of the tightening device. Push the crankshaft with the crank web onto the axial bearing (locating bearing) and secure axially. Using a hand pump, build up an oil pressure of ⇒ Press the flywheel hub and the crankshaft gear into the final position by means of the tightening device and oil press fit.

P = 1650

RM: Final position is reached when the end clearance at (7) is ⇒ VM: Final position is reached when the end clearance at (7) is ⇒ (1.91.7-73.40.00-03)

0.30 + 0.20 mm 0.30 + 0.30 mm

bar

The hydraulic pressure at the tightening device is

⇒

P = 300

bar

at a piston area of

⇒

A = 133

cm2

M = 2200

Nm

33 - 6.5 30 - 3.5

mm mm

M = 215

Nm

Torque at the nut of the device (1.90.7-73.40.00-03): The slide-on distance is The slide-on distance (1.90.7-73.40.00-03) is

⇒ ⇒

Carry out final assembly of flange ring with gear on flywheel hub: Tighten screws (4) with ⇒ Molykote Install the oil thrower.

Loosen the device at the earliest 12 hours (variant 1.90.7-73.40.00-03: 60 minutes) after releasing the oil pressure. Start the engine at the earliest 72 hours after removing the device. Screws used for the flywheel hub installation: 1.90.7-73.40.00-03 / -04 6 pcs. hexagon head bolts 16 pcs. hexagon head screws 38 pcs. hexagon socket head cap screws

M 10 x 50 DIN 931 10.9 M 16 x 45 ISO 4017 8.8 -A3C M 16 x 100 ISO 4762 10.9

1.91.7-73.40.00-02 / -03 6 pcs. hexagon head bolts 19 pcs. hexagon head screws 38 pcs. hexagon socket head cap screws

M 10 x 50 M 16 x 45 M 16 x 100

DIN 931 10.9 ISO 4017 8.8 -A3C ISO 4762 10.9

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

147

m

Engineer’s Handbook Crankshaft Seal and Flywheel Hub Installation

M 32

c2

Dismounting and mounting of flywheel hub and crankshaft gear Caution! The following work shall only be executed by qualified MaK personnel! Contact Parts Operations in Kiel to hire the required tools and qualified professionals. Fitting of the device 1. Fasten sleeve (1) with the threaded bolt (2). 2. Fit thrust plate (3) together with high-pressure tube (4) and screw high-pressure tube (4) into the crankshaft connection. 3. Push on thrust plate (3) and screw on hydraulic jack (5).

Removing flywheel hub and gear 1. Mount the device as described above. 2. Unscrew the stepped piston of the hydraulic jack by approx. 30 mm. Connect hand pump to connection (6) and pump up the hydraulic jack. 3. Connect the pump unit to the high-pressure tube (4) and slowly increase the pressure. 4. Slowly open the valve at the hand pump. This will make the flywheel hub ’creep’ off the cone together with the gear. Installing flywheel hub and gear 1. Mount the device as described above. 2. Connect the pump unit for an oil pressure of approx. 1650 bar and the hand pump. 3. Slowly increase the pressure at the pump unit, at the same time increase the pressure of the hand pump (approx. 300 bar) until the flywheel hub together with the gear fits closely on the locating bearing. Pay attention to the end clearance. 4. Loosen the device at the earliest 12 hours after releasing the oil press fit. Start the engine at the earliest 72 hours after removing the device.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

148

m

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

c2

Timing gear train (M 32 and VM 32) Note: When removing gears position the centre of gravity of the gear with mounting device as precisely as possible under the crane hook and counterhold to prevent sudden swivelling out of the gear with mounting device.

Gear on crankshaft 1.90.7-25.30.00-02 (RM) Gear installation with device and oil press fit The only engine equipped with this variant is serial No. 37005, cost unit 261009. ⇒

Press connection Z with onto the crankshaft cone into final position.

P = 450

bar

Final position is reached when the gear rests against the spacer. The spacer simulates the locating bearing. Adjust the spacer so that there will be a dimension of ⇒ 174 + 0.1 mm between gear and crank web of cylinder 1 when the gear has reached final position. ⇒

The slide-on distance is

12 - 3.2 mm

The device must still remain fitted for 20 minutes after releasing the oil pressure. Start the engine at the earliest 2 hours after releasing the oil pressure. A retrofit to variant 1.90.725.30.00-03 is possible.

Gear on crankshaft 1.90.7-25.30.00-03 (RM) Gear installation with device and oil press fit This variant is installed in engines with the following serial numbers: 37002 37004 37006

37007 37009 37010

37011 37012 37013

37014 37017 37021

Press connection Z with onto the crankshaft cone into final position.

37022 37023 37024

37025 37038 37039 ⇒

37040 37060

P = 650

bar

Final position is reached when the gear rests against the spacer. The spacer simulates the locating bearing. Adjust the spacer so that there will be a dimension of ⇒ 174 + 0.1 mm between gear and crank web of cylinder 1 when the gear has reached final position. The slide-on distance is

⇒

17.5 - 3.2 mm

The device must still remain fitted for 20 minutes after releasing the oil pressure. Start the engine at the earliest 2 hours after releasing the oil pressure. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

149

m

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

c2

Spacer

Connection Z

Gear on crankshaft 1.90.7-99.25.30-01 (RM) Gear installation with device and oil press fit This variant is installed in engines with the following serial numbers: 37003

37019

37008

37020

Press connection Z with onto the crankshaft cone into final position.

⇒

P = 650

bar

Final position is reached when the gear rests against the spacer. The spacer simulates the locating bearing. Adjust the spacer so that there will be a dimension of ⇒ 174 + 0.1 mm between gear and crank web of cylinder 1 when the gear has reached final position. The slide-on distance is

⇒

15 - 3.2 mm

The device must still remain fitted for 20 minutes after releasing the oil pressure. Start the engine at the earliest 2 hours after releasing the oil pressure. Gear on crankshaft (all other RM and VM engines) See chapter “Crankshaft Seal and Flywheel Hub Installation”

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

150

m

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

c2

Intermediate gear installation 1.90.7-51.40.00- 01/02 (RM) ⇒

M = 130 Nm

Min.

⇒

0.30

mm

Max.

⇒

1.40

mm

Tighten screws (1) (M16x70 8.8) with Molykote Gap dimension (2) at X (between shaft and tab washer)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

151

m

c2

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

Intermediate gear installation 1.90.7-51.40.00-02 (RM) Cool bush for intermediate gear down to -195 °C and freeze fit it in the intermediate gear. The bush shall recede at the edges by 1 mm. Reference dimension after freeze fitting: ⇒

Ø 120.082 mm + 0.058 mm

End clearance S at Y: Min.

⇒

0.30

mm

Max.

⇒

0.60

mm

Backlash: Crankshaft gear - intermediate gear

⇒

0.28 - 0.44

mm

Backlash: Intermediate gear - camshaft gear

⇒

0.20 - 0.37

mm

Limit value for axle: min.

⇒

119.942

mm

Limit value for bush: max.

⇒

120.14

mm

Wear limits for intermediate gear (M 32)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

152

m

c2

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

Intermediate gear installation 1.91.7-51.40.00-01 (VM) Tighten screws (1) (M16x65 8.8) with Molykote

⇒

M = 130

Nm

Clearance S

⇒

0.50 - 1.0

mm

Backlash:Crankshaft gear - intermediate gear

⇒

0.31 - 0.43

mm

Backlash:Intermediate gear - camshaft gears

⇒

0.19 - 0.38

mm

Paste the thrust rings (4) in the engine block. Thoroughly clean the surfaces to be pasted. Apply a thin coat of adhesive on the thrust ring. Keep both parts under slight pressure for about 45 minutes. Final curing after 4 to 5 hours. After installing the intermediate gear check the circlip (8) for snug fit.

Reference dimension after pasting

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

153

m

c2

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

Intermediate gear installation 1.91.7-51.40.00-02 (VM) End clearance S1 at X to engine block 1.96 / 98.7-11.11.00-02: Min. Max.

⇒ ⇒

0.30 0.60

mm mm

End clearance S1 at X from engine block 1.96 / 98.7-11.11.00-04: Min. Max.

⇒ ⇒

0.70 1.00

mm mm

Backlash:Crankshaft gear - intermediate gear

⇒

0.31 - 0.43

mm

Backlash: Intermediate gear - camshaft gears

⇒

0.19 - 0.38

mm

Lubricating oil nozzles for gears Tighten the screws with Molykote

⇒

M = 160

Nm

After installing the intermediate gear check the circlip (8) once again for snug fit. Cool the bush for the intermediate gear with liquid nitrogen down to -195 °C and insert it. The bush must recede at the edges by 1 mm. Reference dimension after freeze fitting: Bush inside diameter

⇒

120.081 mm + 0.059 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

154

m

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

c2

Intermediate gear installation 1.91.7-51.40.00-03 (VM) Tighten screws (1) with Loctite 243

⇒

M = 130 Nm

Tighten screws (2) with Molykote

⇒

M = 130 Nm

If a bush is fitted, remove it. Cool flange sleeve (3) down to -195 °C with liquid nitrogen and freeze fit it. Seal the sealing face with Dirko 610.020. End clearance S: see variant 1.91.7-51.40.00-02 Backlash:

see variant 1.91.7-51.40.00-02

Cool the bush (4) for the intermediate gear with liquid nitrogen down to -195 °C and insert it. The bush must recede at the edges by 1 mm. Reference dimension after freeze fitting: Bush inside diameter

⇒

120.081 mm + 0.059 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

155

m

c2

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

Installation of crankshaft gear (RM and VM) For installation of the gear on the crankshaft see chapter “Crankshaft Seal”

Camshaft gear installation (RM and VM) - The bearing journal (1) must not project into the gear case. - Swing the camshaft gear (2) into the gear case with the device. - Push the journal until it contacts the camshaft gear cone. - Prefit thrust washer (3) until it contacts the camshaft gear. - Mount the camshaft gear up to the limit stop on the bearing journal cone with the oil press fit by tightening the screws (4). Tightening torque see chapter “Camshaft”. Tighten screws (4) evenly. Final position: Pull thrust washer (3) against bearing journal (1). Slide-on distance:

⇒

L = 11.5 - 2.9

mm

Oil pressure, old design

⇒

P = 1200

bar

Oil pressure, new design

⇒

P = 1200 - 1600

bar

M = 160

Nm

Lubricating oil nozzles for timing gear train (RM and VM) Tighten the screws with ⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

156

m

c2

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

Molykote The arrows indicate the correct direction of injection of the lubricating oil nozzles:

RM: Camshaft gear

Intermediate gear

Crankshaft gear

VM: Intermediate gear Camshaft gear Bank A

Camshaft gear Bank B Crankshaft gear

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

157

m

c2

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

Removal and installation of the gear for pump drive Note: For installing the gear for pump drive please also refer to chapter “Crankshaft Seal and Flywheel Hub Installation” and chapter “Crankshaft”, section “Vibration damper installation”. 1. For dismounting the gear (4) remove all fitted bolts (1) except for two. 2. Unscrew the other two fitted bolts (1) about 15 mm and pull off the gear (4). 3. Fasten the device on the face end of the engine as shown. 4. Insert the fork (3) of the device into the suitable holes of the gear and secure with spring cotter (11). 5. Screw up the fork until the bolts have reached contact in the holes. 6. Remove the fitted bolts (1). 7. Lift the gear (4) about 140 mm by turning the threaded spindle (1.3). Then swing out the gear. 8. Attach the gear to the crane and remove the device from the gear. 9. Installation takes place in reverse order.

For gear only For pump gear support only

1

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

158

m

Engineer’s Handbook Timing Gear Train (M 32 and VM 32)

M 32

c2

Pump gear support installation and removal Note: For installation of the gear on crankshaft please also refer to chapter “Crankshaft”, section “Vibration damper installation”. 1. For removing the pump gear support (5) insert the fork (3) of the device into the appropriate holes and secure with screw M16x1.5x30 (12). 2. Screw the fork (3) upwards until all bolts have reached contact in the holes. 3. Remove the two holding screws (2) and pull off the pump gear support (5). 4. Lift the pump gear support (5) about 120 mm by turning the threaded spindle (1.3). Then swing out the pump gear support. 5. Attach the gear to the crane and remove the device from the pump gear support. 6. Installation takes place in reverse order.

For gear only For pump gear support only

2

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

159

m

Engineer’s Handbook Timing Gear Train (M 32 C and VM 32 C)

M 32

c2

Timing gear train (M 32 C and VM 32 C) Note: When removing gears position the centre of gravity of the gear with mounting device as precisely as possible under the crane hook and counterhold to prevent sudden swivelling out of the gear with mounting device. Timing wheel installation for Common Rail engines For installing the timing wheel on the camshaft gear (for Common Rail engines only) please refer to chapter “Common Rail Components”. Crankshaft gear installation (RM 32 C and VM 32 C) See chapter “Crankshaft Seal and Flywheel Hub Installation”

Intermediate gear installation (RM 32 C) Tighten screws (M16 x 70 8.8) (1) with Molykote

⇒

M = 130

Nm

Gap dimension (2) at X (between shaft and tab washer) Min. Max.

⇒ ⇒

0.30 1.40

mm mm

End clearance S Min. Max. Wear limit for S

⇒ ⇒ ⇒

0.30 0.60 1.20

mm mm mm

Backlash Crankshaft gear - intermediate gear Intermediate gear - camshaft gear

⇒ ⇒

0.28 - 0.44 mm 0.20 - 0.37 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

160

m

Engineer’s Handbook Timing Gear Train (M 32 C and VM 32 C)

M 32

Lubricating oil nozzles for timing gear train (RM 32 C) Tighten the screws with ⇒ Molykote

c2 M = 160

Nm

The arrows indicate the correct direction of injection of the lubricating oil nozzles:

Camshaft gear

Intermediate gear

Crankshaft gear

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

161

m

Engineer’s Handbook Timing Gear Train (M 32 C and VM 32 C)

M 32

c2

Camshaft gear installation (RM 32 C and VM 32 C) - The bearing journal (1) must not project into the gear case. - Swing the camshaft gear (2) into the gear case with the device. - Push the journal until it contacts the camshaft gear cone. - Prefit thrust washer (3) until it contacts the camshaft gear. - Mount the camshaft gear up to the limit stop on the bearing journal cone with the oil press fit by tightening the screws (4). Tightening torque see chapter “Camshaft”. Tighten screws (4) evenly. Final position: Pull thrust washer (3) against bearing journal (1). Slide-on distance

⇒

L = 11.5 - 2.9

Oil pressure

⇒

P = 1200 - 1600 bar

mm

Do not start the engine earlier than 2 hours after releasing the press fit.

Grease here

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

162

m

c2

Engineer’s Handbook Timing Gear Train (M 32 C and VM 32 C)

M 32

Intermediate gear installation (VM 32 C) Tighten screws (1) (M16x65 8.8) with Molykote

⇒

M = 130

Nm

End clearance S (VM) Min. Max. Wear limit for S

⇒ ⇒ ⇒

0.90 1.20 1.80

mm mm mm

Backlash values (VM) Crankshaft gear - intermediate gear Intermediate gear - camshaft gears

⇒ ⇒

0.31 - 0.43 mm 0.19 - 0.38 mm

After installing the intermediate gear check the circlip (8) for snug fit. .

O-ring

Lubricating oil nozzles for timing gear train (VM 32 C) Tighten the screws with ⇒

M = 160

Nm

The arrows indicate the correct direction of injection of the lubricating oil nozzles:

Intermediate gear Camshaft gear Bank A

Camshaft gear Bank B Crankshaft gear

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

163

m

c2

Engineer’s Handbook Timing Gear Train (M 32 E and VM 32 E)

M 32

Timing gear train (M 32 E and VM 32 E) Note: When removing gears position the centre of gravity of the gear with mounting device as precisely as possible under the crane hook and counterhold to prevent sudden swivelling out of the gear with mounting device. Camshaft gear installation (RM 32 E) - The bearing journal (4) must not project into the gear case. - Swing the camshaft gear (1) into the gear case with the device. - Push the oiled journal until it contacts the camshaft gear cone. - Prefit thrust washer (2) until it contacts the camshaft gear. - Mount the camshaft gear until it contacts the end stop on the bearing journal cone with the oil press fit by tightening thrust washer. Tighten screws (6) evenly with Molykote G Rapid Plus

⇒

M = 260 Nm

Final position: Pull thrust washer (2) against bearing journal (4). Slide-on distance

⇒

L = 11.5 - 2.9 mm

End clearance at S

⇒

S = 0.5 - 0.95 mm

Do not start the engine earlier than 2 hours after releasing the press fit.

Hydraulic connection

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

164

m

Engineer’s Handbook Timing Gear Train (M 32 E and VM 32 E)

M 32

Tighten screws (10) with Molykote G Rapid Plus

⇒

c2 M = 130 Nm

Tightening torque for screw plug M42x2 (14) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

165

m

c2

Engineer’s Handbook Governor Drive

M 32

Governor drive Old design (RM and VM) Fastening of the big helical gear: Tighten screws (1) (M16 x 220) with Molykote End clearance at (2)

⇒

M = 190

⇒

0.30 - 0.80 mm

New design (RM and VM) Fastening of the big helical gear: Tighten screws (3) (M20 x 130) with Molykote End clearance at (4)

⇒

M = 260

⇒

0.30 - 0.75 mm

Old design

Backlash at (5)

Nm

Nm

New design

⇒

0.30 - 0.60

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

mm

166

m

c2

Engineer’s Handbook Governor Drive

M 32

Tighten castle nut (1) (M16 x 1.5) for the small helical gear for RM 32 with Molykote

⇒

M = 70

Nm

On the VM 32 tighten this nut with Molykote

⇒

M = 100

Nm

End clearance at (2)

⇒

0.30 - 0.60 mm

If the bushes (1) and (2) in the engine block need to be exchanged, make sure that the dimensions stated in the drawing are observed. Before pressing-in lightly oil the bushes, do not use Molykote.

Long slot centered with respect to bore

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

167

m

c2

Engineer’s Handbook Governor Drive

M 32

RM 32 C - VM 32 C The in-line and V-engine governor drives differ from each other in the number of teeth of the helical gears. This is due to their different speeds. Backlash and end clearance (M 32 C) Backlash of gear (1) - camshaft gear

⇒

0.25 + 0.15 mm

End clearance at (2)

⇒

0.20 + 0.30 mm

End clearance at (3)

⇒

0.20 + 0.20 mm

The backlash between camshaft gear and governor driving gear is adjusted by means of gaskets which are available in 2 different thicknesses: 0.30 mm corresponds to a backlash difference of 0.19 mm 0.50 mm corresponds to a backlash difference of 0.32 mm Tightening torque for screw plug M33x2 (if existing) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Serration

Heat up to 40 °C for shrink fitting

Cool down to -195 °C

Heat up to 70 °C for shrink fitting

Heat up to 110 °C for shrink fitting

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

168

m

Engineer’s Handbook Camshaft Bearings

M 32

c2

Camshaft bearings Bearing evaluation For details on bearing evaluation see “General Part” of the Engineer’s Handbook. Camshaft bearing 1.90.7-31.91.01-30 (RM 32) A Engine Nos. 37002, 37003 and 37008 are equipped with freeze fitted normal camshaft bearings. If these bearings need to be changed, use variant 1.90.7-31.91.01-32 with locating screw 1.90.7-11.10.11-01 as replacement. For removal, the freeze fitted bearings must be made stress-free by sawing or similar measures. The holes provided for the locating screws are plugged with screw plugs M33x2 DIN 908 and sealing ring A33x39 DIN 7603.

B Engine Nos. 37002 - 37017 / 37019 - 37030 / 37036 - 37041 as well as engine Nos. 37043, 37046, 37050, 37051, 37054, 37055 and 37103 are equipped with freeze fitted camshaft end bearings. Replacement: Variant 1.90.7-31.91.02-32 with locating screw 1.90.7-11.10.11-01. All other engines are equipped with variant 1.90.731.91.02-32 with locating screw 1.90.7-11.10.11-01.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

169

m

c2

Engineer’s Handbook Camshaft Bearings

M 32

Camshaft normal bearing 1.90.7-31.91.01-32 with locating screws The following engines are equipped with this variant: 37007 / 37009 - 37017 / 37019 - 37031 / 37036 / 37038 - 37044 / 37046 - 37060 / 3706237067 / 37069 - 37071 / 37074 / 37079 - 37081 / 37084 - 37088 / 37091 - 37093 / 3709637107 Replacement: Same variant. Attention: The notch in the bearing shell (if provided) must point upwards! Tighten locating screws (1) with ⇒ Apply Molykote to the contact surfaces and Loctite 243 to the threads.

M = 250 Nm

Pay attention to the position of the holes

Locating screws (1) 1.90.7-11.10.11-01

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

170

m

c2

Engineer’s Handbook Camshaft Bearings

M 32

Normal camshaft bearing 1.90.7-31.91.01-32 with hexagon socket head cap screws (RM 32 C) All further engines and those not mentioned before are equipped with this variant. Tighten locating screw (1) with Loctite 243

⇒

M = 250 Nm

Tighten hexagon socket head cap screw (2) with Molykote

⇒

M = 100 Nm

Attention: The notch in the bearing shell (if provided) must point upwards!

Pay attention to the position of the holes

Hexagon socket head cap screws (2)

Locating screw (1) 1.90.7-11.10.11-01 with Loctite 243

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

171

m

c2

Engineer’s Handbook Camshaft Bearings

M 32

Camshaft bearing (RM 32 C) Tighten hexagon socket head cap screws (1) and (2) with Molykote

⇒

Tighten locating screw (3) with ⇒ Apply Molykote to the thread and Loctite 243 to the contact surface.

M = 100 Nm M = 250 Nm

Camshaft bearing clearance Clearance in new condition

⇒

0.20 - 0.27 mm

Limit clearance

⇒

0.38

mm

When the limit clearance is reached or exceeded, check the camshaft bearing clearance of all other camshaft bearings and replace the camshaft bearing shell.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

172

m

c2

Engineer’s Handbook Camshaft Bearings

M 32

Camshaft bearing (VM 32 and VM 32 C), banks A and B ⇒

M = 100

Clearance in new condition

⇒

0.20 - 0.27 mm

Limit clearance

⇒

0.38

Tighten hexagon socket head cap screws (1) with Molykote

Nm

Camshaft bearing clearance

mm

When the limit clearance is reached or exceeded, check the camshaft bearing clearance of all other camshaft bearings and replace the camshaft bearing shell. Attention: The notch in the bearing shell (if provided) must point upwards!

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

173

m

c2

Engineer’s Handbook Camshaft Bearings

M 32

Camshaft bearing (RM 32 E) Attention: The notch in the bearing shell (if provided) must point upwards! Align the locating hole of the bearing shells with respect to the thread in the engine block. Tighten locating screw (3) with Loctite 542

⇒

M = 250

Nm

Tighten hexagon socket head cap screws (12) with Apply Molykote to thread and contact surfaces

⇒

M = 100

Nm

Tightening torque for screw plugs M33x2 (11) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Apply oil to thread and contact surfaces

Pay attention to the position of the hole

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

174

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft Camshaft assembly - RM Tighten nuts (1) with Molykote

⇒

M = 210 Nm

Tighten nuts (2) with Molykote

⇒

M = 210 Nm

For versions with separate bearing journals between the camshaft sections: ⇒

Tighten screws (3) with Molykote

M = 220 Nm

For versions without separate bearing journals between the camshaft sections: ⇒

Tighten screws (3) with Molykote

M = 260 Nm

With bearing journals

Without bearing journals

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

175

m

c2

Engineer’s Handbook Camshaft

M 32

Assembly of camshaft sections (separate bearing journals / RM) Before assembling the camshaft sections provide the bearing journals with 2 parallel pins each. Marking of the pins on the bearing journal, seen from the driving end. Arrangement for 6 M 32

Arrangement for 8 M 32

Arrangement for 9 M 32

Arrange the pins according to the following tables. Insert the pins in the following holes. Bearing journal No.

6 M 32 1 2 3 4 5 6 8 M 32 1 2 3 4 5 6 7 8 9 M 32 1 2 3 4 5 6 7 8 9

Driving end 1 2 3 4 5 6 Driving end 1 2 3 4 5 6 7 8 Driving end 1 2 3 4 5 6 7 8 9

Free end 2 3 4 5 6 Free end 2 3 4 5 6 7 8 Free end 2 3 4 5 6 7 8 9 -

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

176

m

c2

Engineer’s Handbook Camshaft

M 32

Assembly of camshaft sections (integrated bearing journals / RM) Before assembly of the camshaft provide the camshaft flanges with one parallel pin each according to the following tables.

6 M 32

Bearing journal No. 1 2 3 4 5 6 Bearing journal No. 1 2 3 4 5 6 7 8 Bearing journal No. 1 2 3 4 5 6 7 8 9

8 M 32

9 M 32

for 6 M 32, for 8 M 32 and for 9 M 32

Inlet cam

Here flange index 1 flange index 2 flange index 8

Flange index 5 1 6 5 3 7 Flange index 1 2 3 4 5 6 7 8 Flange index 5 8 2 6 4 4 6 2 8

Cyl. 6/8/9

Cyl. 2

Cyl. 1

Here flange index 5 flange index 1

for 6 + 9 M 32, for 8 M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

177

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - RM32C Note: For information regarding installation of the timing wheel for Common Rail engines, see chapter “Common Rail components“. Tighten screws (3) with Molykote

⇒

M = 260 Nm

Tighten screws (1) with Dry without oil and Molykote

⇒

M = 50

Nm

Thrust washer

Tight fit with contact surface

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

178

m

c2

Engineer’s Handbook Camshaft

M 32

Tighten nuts (2) with Molykote

⇒

M = 210 Nm

Tighten screws (4) (M16x45) with Molykote

⇒

M = 130 Nm

End clearance at (5)

⇒

0.50 - 0.95 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

179

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - 6 M 32 C and 9 M 32 C 6 M 32 C: Before assembling the camshaft press in parallel pin at the corresponding flange index. Flange index here 0+5

0+1

Section-cylinder Flange index

0+6

0+5

0+3

0+7

1

2

3

4

5

6

0+5

0+1

0+6

0+5

0+3

0+7

Holes 2 - 4 and 8 are left out of count on the 6 M 32.

9 M 32 C: Before assembling the camshaft press in parallel pin at the corresponding flange index. Flange index here 0+5

0+8

Section-cylinder Flange index

0+2

0+6

0+4

0+4

0+6

0+2

0+8

1

2

3

4

5

6

7

8

9

0+5

0+8

0+2

0+6

0+4

0+4

0+6

0+2

0+8

Holes 1 - 3 and 7 are left out of count on the 9 M 32.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

180

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly 8 M 32 C 8 M 32 C: Before assembling the camshaft press in parallel pin at the corresponding flange index. Flange index here 0+1

Section-cylinder Flange index

0+2

0+3

0+4

0+5

0+6

0+7

0+8

1

2

3

4

5

6

7

8

0+1

0+2

0+3

0+4

0+5

0+6

0+7

0+8

Camshaft assembly 6 M 32 E Before assembly of the camshaft provide the flanges with one parallel pin each according to the table. Press in parallel pin at the corresponding flange index. Section-cylinder

1

2

3

4

5

6

Flange index

5

1

6

5

3

7

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

181

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly 8 M 32 E Before assembly of the camshaft provide the flanges with one parallel pin each according to the table. Press in parallel pin at the corresponding flange index. Section-cylinder

1

2

3

4

5

6

7

8

Flange index

1

2

3

4

5

6

7

8

Camshaft assembly 9 M 32 E Before assembly of the camshaft provide the flanges with one parallel pin each according to the table. Press in parallel pin at the corresponding flange index. Section-cylinder

1

2

3

4

5

6

7

8

9

Flange index

5

3

8

4

2

2

4

8

3

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

182

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly RM 32 E Insert studs (5) with Dry

⇒

M = 50

Tighten hexagon nuts M16 (7) with Molykote G Rapid Plus

⇒

M = 210 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

183

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - VM 32 Tighten screws (1) with Molykote Tighten screw (2) with Molykote For variants with thrust washer / governor drive pinion Tighten screws (3) with Molykote Tighten screws (4) with Molykote

⇒

M = 210 Nm

⇒

M = 210 Nm

⇒

M = 190 Nm

⇒

M = 220 Nm

Driving end

Camshaft bank A

Driving end

Camshaft bank B without thrust washer (partly also equipped with governor drive pinion / at bank A thrust washer instead)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

184

m

c2

Engineer’s Handbook Camshaft

M 32

Arrangement for 12 M 32 Bank A

Free end

Marking of the pins on the bearing journal, seen from driving end

Driving end

Bearing journal A1

Bearing journal No. 12 M 32 A1 A2 A3 A4 A5 A6

Driving end 1 1 1 1 1 1

B1 B2 B3 B4 B5 B6

2 3 4 5 6 1

Free end 2 3 4 5 6 1 1 1 1 1 -

Bank B

Free end

Driving end

Marking of the pins on the bearing journal, seen from driving end

Bearing journal B1 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

185

m

c2

Engineer’s Handbook Camshaft

M 32

Arrangement for 16 M 32 Bank A

Bearing journal No. 16 M 32 A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8

Free end

Marking of the pins on the bearing journal, seen from driving end

Driving end

Bearing journal A1

Driving end 2 3 4 5 6 7 8 1 1 1 1 1 1 1 1 1

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

Marking of the pins on the bearing journal, seen from driving end

Free end

Driving end

Bank B

Bearing journal B1 Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

186

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly VM 32 C Tighten screws (1) with Molykote

⇒

M = 210

Nm

Tighten screws (2) with Molykote

⇒

M = 210

Nm

Tighten screws (3) with Molykote

⇒

M = 260

Nm

End clearance at (5)

⇒

0.50 - 0.95 mm

Thrust washer

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

187

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - 12 M 32 C, bank A Example: Bearing journal

Driving end

Free end

Pin Driving end

Pin Free end

Flange index here 1

6 1

5 1

4 1

3 1

2 1

Press in parallel pin at the corresponding flange index. A1

A2

A3

A4

A5

A6

Flange index Driving end

1

1

1

1

1

1

Flange index Free end

2

3

4

5

6

-

Bearing journal No.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

188

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - 12 M 32 C, bank B Example: Bearing journal

Free end

Driving end

Pin Free end

Pin Driving end

Flange index here 2 1

3 1

4 1

5 1

6 1

1

Press in parallel pin at the corresponding flange index. B1

B2

B3

B4

B5

B6

Flange index Driving end

2

3

4

5

6

1

Flange index Free end

1

1

1

1

1

-

Bearing journal No.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

189

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - 16 M 32 C, bank A Example: Bearing journal

Driving end

Pin Driving end

Pin Free end

1

1 8

1 7

1 6

Flange index here 1 5 1 4

Free end

1 3

1 2

Press in parallel pin at the corresponding flange index. A1

A2

A3

A4

A5

A6

A7

A8

Flange index Driving end

2

3

4

5

6

7

8

1

Flange index Free end

1

1

1

1

1

1

1

-

Bearing journal No.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

190

m

c2

Engineer’s Handbook Camshaft

M 32

Camshaft assembly - 16 M 32 C, bank B Example: Bearing journal

Free end

Driving end

Pin Free end

Pin Driving end

Flange index here 1 2

1 3

1 4

1 5

1 6

1 7

1 8

1

Press in parallel pin at the corresponding flange index. B1

B2

B3

B4

B5

B6

B7

B8

Flange index Driving end

1

1

1

1

1

1

1

1

Flange index Free end

2

3

4

5

6

7

8

-

Bearing journal No.

Gear wheel on camshaft See chapter “Timing Gear Train RM 32 and VM 32” or chapter “Timing Gear Train RM 32 C and VM 32 C” or chapter “Timing Gear Train RM 32 E and VM 32 E”, section “Camshaft gear installation”

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

191

m

c2

Engineer’s Handbook Camshaft

M 32

Vibration damper installation Before dismounting the intermediate piece from the camshaft, mark or take a note of which holes are provided with screws (2)! On newer engines the intermediate piece has an oil groove. The oil cools the vibration damper. Maintenance intervals and replacement deadlines are specified in the maintenance plan of the operating instructions. The following tables indicate the tightening torques for screws (1) and bolts / nuts (2). Use Molykote for each screw connection.

Screws (1)

Tightening torque

6 M 32 / 8 M 32

M10x60 -10.9

50 Nm

Nut M16

210 Nm

6 M 32 C / 8 M 32 C

M10x60 -10.9

50 Nm

Nut M16

210 Nm

8 M 32 C

M10x65 -10.9

50 Nm

Nut M16

210 Nm

9 M 32 C

M16x100 - 8.8

130 Nm

Nut M16

210 Nm

9 M 32 C

M16x100 - 10.9

210 Nm

Nut M16

210 Nm

VM 32 / VM 32 C

M10x60 - 10.9

50 Nm

M16x75 - 10.9

210 Nm

12 M 32 C

M16x80 - 8.8

130 Nm

M16x75 - 10.9

210 Nm

Engine

Bolts or nuts (2)

Tightening torque

RM 32 and RM 32 C:

VM 32 and VM 32 C:

Position of last bearing Bank A

Position of last bearing Bank B

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

192

m

Engineer’s Handbook Camshaft

M 32

c2

Vibration damper removal and installation 1. Fasten brackets (4) and (5) as shown. 2. Put the bridge (1) with cross slide (2) onto the bracket (5) and fix with pin (7). 3. For damper diameter 330 insert the receptacle (3) into the cross slide (2). 4. Lift the bridge (1) and push the cross slide (2) underneath the damper. Then, lower the bridge again. 5. After that, screw the tightener (6) to full length and fix in the bracket (5) with pin. 6. Unscrew the damper, extract it with the cross slide (2) and take it over with the crane. 7. Installation takes place in reverse order.

For vibration damper ∅ 400

For vibration damper ∅ 330

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

193

m

c2

Engineer’s Handbook Camshaft

M 32

Installation of additional masses (9 M 32 CCR) (with and without FCT) The additional masses are installed instead of the vibration damper. Tighten screws (8) M16x100 with Molykote

⇒

M = 130 Nm

Tighten nuts (10) M16 with Molykote

⇒

M = 210 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

194

m

c2

Engineer’s Handbook Camshaft

M 32

Installation of additional masses (6/8 M 32 CCR) (with and without FCT) The additional mass is installed instead of the vibration damper. Tighten screws (8) M16x150 8.8 with Molykote

⇒

M = 130 Nm

Hole assignment 6 M 32 C:

Insert the screws here

Hole assignment 8 M 32 C:

Insert the screws here

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

195

m

Engineer’s Handbook Starting Air Distributor

M 32

c2

Starting air distributor Installation (new design) - RM 32 Tighten screws (6) with Molykote

⇒

M = 17

Nm

Tighten screws (7) with Molykote

⇒

M = 34

Nm

Tighten nut (8) with Molykote

⇒

M = 30 - 40 Nm

Adjusting instruction (new design) - RM 32 1. Bar the piston of cylinder 1 to 7° after firing TDC. 2. Loosen nut (8). 3. Turn washer (9) on the shaft cone until the slot of the washer intersects the hole for cylinder 1 (see also sketch above, under old design). In doing so, pay attention to the direction of rotation of the engine. 4. Tighten nut (8) by hand. 5. Fasten shaft (10) in a vice (soft jaws). Tighten nut (8) with 30 - 40 Nm and secure with washer (11). Molykote 6. Before assembly check the position of shaft and washer. Clearance at A = 1.85 mm ± 0.2 mm End clearance at B = 0.5 mm - 0.95 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

196

m

c2

Engineer’s Handbook Starting Air Distributor

M 32

RM 32 - VM 32 - M 32 C - M 32 E Installation (old design) Tighten screws (1) with Molykote Tighten screws (2) with Molykote Tighten nut (3) with Molykote

⇒

M = 17

Nm

⇒

M = 34

Nm

⇒

M = 30 - 40 Nm

For RM 32: Helical gear wheel For VM 32: Thrust washer

Direction of rotation of the engine

Clockwise

Cyl. 1 Counterclockwise

Adjusting instruction (old design) 1. Bar the piston of cylinder 1 to 7° after firing TDC. 2. Loosen nut (3). Attention! The nut has a left-hand thread. 3. Turn washer (4) on the shaft cone until the slot of the washer intersects the hole for cylinder 1 (see sketch). In doing so, pay attention to the direction of rotation of the engine. After completion of the installation the adjustment must be checked. 4. Tighten nut (3) by hand. 5. Fasten shaft (5) in a vice (soft jaws) and tighten nut (3) with 30 - 40 Nm. Molykote 6. Before assembly check the position of shaft and washer. Clearance at A = 0.5 mm + 0.2 Attention: At B there must be a clearance of 1.5 ± 0.5 mm between nut with lefthand thread and cover, otherwise there is a risk of damage. On the VM 32 engine the starting air distributor is installed on the A side.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

197

m

Engineer’s Handbook Starting Air Distributor

M 32

c2

Pipes on the starting air distributor Tighten screws (6) for fastening the pipes with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 10 Nm

198

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Lower valve drive Attention! When installing/removing valve drive cylinder units make sure that the cam follower bracket piece are kept together according to their marking!It is not admissible to interchange cam follower bracket parts with parts of other cylinder units! Lower valve drive: Installation (RM 32, RM 32 C, and RM 32 E with FCT) 1. Start the assembly at the free end of the engine and proceed towards driving end. 2. Install the first cylinder unit and tighten the screws for the bearing brackets finger tight. The lower drive shall come to rest on screws (2) (M20x180 8.8) because of its own weight. 3. After assembly of the first drive unit at the free end mount the toothed shaft (toothed shaft is movable). 4. Assemble the next valve drive units the same way. 5. When connecting the valve drives by means of the toothed shaft pay attention to the position of the cam follower shafts. Hole (Ø 8 mm) in the cam follower shaft must be oriented vertically upward, see figures below (use mandrel for orientation). 6. After connecting the cylinder units mount limit stop (4). Observe the mounting position. 7. Install all cylinder units. Starting from the centre of the engine and proceeding towards the outside, tighten screws (1) and (2) for bearing brackets with M = 300 Nm. Use Molykote. Check the valve drive structure for ease of movement. If necessary, loosen valve unit and align it until ease of movement is ensured. 8. After checking ease of movement insert push-rods and install gear wheel (7). Mount gear wheel (7) with clamping collar (6) as described on the next page. Tighten screws (5) with ⇒ Molykote Tighten screws (3) with ⇒ Molykote Tighten screw plugs in the cam follower shaft (if provided) with Oil During assembly pay attention

to position of the hole (other cylinders)

M = 55

Nm

M = 130 Nm M = 200 Nm

During assembly pay attention to position of the hole (other cylinders)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

199

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Assembly of gear wheel with clamping collar (RM 32, RM 32 C, and RM 32 E with FCT) 1. Unscrew clamping screws (8) on clamping collar (6) by a few turns. 2. Unscrew as many clamping screws as there are jacking threads and screw them into the jacking holes to maintain a clearance between inner and outer part. 3. Lightly oil clamping collar (6). Do not use oil with molybdenum sulphide or high-pressure additives nor grease. 4. Insert clamping collar (6) into gear wheel and push onto the shaft. 5. Unscrew screws out of the jacking threads and screw them back into the clamping holes. 6. Tighten clamping screws (8) crosswise by hand. In doing so, align the hub. 7. Tighten clamping screws (8) crosswise with half the tightening torque M = 17 Nm using a torque wrench. 8. Tighten clamping screws (8) in sequence several times with the full tightening torque M = 35 Nm 9. The tightening operation is completed when none of the screws is turning any more when applying tightening torque.

Installation of limit switch bracket (RM 32, RM 32 C, and RM 32 E with FCT) The installation of limit switch bracket (9) depends on the direction of rotation of the engine: Engine turning counter-clockwise: Fit bracket (9) to lower limit stop (4). Engine turning clockwise: Fit bracket (9) to upper limit stop (4). (Figure shows an engine turning counter-clockwise.)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

200

m

c2

Engineer’s Handbook Lower Valve Drive

M 32

Position switch (FCT) On RM tighten the nut (1) of the position switch (2) with max. During installation make sure that the distance between switch and limit stop is 4 mm. On VM tighten the nut (3) of the position switch with max. During installation make sure that the distance between switch and limit stop is 3 mm.

⇒

M = 20 Nm

⇒

M = 36 Nm

These values apply to both counter-clockwise and clockwise turning engines.

RM:

VM:

Adjustment of start of fuel delivery see chapters “IMO Adjustment” and “Injection Pump”

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

201

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Adjusting unit: Blocking screw Installation of the blocking screw without blocking in normal operation using the example of an adjusting unit of variant -01: Blocking screw

Position of the blocking screw for an engine turning counter-clockwise in normal operation

Mounting of the blocking screw for blocking the lever in emergency operation: Blocking screw

Position of the blocking screw for an engine turning counter-clockwise in emergency operation

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

202

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Adjusting unit: Assembly - RM 32 C (early variant 1.90.7-44.81.00-01) Preparation of the valve drive: •

Check the position of the cam follower shafts with respect to each other; all eccentrics of the cam follower shafts must point in one direction (mandrel, Ø 8 mm).

•

Adjust cam follower shaft: Engine turning counter-clockwise: Turn the cam follower shafts of the lower valve drive so that the limit stop (clamping piece) at cylinder 1 points downward. This corresponds to “Normal” position. Engine turning clockwise: Turn the cam follower shafts of the lower valve drive so that the limit stop (clamping piece) at cylinder 1 points downward. This corresponds to “Early” position.

•

Fix the position of the limit stop at cyl. 1 by means of a vice or a similar tool.

Preparation of the adjusting unit: • • • • •

Remove the claddings from the adjusting unit so that the lever and the limit contacts are accessible. Push the piston rod with lever into the cylinder up to end position. Move the piston rod 10 to 15 mm* away from the end position and mark the position of lever and piston rod. Check the basic position of the eccentric bearing caps, align “0”-position with marking on the casing (viewed from driving end). Fit lifting gear to eye bolt (28) and lift up adjusting unit.

Attention: Check the hose connections between pneumatic cylinder and 5/2-way valve depending on the direction of rotation of the engine: Engine turning counter-clockwise: Hose connection between connection 2 on the 5/2-way valve and position A on the cylinder. Hose connection between connection 4 on the 5/2-way valve and position B on the cylinder. Engine turning clockwise:

Hose connection between connection 2 on the 5/2-way valve and position B on the cylinder. Hose connection between connection 4 on the 5/2-way valve and position A on the cylinder.

* These dimensions may be too big. Check for reasons of safety whether both mechanical end positions are reached at station 1. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

203

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Installation of the adjusting unit: •

• •

• • •

•

Carefully put the adjusting unit onto mandrels 11.01-1347-001 (centering of the nonpinned adjusting unit via 2 mandrels). When doing so, ensure proper meshing of the gears of adjusting unit and cam follower shaft by slightly turning the lever in both directions at the moment of meshing. For this purpose, the lever may only be moved max. ± 2° from its initial position (next tooth space between adjusting unit gear and cam follower shaft gear). Screw down the adjusting unit. Check the backlash between the adjusting unit gear and the cam follower shaft gear (cap for backlash check). Backlash < 0.7 mm: Eccentric bearing at “0” position (minimum backlash must not be smaller than 0.21 mm). Backlash > 0.7 mm: Eccentric bearing at “-1” position If necessary, correct the backlash by turning the eccentric bearing caps correspondingly. Adjust the position of the lever on the adjusting unit to the position mark when starting the assembly of the adjusting unit. Pin the adjusting unit by means of a parallel pin (diameter 12 mm). Attention: The piston of the adjusting unit must not rest against the end positions of the cylinder. Complete the installation of the adjusting unit. For this purpose, request drawing 1.90.7-44.81.00-01 if necessary.

Adjustment of the limit switches: The limit switches are adjusted on the testbed when the engine is connected to the PLC or when the PLC can process the signals of the limit switches. The limit switches are arranged on the cylinder so that they can be shifted. • • •

Select the position of the limit switches in such a way that the piston position can always be safely detected at end position. Secure the limit switches so that they cannot be shifted any more. Mount the claddings over lever and limit switches.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

204

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Adjusting unit: Installation for M 32 C (new variants 1.90.7-44.81.00-02/-03/-04/-05) Adjusting unit: Installation for M 32 E (variants 3200.7-44.81.00-01/-02) Preparation of the valve drive: •

•

Check the position of the cam follower shafts with respect to each other; all eccentrics of the cam follower shafts must point in one direction (mandrel, Ø 8 mm). Adjust cam follower shaft: Engine turning counter-clockwise: Turn the cam follower shafts of the lower valve drive so that the limit stop (6) at cylinder 1 points downward. This corresponds to “Normal” position. Engine turning clockwise: Turn the cam follower shafts of the lower valve drive so that the limit stop (6) at cylinder 1 points upward. This corresponds to “Normal” position.

•

Fix the position of the limit stop by means of a vice or a similar tool.

Preparation of the adjusting unit: • Remove the claddings of lever and spring. •

Relieve spring (2) by evenly loosening nuts (3).

•

Engine turning counter-clockwise: Move the lever of the adjusting unit downward until the lower mechanical limit stop in the pneumatic cylinder is reached. Engine turning clockwise: Move the lever of the adjusting unit upward until the upper mechanical limit stop in the pneumatic cylinder is reached.

•

Move the piston rod 10 to 15 mm* away from the end position and mark the position of lever and piston rod. Check the basic position of the eccentric bearing caps. Align “0”-position with marking on the casing. Fit lifting gear to eye bolt (28) and lift up adjusting unit.

• •

* These dimensions may be too big. Check for reasons of safety whether both mechanical end positions are reached at station 1.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

205

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Installation of the adjusting unit: Install the adjusting unit with hexagon screws (centering of the adjusting unit via 2 pins). When doing so, ensure proper meshing of the gear of the adjusting unit with the gear of the cam follower shaft, if necessary by slightly turning the lever in both directions at the moment of meshing. For this purpose, the lever may only be moved max. ± 2° from its initial position (next tooth space between adjusting unit gear and cam follower shaft gear).

Check of the adjusting unit: •

Check the backlash between the adjusting unit gear and the cam follower shaft gear (cap for backlash check): Backlash < 0.7 mm: Eccentric bearing at “0” position (minimum backlash must not be smaller than 0.21 mm). Backlash > 0.7 mm: Eccentric bearing at “-1” position

•

If necessary, correct the backlash by turning the eccentric bearing caps correspondingly.

•

(RM 32 E only:) Attention! Only adjust to such an extent that the “-1” eccentric marking moves around below (otherwise there is a risk of jamming)!

•

Adjust the position of the lever on the adjusting unit to the position mark when starting the installation of the adjusting unit. Attention: The piston of the adjusting unit must not rest against the end positions of the cylinder.

•

Check the hoses between pneumatic cylinder and 5/2-way valve for correct connecting positions: Engine turning counter-clockwise:Hose connection between connection 4 on the 5/2way valve and position B on the cylinder. Hose connection between connection 2 on the 5/2-way valve and position A on the cylinder. Engine turning clockwise: Hose connection between connection 4 on the 5/2-way valve and position A on the cylinder. Hose connection between connection 2 on the 5/2-way valve and position B on the cylinder.

Adjustment of the limit switches: The limit switches are adjusted on the testbed when the engine is connected to the PLC or when the PLC can process the signals of the limit switches. •

Move lever of the adjusting unit to “Normal” position (for engines turning counterclockwise: lever down, for engines turning clockwise: lever up). Adjust the limit switch by turning the eccentric cap in such a way that the end position can be safely detected.

•

Move lever of the adjusting unit to “Early” position (for engines turning counter-

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

206

m

c2

Engineer’s Handbook Lower Valve Drive

M 32

clockwise: lever up, for engines turning clockwise: lever down). Adjust the limit switch by turning the eccentric cap in such a way that the end position can be safely detected.

Spring preload • •

Move lever (1) of the adjusting unit to “Normal” position (for engines turning counterclockwise: lever down, for engines turning clockwise: lever up). Preload the spring (2) by evenly tightening both nuts (3) until clamp (4) rests on plate (5).

Engine turning counter-clockwise

Engine turning clockwise

Marking of the lever on the adjusting unit for position detection later on: Engine turning counter-clockwise (as shown by the figures): Move lever of the adjusting unit downward (to “Lever down” position) until reaching the limit stop of the cam follower shaft. Apply marking “P.N.” (normal position) on bearing cap and lever in accordance with view Q by means of an electric engraver or embossed figures (min. height 8 mm). Move lever of the adjusting unit upward (to “Lever up” position) until reaching the limit stop of the cam follower shaft. Apply marking “P.E.” (early position) on bearing cap and lever in accordance with view W by means of an electric engraver or embossed figures (min. height 8 mm).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

207

m

c2

Engineer’s Handbook Lower Valve Drive

M 32

Engine turning clockwise (no figure): Move lever of the adjusting unit upward (to “Lever up” position) until reaching the limit stop of the cam follower shaft. Apply marking “P.N.” (normal position) on bearing cap and lever in accordance with view W by means of an electric engraver or embossed figures (min. height 8 mm). Move lever of the adjusting unit downward (to “Lever down” position) until reaching the limit stop of the cam follower shaft. Apply marking “P. E.” (early position) on bearing cap and lever in accordance with view Q by means of an electric engraver or embossed figures (min. height 8 mm). Install the claddings for lever and spring. Attention! Upon each reinstallation of an adjusting unit make sure the setting positions of adjusting unit and valve drive are matching! The following example illustrations show an engine turning counter-clockwise:

Lever down: “Normal” position

Here marking on bearing cap and lever

Lever up: “Early” position

Here marking on bearing cap and lever

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

208

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Adjusting unit: Installation for VM 32 C (variant 1.91.7-44.81.00-01) (all data for engines turning counter-clockwise) Preparation of the valve drive: •

Check the position of the cam follower shafts with respect to each other; all eccentrics of the cam follower shafts of one cylinder bank must point in one direction (mandrel, Ø 8 mm).

•

Adjust cam follower shaft:

•

A side:

Turn the cam follower shafts of the lower valve drive so that the limit stop (6) at cylinder 1 points upward. This corresponds to “Normal” position.

B side:

Turn the cam follower shafts of the lower valve drive so that the limit stop (6) at cylinder 1 points downward. This corresponds to “Normal” position.

Fix the position of the limit stop at cylinder A1 and cylinder B1 by means of a vice or a similar tool.

Preparation of the adjusting unit: • • • •

• • •

Mount the claddings of lever and spring. Relieve spring (2) by evenly loosening nuts (3). Push the piston rod with lever into the cylinder up to end position. A side: Move the lever of the adjusting unit upward until the upper mechanical limit stop in the pneumatic cylinder is reached. B side: Move the lever of the adjusting unit downward until the lower mechanical limit stop in the pneumatic cylinder is reached. Move the piston rod 10 to 15 mm* away from the end position and mark the position of lever and piston rod. Check the basic position of the eccentric bearing caps. Align “0”-position with marking on the casing. Take up adjusting unit in mounting device.

* These dimensions may be too big. Check for reasons of safety whether both mechanical end positions are reached at station 1. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

209

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Installation of the adjusting unit: Install the adjusting unit with hexagon screws (centering of the adjusting unit via 2 pins). When doing so, ensure proper meshing of the gear of the adjusting unit with the gear of the cam follower shaft, if necessary by slightly turning the lever in both directions at the moment of meshing. For this purpose, the lever may only be moved max. ± 2° from its initial position (next tooth space between adjusting unit gear and cam follower shaft gear). Check of the adjusting unit: •

Check the backlash between the adjusting unit gear and the cam follower shaft gear (cap for backlash check): Backlash < 0.7 mm: Eccentric bearing at “0” position (minimum backlash must not be smaller than 0.21 mm). Backlash > 0.7 mm: Eccentric bearing at “-1” position

•

If necessary, correct the backlash by turning the eccentric bearing caps correspondingly.

•

Adjust the position of the lever on the adjusting unit to the position mark when starting the installation of the adjusting unit. Attention: The piston of the adjusting unit must not rest against the end positions of the cylinder.

•

Check the hoses between pneumatic cylinder and 5/2-way valve for correct connecting positions: A side:

Hose connection between connection 2 on the 5/2-way valve and position B on the cylinder. Hose connection between connection 4 on the 5/2-way valve and position A on the cylinder.

B side:

Hose connection between connection 2 on the 5/2-way valve and position A on the cylinder. Hose connection between connection 4 on the 5/2-way valve and position B on the cylinder.

Adjustment of the limit switches: The limit switches are adjusted on the testbed when the engine is connected to the PLC or when the PLC can process the signals of the limit switches. •

Move lever of the adjusting unit to “Normal” position (A side: lever up, B side: lever down). Adjust the limit switch by turning the eccentric cap in such a way that the end position can be safely detected.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

210

m

c2

Engineer’s Handbook Lower Valve Drive

M 32

•

Move lever of the adjusting unit to “Early” position (A side: lever down, B side: lever up). Adjust the limit switch by turning the eccentric cap in such a way that the end position can be safely detected.

•

If necessary, shift the contact washer at the gear wheel of the adjusting unit (accessible via screw plugs) so that the end positions can be safely detected.

Spring preload •

Move lever (1) of the adjusting unit to “Normal” position (A side: lever up, B side: lever down).

•

Preload the spring (2) by evenly tightening both nuts (3) until clamp (4) rests on plate (5).

•

Install the claddings for lever and spring.

Attention: Upon each reinstallation of an adjusting unit make sure the setting positions of adjusting unit and valve drive are matching!

A side

B side

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

211

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

RM 32 - VM 32 Bearing brackets for eccentric cam follower shafts (non FCT) Tighten screws (1) and (2) for the bearing brackets with ⇒ Nm. Molykote

M = 260

In order to be able to adjust the start of fuel delivery, the cam follower shafts of this variant are designed as eccentrics. After loosening screws (2) from the bearing bracket and removing part (3) hole (4) becomes visible. After inserting a cylindrical lever into the hole the cam follower shaft can be turned as needed. For this version the pins (5) are not provided any more. Adjust the end clearances of 0.30 mm at (6) by shifting the non-pinned (central) bearing brackets.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

212

m

c2

Engineer’s Handbook Lower Valve Drive

M 32

Bearing brackets with shims Tighten screws for bearing brackets (1) before IMO adjustment with ⇒ Molykote

M = 150 Nm

⇒

M = 300 Nm

Tighten screws for bearing brackets (1) after IMO adjustment with Molykote

The shims (2) between engine block and bearing brackets are emission relevant components. It is not admissible to interchange any shims with those of other cylinder units! If, for whatever reason, an IMO readjustment should become necessary on any of the cylinder units, bar the engine until all rollers of the cylinder unit are on the base circle of the camshaft. Observe the tightening torques above. After that, adjust as described in chapter “IMO Adjustment“, paragraph “IMO adjustment of start of fuel delivery, lower valve drive (M 32 C)”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

213

m

Engineer’s Handbook Lower Valve Drive

M 32

c2

Cam follower

Clockwise execution

Counter-clockwise execution

For fitting ball socket (1) or ball piece (2) cool ball socket or ball piece down to -195 °C with liquid nitrogen and press into the cam follower as far as it will go. Ball socket (1) or ball piece (2) must rest against the cam follower without any gap at least at one point on the circumference. Degrease the thread of the headless screw (3) and secure with Loctite 243. For fitting bush (6) cool the bush down with liquid nitrogen and press into the cam follower as far as it will go. Align the “0” marking with respect to the pin. Cool the bolt (4) down to -195 °C with liquid nitrogen for installation in the cam follower. Inserting the expanders (no figure) according to the instructions of the manufacturer and with the tools and tests specified by the manufacturer.

Push-rods Heat push-rod up to approximately 80 °C. Cool ball socket and ball insert down to -195 °C using liquid nitrogen. Assemble without locating blow (risk of cracks)! For variant 1.90.7-35.70.00-04 press in ball socket and ball insert with 100 kN.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

214

m

c2

Engineer’s Handbook Injection Pump

M 32

Injection pump Note: Injection pumps are loosing lubricating oil during operation. This is attributable to their design and operation. The max. limit is 100 ml / pump / hour Reuse of the leak oil is not possible because it is contaminated with HFO.

Fastening of the pump Insert the studs into the engine block with a torque of Molykote Tighten the fastening nuts with Molykote

⇒

= 150 Nm

⇒

= 260 Nm

Before installing the pump bar the engine until the roller of the cam follower rests on the camshaft base circle. Pumps

PEO-G055a PEO-G058 PEO-G062 Tighten screws (1) with

⇒

M = 140

Nm

Tighten screws (2) with

⇒

M = 70

Nm

Tighten screws (3) with

⇒

M = 30

Nm

PEO-G058a PEO-G062a Tighten screws (1) with

⇒

M = 140

Nm

Tighten screws (2) with

⇒

M = 80

Nm

Tighten screws (3) with

⇒

M = 30

Nm

⇒

M = 140

Nm

⇒

M = 70

Nm

⇒

M = 30

Nm

Pumps

Pumps

PEO-G055c PEO-G072 PEO-A086V1 Tighten screws (1) with Oil Tighten screws (2) with Oil Tighten screws (3) with Oil Pumps Pump Pumps Pump

PEO-G055a, PEO-G055c, PEO-G058 are used in RM 32 engines. PEO-G058 is used in all engine variants. PEO-G072, PEO-G062, and PEO-G062a are used in VM 32 engines. PEO-A086V1 is used in IMO II engines and has a leak rate of only max. 50 ml/hour

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

215

m

Engineer’s Handbook Injection Pump

M 32

c2

Adjustment and determination of injection pump spacer plate thickness When installing the pump bar the engine until the roller of the cam follower rests on the camshaft base circle. 1. Determine the reference dimension 78.5 (including 0.2 mm clearance) by means of device 11.01-0913. During this, the eccentric has to point vertically upward. 2. Place the device onto a level support. Put on digital dial gauge with device and set digital dial gauge to 0. 3. Bar the engine until the roller of the fuel pump drive is on the cam base circle. 4. Insert the measuring device into the injection pump hole in the engine block and read the value off the dial gauge. 5. Displayed value = thickness of spacer plates. Upon removal/installation make sure not to remove the related spacer plates. If it is indispensable to remove spacer plates, mark them with the respective cylinder number. The thickness of the spacer plates for each cylinder is indicated in the acceptance test record!

Available thicknesses: 2.40 mm 2.50 mm 2.60 mm 2.70 mm 2.80 mm 2.90 mm 3.00 mm 3.10 mm 3.20 mm 3.30 mm 3.40 mm 3.50 mm 3.60 mm 3.70 mm 3.80 mm 3.90 mm 4.00 mm 4.10 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

216

m

c2

Engineer’s Handbook Injection Pump

M 32

For adjusting the correct dimension use a spacer plate

Adjustment of start of fuel delivery (RM) for engine Nos. 37003* - 37005 - 37006 - 37008* - 37010 * = Twin-engine plant Adjust the eccentric of the cam follower shaft depending on direction of rotation. Engine turning counter-clockwise: 33.6° in direction of the outer edge of the engine. Engine turning clockwise: 47.7° in direction of the engine center.

Engine turning clockwise

Engine turning counter-clockwise

Basic setting Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

217

m

c2

Engineer’s Handbook Injection Pump

M 32

Adjustment of start of fuel delivery for engines without eccentric This adjustment must be applied when a major overhaul has taken place and the fuel injection pumps are empty. 1. The flywheel diameter of all engines is Ø 1439 mm, i.e. 1° ~12.6 mm. 2. The TDC positions of the individual cylinders are marked on the flywheel. 3. Bar the engine so that the roller of the fuel pump drive of cylinder 1 is on the cam base circle. 4. Remove the connection piece from the fuel injection pump of cylinder 1. Attention: Pay attention to delivery valve spring and valve spring. Insert digital dial gauge (magnetic support) with a preload of about 3 mm into the hole for the delivery valve. Set the digital dial gauge to 0. Bar the engine in direction of rotation until the digital dial gauge indicates 7.8 mm (prelift). 5. Fit the hydraulic connection to the hub for the camshaft gear wheel and increase pressure to P = 800 bar. 6. Bar the engine until at the flywheel 11.5° CA (crank angle) before TDC appears for cylinder 1. Attention: Remove the hydraulic connection immediately because otherwise damage is inevitable. 7. For checking the adjustment, bar the engine in direction of rotation until the digital dial gauge at cylinder 1 indicates 7.8 mm. Now the value of 11.5° CA before TDC must appear again at the flywheel. The adjustment is complete. Camshaft gear wheel in new design

Hub for camshaft gear wheel, old design

Hydraulic connection for adjustment. Remove connection immediately after adjusting.

Remove screw plug for adjusting

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

218

m

Engineer’s Handbook Injection Pump

M 32

c2

RM 32 - VM 32 Adjustment of start of fuel delivery for engines with eccentrics on the cam follower shafts The flywheel diameter of all engines is Ø 1439 mm, i.e. 1° ~ 12.6 mm. These engines are equipped with a new fuel injection pump, furthermore the cam follower shafts feature an eccentricity of 1.50 mm. By turning the cam follower shafts (depending on direction of rotation) the start of fuel delivery and ignition pressure can be adjusted. The spacer plates of the individual cylinders are determined as described above.

1. Place the dial gauge with 72.3 mm gauge block onto a level support and set to 0. (preload). 2. Remove the fuel injection pump from cylinder 1, mount the dial gauge with gauge block and bar the engine until the dial gauge indicates 0 again. The camshaft must be maintained in its position. 3. Remove the screw plug under the starting air distributor, pump up the camshaft gear wheel and bar the engine until the following is displayed: 6.5° ± 0.5° CA before TDC for RM 32 of IMO version and 11.5° CA before TDC for RM 32 with and without eccentric as well as 14° CA before TDC for VM 32 that is always equipped with eccentrics on the cam follower shafts. In doing so, observe the dial gauge, it must continue to indicate 0.After that, it is absolutely required to remove the hydraulic connection to the camshaft gear wheel. Only bar the engine when the hydraulic connection has been removed. 4. Bar the engine for one complete revolutionAt 6.5° ± 0.5° / 11.5° CA before TDC or 14° CA before TDC the dial gauge must indicate 0 again. If necessary, repeat the operation. Ignition pressure differences between the individual cylinders can be balanced by adjusting the cam follower shafts. For adjusting remove the small caps of the camshaft covering. Loosen the two outer bearing brackets and remove the bearing cap of the central bearing bracket. After removal a hole (Ø 6 mm) becomes visible. This hole is to be used for adjusting. Turning by 1 mm ~ about 8 bar

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

219

m

Engineer’s Handbook Injection Pump

M 32

c2

RM 32

Engine turning clockwise Early ignition

Retarded ignition

Cam follower shaft with eccentric

Engine turning counter-clockwise Retarded ignition

Early ignition

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

220

m

Engineer’s Handbook Injection Pump

M 32

c2

VM 32 Engine turning clockwise Early ignition

Retarded ignition

Cam follower shaft with eccentric

Engine turning counter-clockwise Retarded ignition

Early ignition

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

221

m

c2

Engineer’s Handbook Injection Pump

M 32

Attention! The following information only applies to engines without FCT! The engines listed below are equipped with eccentrics on the cam follower shafts to balance ignition pressures. Boldface = IMO engines 6 M 32

37032 37083 37136 37170 37208

37035 37103 37137 37171 37230

37073 37105 37150 37200 37236

37075 37122 37151 37201 37237

37076 37134 37155 37202

37082 37135 37156 37207

8 M 32

37018 37087 37107 37113 37123 37129 37139 37157 37164 37172 37178 37184 37197

37033 37088 37108 37114 37124 37130 37140 37158 37165 37173 37179 37185 37198

37034 37089 37109 37115 37125 37131 37141 37159 37166 37174 37180 37186 37206

37077 37090 37110 37116 37126 37132 37152 37161 37167 37175 37181 37187 37209

37078 37098 37111 37118 37127 37133 37153 37162 37168 37176 37182 37188 37220

37085 37106 37112 37119 37128 37138 37154 37163 37169 37177 37183 37189 37221

9 M 32

37061 37099 37190 37205 37232

37071 37100 37191 37214 37233

37072 37120 37192 37215 37234

37093 37121 37193 37225 37235

37094 37143 37203 37226

37095 37144 37204 37231

All further engines are equipped with eccentrics on the cam follower shafts. Starting with engine number 37238 all engines are IMO engines. VM 32 engines are always equipped with eccentrics on the cam follower shafts.

Stop cylinder at the injection pump Degrease nut and thread of the stop cylinder (1) at the injection pump and secure with Loctite 243.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

222

m

Engineer’s Handbook Common Rail Components

M 32

c2

Common rail components Safety note - observe before carrying out any work!

DANGER Attention, danger to life! The high-pressure system has an operating pressure of approximately 1,600 bar. If this pressure is released in an uncontrolled manner, there is danger to life! Therefore, before carrying out any work on the high-pressure system: - Shut off the fuel supply to the engine - Set the selector switch on the local control stand to “Repair” - Check whether the pin projects out of the circulation valve. If this is the case, the system is under pressure. Depressurize the fuel system. The pin must not be visible when starting any work!

NOTE Do not contaminate the fuel system. When carrying out any work on the fuel system always ensure cleanliness. Even the slightest contamination may cause engine malfunction.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

223

m

Engineer’s Handbook Common Rail Components

M 32

c2

Installation of the high-pressure pipes Before installing the rail segments the connection segments of the jacket tube must be aligned with respect to the sealing faces of the high-pressure outlets. For this purpose the tool kit includes 2 alignment mandrels: 9.1027-001 and 0.1027-002. Align the connection segments to the sealing faces of the rail by means of the alignment mandrels to reach an optimal position of the sealing faces with respect to each other. This must be done before putting on the high-pressure pipes. It must be easily possible to insert the alignment mandrel into the corresponding high-pressure outlet of the rail. In order to avoid leaks upon installation of the high-pressure pipes check reference dimension S between pipe tip and thrust ring by means of a sliding rule and adjust if necessary. There are different reference dimensions for the individual threaded connections on the rail: Threaded connection

Reference dimension S

Rail - injector (on rail side)

5.7 ± 0.3 mm

Rail - rail (on both sides)

11.9 ± 0.3 mm

Rail - pump, top (on both sides)

7.6 ± 0.3 mm

Rail - pump, bottom (on both sides)

7.6 ± 0.3 mm

If these values are not reached, the high-pressure pipe must be replaced.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

224

m

c2

Engineer’s Handbook Common Rail Components

M 32

High-pressure pump To check the backlash of 0.2 - 0.4 mm unscrew screw plug (1). If necessary, correct the backlash by mounting a different shim between engine block and pump support casing. Available thicknesses: 5.10 mm

5.05 mm

5.00 mm

4.95 mm

4.90 mm

When fitting a shim, apply liquid sealing compound to both sides (DIRKO HT, No. 465.763). Ensure correct post-assembly position of the pump. The pump shaft positions must be at a 90° offset with respect to each other. The marking on the camshaft shows the position of the first cam of the high-pressure pump (X). Tighten screws (2) with Molykote Tighten screws (3) with Molykote Tighten screws (5) with Molykote Tighten screw plug (7) for filter element with Molykote Tighten lubricating oil connections (6) with Tighten screws (8) with Molykote

⇒

M = 85

Nm

⇒

M = 60

Nm

⇒

M = 30

Nm

⇒

M = 430

Nm

⇒

M = 40

Nm

⇒

M = 145 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

225

m

c2

Engineer’s Handbook Common Rail Components

M 32

The two oil grooves of the thrust bearings at (7) must point towards the pump camshaft. Press on gear wheel (11) hydraulically. Slide-on distance

⇒

6.5 mm + 0.2 mm

Tighten nut (8) with

⇒

100 Nm

Tighten screws (9) (4 pcs.) with

⇒

10 Nm

Tighten screws (10) (6 pcs.) with

⇒

30 Nm

Total end clearance X + Y of the pump camshaft

⇒

0.2 to 0.8 mm

Apply a thin coat of Petro Gel Amber to the O-rings in the area of the pump drive.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

226

m

c2

Engineer’s Handbook Common Rail Components

M 32

Tighten connection for fuel pressure sensor (12) with

⇒

20

Tighten hexagon socket screw (13) with

⇒

250 Nm

Tighten connection for fuel inlet (14) with

⇒

100 Nm

Tighten screws (15) (3 pcs.) with

⇒

30

Nm

Tighten screws (16) for the casing (6 pcs.) with Observe tightening order from 1 to 6.

⇒

70

Nm

⇒ ⇒

20 Nm + 2 Nm 90° + 5°

Tighten screws (17) (8 pcs.) for the pump element in 2 steps: First pretighten with Then finally tighten with a torque angle of

Nm

Observe tightening order from A to D.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

227

m

c2

Engineer’s Handbook Common Rail Components

M 32

Tighten the connection thread for the lubricating oil inlet (18) with For high-pressure pumps 0.00.6-73.16.00-13 and 0.00.6-73.16.00-14: Tighten the connection thread for the lubricating oil inlet (18) with

Tighten screws (19) with

⇒

40 Nm

⇒

40 Nm

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

30 Nm

228

m

c2

Engineer’s Handbook Common Rail Components

M 32

Injector Installation instructions • Insert injector into cylinder head. As the bottom side of nozzle cap (5) is a sealing face, it is critical to ensure cleanliness during installation! • Loosen nut W 18 (2) at the cable gland (7) in the cylinder head wall (push-rod side) so that it can be shifted. • Loosen nut W 36 (6) of the bulkhead connector (8) and remove it. • Push flange over plug and injector cable and fasten injector. • Pass the injector cable with plug through the hole in the area of the push-rod space. • Install bulkhead connector (8). In doing so, pay attention to the supplied O-ring! Tighten nut (6) of the bulkhead connector with • • • •

⇒

M = 50 Nm

Install the bracket (79) for the injector cable between the rocker arms. Fasten the injector cable with clamp (92) on bracket (79). The injector cable must not contact any moving parts. Make sure the injector cable is installed without being subject to any stress!

• Tighten nut (2) of the cable gland with

⇒

M = 10 Nm

• Tighten screw (1) for the bracket (79) of the injector cable with Loctite 243

⇒

M = 50 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

229

m

c2

Engineer’s Handbook Common Rail Components

M 32

To fasten the injector, tighten nuts (3) evenly by hand (without tool). Ensure flush contact of the flange. Tighten nuts (3) in two steps with Molykote

⇒

M = 60

Tighten nozzle cap (5) with Apply Molykote to thread and shoulder

⇒

M = 350 ± 15 Nm

Nm

Tightening torque for screw plug (9) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Insert nozzle element (4) with high-temperature thread paste and install with mounting device 30-450-00638. Apply a thin coat of high-temperature thread paste to injector seat and injector.

Attention! No sealing ring

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

230

m

c2

Engineer’s Handbook Common Rail Components

M 32

Rail installation according to EV 1.90.7-85.28.00-01 Attention! Rail segments are supplied in aligned condition and with transportation locks. These locks shall remain on the rail until it is fitted to the cylinder head. Observe the information provided in the paragraph “Installation of the high-pressure pipes“ (see above). Before installation of all high-pressure pipes lubricate the threads and contact surfaces of the thrust rings with oil. • Loosen rail brackets at the rail so that they can be shifted lengthwise. • Lift rail by means of a cross piece attached to the transportation locks of the outer highpressure outlets and put onto the pre-assembled cast brackets. Tighten screws (2) with the specified torque. Proceed in the same way for the other rail segments. • Remove transportation locks. • Check the high-pressure outlets for correct alignment by means of a mandrel and readjust if necessary. (details see above: Installation of the high-pressure pipes). This requires the flow limiters to be removed.

Mandrel 1:

Mandrel 2:

Use mandrel 1 (MaK ord. No. 9.1027-001) for high-pressure outlets (6) to the cylinder head. Use mandrel 2 (MaK ord. No. 9.1027-002) for high-pressure outlets (5) of the connecting pipe. • Observe the following assembly sequence: In a first step, fasten the threaded connections finger tight. 1. High-pressure pipes to the cylinder head 2. Connecting pipe(s) 3. High-pressure pipes L1 and L2 to the pumps • Tighten all high-pressure pipes with the specified tightening torques. • Repeat the tightening procedure of the high-pressure threaded connections with the specified torque three times by loosening them in the interim. • Install bracket 1 at pump and high-pressure pipe L1 so as to be free of stress and tighten high-pressure threaded connection (3) of the pipe first at the rail and then at the pump by applying the specified tightening torque. • Install bracket 2 between high-pressure pipes L1 and L2 to the pumps so as to be free of stress and tighten high-pressure threaded connection (3) of pipe L2 first at the rail and then at the pump by applying the specified tightening torque. • Tighten clamping screws (9) of the rail brackets with the specified tightening torque. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

231

m

c2

Engineer’s Handbook Common Rail Components

M 32

Attention! Do not loosen screws (1)! Installation / removal may only be carried out by L’Orange!

Tighten screws (2) with Oil Tighten high-pressure threaded connections (3) with Oil Tighten high-pressure threaded connections (4) with Oil Tighten high-pressure threaded connections (5) with Oil Tighten high-pressure threaded connections (6) with Oil Tighten circulation valve (7) with Oil Tighten relief valve (8) with Oil Tighten clamping screws (9) at the rail brackets with Oil

⇒

M = 68

⇒

M = 300 + 10 Nm

⇒

M = 150 + 10 Nm

⇒

M = 300 + 10 Nm

⇒

M = 300 + 10 Nm

⇒

M = 250 + 10 Nm

⇒

M = 300 + 10 Nm

⇒

M = 10

Nm

Nm

Bracket 2

Bracket 1

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

232

m

Engineer’s Handbook Common Rail Components

M 32

c2

Use screw (10) only in case of emergency for pressure relief or draining. Tighten screw (10) with

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 15 Nm

233

m

c2

Engineer’s Handbook Common Rail Components

M 32

Rail installation according to EV 1.90.7-85.28.00-02 Rail segments are supplied in aligned condition and with transportation locks. At each high-pressure outlet of the rail segment there is a transportation lock with an M10 threaded hole on the top surface for fastening of a lifting eye bolt. Attention! The transportation locks are to remain on the rail until installation of the high-pressure pipes to the cylinder head! Observe the information provided in the paragraph “Installation of the high-pressure pipes“ (see above). 1. Take up first rail segment (10) with a suitable device. Check reference dimension 107.5 ± 0.5 (see detail V) on the first rail segment (applies to 3- and 4cylinder segment). Position and fix the rail segment on the engine.

Detail V

2. Align the first rail segment (10) with respect to the engine block and firmly mount on the preassembled cast brackets (4) with screws (5) and (9). 3. Using the alignment mandrel (MaK ord. No. 9.1027001, see detail W) check the alignment of the highpressure outlet with respect to cylinder 1 according to the assembly drawing and realign if necessary (for realignment the flow limiters must be removed).

Detail W

4. Check the high-pressure pipe for cleanliness. 5. Put in place the fuel delivery pipe from the first rail segment (10) to cylinder 1 and tighten the threaded connections by hand (if necessary, insert beforehand the flow limiter removed for adjusting the high-pressure outlet). 6. 6 M 32 and 9 M 32: Repeat steps 3. to 5. for the highpressure outlet to cylinder 2. 8 M 32: Repeat steps 3. to 5. for the high-pressure outlets to cylinders 2 and 3. 7. Take up second rail segment (11) with a suitable device. Check reference dimension 147.5 ± 0.5 (see detail X). Position and fix the rail segment on the engine.

Detail X

8. Align the second rail segment (11) with respect to the engine block and firmly mount on the pre-assembled cast brackets (4) with screws (5) and (9).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

234

m

c2

Engineer’s Handbook Common Rail Components

M 32

9. Using the alignment mandrel (MaK ord. No. 9.1027002, see detail Y) check the alignment of the highpressure outlets for the high-pressure connection pipe between first and second rail segment according to the assembly drawing and readjust if necessary.

Detail Y

10. Check the high-pressure outlets for cleanliness. 11. Put in place the high-pressure connection pipe between first and second rail segment and tighten threaded connections by hand. 12. 6 M 32: Repeat steps 3. to 5. for the high-pressure outlets to cylinders 3, 4, 5, and 6 and continue with step 17. 8 M 32: Repeat steps 3. to 5. for the high-pressure outlets to cylinders 4, 5, 6, 7, and 8 continue with step 17. 9 M 32: Repeat steps 3. to 5. for the high-pressure outlets to cylinders 3, 4, and 5, and continue with step 13. 13. Take up third rail segment (no picture) with a suitable device. Check reference dimension 147.5 ± 0.5 (see detail X). Position and fix the rail segment on the engine. 14. Align the third rail segment (no picture) with respect to the engine block and firmly mount on the pre-assembled cast brackets (4) with screws (5) and (9). 15. Repeat steps 9. to 11. for the high-pressure connection pipe between second and third rail segment. 16. Repeat steps 3. to 5. for the high-pressure outlets to cylinders 6, 7, 8, and 9. 17. Tighten all high-pressure threaded connections with the specified tightening torques. Repeat the tightening procedure of the high-pressure threaded connections with the specified torque three times by loosening them in the interim. 18. Loosen screws (5) and (9) of the rail segments and tighten again with the standard tightening torque for Molykote. 19. Put in place pipe clamp (6) (1x for 6 M 32 and 8 M 32, 2x for 9 M 32) together with bracket (3) so as to be finger tight. The parting surface of the rings in the pipe clamp must be parallel to the parting of the pipe clamp. 20. Align bracket (3) and tighten the fixing screw with the standard tightening torque for Molykote. 21. Tighten screws for pipe clamp (6) again with the standard tightening torque for Molykote . 22. Put in place high-pressure pipe L1 from lower high-pressure pump to the first rail segment and tighten by hand. 23. Put in place high-pressure pipe L2 from upper high-pressure pump to the first rail segment and tighten by hand. 24. Put in place pipe clamp (7) together with bracket (1) so as to be finger tight. The parting surface of the rings in the pipe clamp must be parallel to the parting of the pipe clamp. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

235

m

c2

Engineer’s Handbook Common Rail Components

M 32

25. Put in place pipe clamps (8) together with bracket (2) so as to be finger tight. The parting surface of the rings in the pipe clamp must be parallel to the parting of the pipe clamp. 26. Tighten the high-pressure threaded connections of the high-pressure pipes from the high-pressure pumps to the first rail segment on rail side with 300 + 10 Nm and oil. Repeat the tightening procedure of the high-pressure threaded connections with the specified torque three times by loosening them in the interim. 27. Tighten the high-pressure threaded connections of the high-pressure pipes from the high-pressure pumps to the first rail segment on pump side with 300 + 10 Nm and oil. Repeat the tightening procedure of the high-pressure threaded connections with the specified torque three times by loosening them in the interim. 28. Align bracket (1) and tighten the fixing screws again with the standard torque for Molykote. 29. Tighten fixing screws for pipe clamp (7) again with the standard torque for Molykote. 30. Align bracket (2) and tighten the fixing screws again with the standard torque for Molykote. Tighten high-pressure threaded connections W 46 (12) with Oil

⇒

M = 300 + 10 Nm

Tighten high-pressure threaded connections (13) with Oil

⇒

M = 250 + 10 Nm

Tighten high-pressure threaded connections W 36 (14) with Oil

⇒

M = 150 + 10 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

236

m

Engineer’s Handbook Common Rail Components

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

237

m

Engineer’s Handbook Common Rail Components

M 32

c2

Circulation valve A closed valve (pressure in the rail) is indicated by a projecting pin at the top. For closing the valve apply at least 5 bar to compressed air connection B. Installation: Align threaded holes of the connections for compressed air and fuel so as to be parallel to the rail axis. Permissible deviation: ± 1° M = 250 + 10 Nm Hold the valve in this position and tighten W 50 with ⇒ Oil After installation check the contact surface at D between valve and rail segment with 1800 bar for leaks. A = Fuel pipe B = Compressed air pipe Tighten nut (1) with DELO ML 5327

⇒

M= 4

Tighten sleeve (2) with

⇒

M = 200 Nm

Tighten cap (3) with

⇒

M = 140 Nm

Tighten screws (4) with

⇒

M = 10

Nm

M= 7

Nm

Tighten item (5) with ⇒ Upon assembly, lubricate points of contact C with Molykote.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

238

m

c2

Engineer’s Handbook Common Rail Components

M 32

Combi valve When installing cap (15) make sure that the ventilation groove (N) is located opposite the side with the connection for the nozzle leak (D). Tighten hexagon socket screws (1) with

⇒

M = 15 Nm

Tighten bolt flange (2) with After that, secure bolt flange on the upper support by caulking with a positive fit so that it cannot work loose.

⇒

M = 100 Nm

Tighten hexagon socket screws (3) with

⇒

M = 10 Nm

At grub screw (4) adjust an opening pressure of

⇒

P = 1850 ± 50 bar

Tighten nut (5) after adjusting the opening pressure with

⇒

M = 60 Nm

Use a tab washer (18) to prevent turning of nut (5). After that, drill holes (2 mm) for the locking wire and guide the locking wire through the holes as shown by the illustration below. In case of valves without connection for pressure relief (A) mark the locations designated with S by means of locking varnish (UN No. -1263). Tighten 4 hexagon socket head cap screws (not shown) at (6) for fastening the valve on the rail in two steps alternately with ⇒ Apply oil to threads and bolt head contact surfaces. After installation check the contact surface between valve and rail segment with 1700 bar for leaks.

M = 110 + 10Nm

A = Connection for pressure relief (not applicable for newer design) B = Connection for pressureless leak C = Connection for compressed air D = Connection for nozzle leak Tighten the threaded connection (not shown) at the connection for compressed air (C) at valve VUO-U403V5 (0.00.6-41.29.00-11) with ⇒ M = 15 + 2 Nm at valve VUO-U403V6 (0.00.6-41.29.00-25) with

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 35 + 4 Nm

239

m

c2

Engineer’s Handbook Common Rail Components

M 32

Flow limiter Tighten valve at W 50 with Apply Molykote to thread and contact surface

⇒

M = 800 ± 30 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

240

m

c2

Engineer’s Handbook Common Rail Components

M 32

Relief valve Upon installation lubricate points of contact at (6) with Molykote and fasten valve at W 46 with on the rail. Molykote

⇒

M = 300 + 10 Nm

Tighten threaded bush (3) with Apply Molykote to thread and contact surface

⇒

M = 120

Nm

Tighten hexagon bolt (2) with Molykote

⇒

M = 84

Nm

Tighten swivel nut of leak pipe (1) with Molykote

⇒

M = 100

Nm

Use new O-rings (8). Put on leak container (5), put on slip-on bush (4).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

241

m

Engineer’s Handbook Common Rail Components

M 32

c2

Intermediate shafts (RM) There are two intermediate shaft designs: The originally used A design uses the following mechanism in case of an overload on one thread: The gear wheel disengages from the meshing with the driving gear wheel. Intermediate shaft (1) and gear wheel (3) are two components. In the newer B design intermediate shaft and gear wheel are one component. In case of an overload, the gear wheel on the high-pressure pump disengages from the meshing with the intermediate shaft. A design: Tighten screws (9) of A design with

⇒

M=

40 Nm

After tightening of screws (9) check the gap 2 -1 mm (see Detail Y). Cool the bearing (4) with liquid nitrogen down to and freeze fit it.

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

T = -195 °C

242

m

Engineer’s Handbook Common Rail Components

M 32

B design: Tighten screws (9) of B design with Cool the bearing (6) with liquid nitrogen down to and freeze fit it so as to be flush (see Detail Z). Reference dimensions after freeze fitting: Min. inside diameter of the bearing Max. inside diameter of the bearing

c2

⇒

M = 68 Nm

⇒

T = -195 °C

⇒ ⇒

50 + 0.022 mm 50 + 0.063 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

243

m

Engineer’s Handbook Common Rail Components

M 32

c2

Bearing shells of the intermediate shafts (RM) Removal 1. Remove high-pressure pump and intermediate shaft. 2. Remove screw plug (1) and the positioning screw behind it. 3. Pull the bearing shell out of the casing by means of the device (Fig. 2 and 4). Screw stud (7) into the gear casing. 4. Prepare the device in such a way that the extractor discs (4) are flush with the guide bush. For this purpose push out the expansion bush (5) by S = 18 mm. 5. Push guide bush (8) into the bearing shell. In doing so, pay attention to the position of pin (13) with respect to the notch in the bearing shell (see Detail W). 6. Put on fixing bridge (2) and tighten the expansion bush by means of hexagon nut (10). 7. Fit flange (3) onto stud (7) and tighten with nuts (18). 8. Pull out bearing shell by turning nut (6).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

244

m

Engineer’s Handbook Common Rail Components

M 32

c2

Installation 1. Before pressing the bearing into the seat, make sure that the lubricating oil groove is in the correct position and that the positioning screw can be fitted. Note: At the edge of the bearing shell (see Figure 3) there is a notch which must be in vertical position when installed. (for the upper pump pointing upward; for the lower pump pointing downward). 2. Prepare the device in such a way that the extractor discs (4) are flush with the guide bush. For this purpose push out the expansion bush (5) by about 18 mm.

Notch

3. Push on bearing shell. Pay attention to the position of pin (13) with respect to the notch in the bearing shell. Tighten the expansion sleeve by means of hexagon nut (10). 4. Screw on flange (3) with nut (6) up to hexagon nut (10). Screw stud (7) into the gear casing. 5. Clean bearing shell and lightly lubricate with oil. Put on device and screw down with nuts (18). 6. Press in bearing shell by turning nut (6) until fixing bridge (2) is seated. In doing so, check bearing shell at times for correct position. 7. Tighten positioning screw. In doing so, make sure that the pin of the positioning screw is within the groove of the bearing shell and does not project into the bearing. Tighten screw plug (1). 8. Reference dimension of the bearing shell (inside) after pressing-in: Min. Ø = 116 + 0.04 mm Max. Ø = 116 + 0.14 mm Measure three times and document the results. 9. Install high-pressure pump and intermediate shaft .

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

245

m

Engineer’s Handbook Common Rail Components

M 32

c2

Bearing and gear wheel on the gear shaft (RM) Cool bearing (3) of the gear shaft (2) down to -195 °C with liquid nitrogen and freeze fit it. Observe the post-assembly position of gear wheel (5) (see Detail Z). Tighten screws (4) M16x90 10.9 mit Molykote

⇒

M = 190 Nm

Replace old screws (4) of strength class 8.8 by new screws of strength class 10.9 and tighten with the a.m. torque.

Post-assembly position

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

246

m

Engineer’s Handbook Common Rail Components

M 32

c2

Timing wheel on camshaft gear wheel Pre-adjustment of camshaft and timing wheel: 1. Bar the crankshaft to firing TDC of cyl. 1. 2. Bar the camshaft to firing TDC of cyl. 1. 3. Take up camshaft gear wheel in device and insert it. 4. Bar the engine until the tell-tale hole of the thrust washer is aligned with the marking of the adjusting angle (5) (Detail R). 5. Block the camshaft. 6. Pump up the oil press fit on the camshaft gear wheel. 7. Bar the crankshaft to firing TDC of cyl. 1. 8. Apply Molykote to the screws (18) for fastening the timing wheel and pre-adjust and fix the timing wheel depending on the direction of rotation of the engine: Counter-clockwise: Align the ACCW marking on the timing wheel horizontally Clockwise: Align the ACW marking on the timing wheel horizontally (Detail T) Note: The ICW markings for engines with clockwise rotation (Detail T) and ICCW for engines with counter-clockwise rotation must not be covered at any time by a clamping piece (17). The markings are important for checking the engine adjustment after installing the pump drive. 9. Tighten screws (18) of the timing wheel (4) evenly so as to be finger tight and align clamping pieces (17). Tighten screws (18) with 60 Nm and Molykote. 10. Do not start the engine earlier than 2 hours after releasing the press fit.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

247

m

Engineer’s Handbook IMO Adjustment

M 32

c2

IMO adjustment General note regarding the IMO certificate If the IMO adjustment is changed, the certificate of the engine will become invalid. Engine adjustments

Engine adjustment 480 kW/cyl. WB1 (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 7.0° (+1.0°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value: 3. Piston clearance Clearance: Desired value: Measured:

45 °C (±5 °C) Piston - cylinder liner 20.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment IMO I 480 kW/cyl. (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 6.5° (+0.5° -1.0°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value: 3. Piston clearance Clearance: Desired value: Measured:

45 °C (± 5 °C) Piston - cylinder liner: 20.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

248

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment 500 kW/cyl. FCT 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 7.0° (+0.3° -1.5°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. LT cooling water temperature LT water inlet temperature: Desired value: 38 °C (±2 °C) 3. HT cooling water temperature HT water inlet temperature: Desired value: 90 °C (±2 °C) 4. Charge air temperature Desired value:

45 °C (±5 °C)

5. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 20.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of TDC mark according to job card AA-MF-510 Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment IMO I / FPP 450 kW/cyl. (RM) Engine adjustment IMO I 480/500 kW/cyl. (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 7.0° (+0.3° -1.5°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 20.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

249

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO II 480/500 kW/cyl. (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 5.5° (-1.0°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value: 45 °C (±5 °C) 3. Piston clearance Clearance: Piston - cylinder liner Desired value: 17.5 mm (±1.0 mm) Measured: Edge of bowl - top edge of sealing ring Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment IMO I and DNV Clean Design 480/500 kW/cyl. (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 4.0° (-1.0°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value: 45 °C (±5 °C) 3. Piston clearance Clearance: Piston - cylinder liner Desired value: 20.5 mm (±1.0 mm) Measured: Edge of bowl - top edge of sealing ring Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment IMO I + DNV Clean Design 480/500 kW/cyl. Pulse charging (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 5.5° (-1.0°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value: 45 °C (±5 °C) 3. Piston clearance Clearance: Piston - cylinder liner Desired value: 20.5 mm (±1.0 mm) Measured: Edge of bowl - top edge of sealing ring Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

250

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO II 480/500 kW/cyl. Pulse charging (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 5.2° (-1.0°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner 17.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”. Application of the IMO marking see below in this chapter.

Engine adjustment IMO II 400 kW/cyl. 550 rpm (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 2.4° (-1.0°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner 17.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”. Application of the IMO marking see below in this chapter.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

251

m

c2

Engineer’s Handbook IMO Adjustment

M 32

Engine adjustment WB2 480 kW/cyl. (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 5° (-0.5°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner 17.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment IMO II 440/480 kW/cyl. Retrofit Napier pulse charging (RM) 1. Start of fuel delivery Test cycle E2

Test cycle E3

Test cycle D2

°CA before TDC

°CA before TDC

°CA before TDC

4.3 -1

3.3 -1

4.3 -1

Test cycle E2: Diesel-electric or main propulsion with controllable-pitch propeller Test cycle E3: FP propeller drive Test cycle D2: Auxiliary drive (generator sets) Start of fuel delivery as arithmetic mean value over all cylinders Measured according to overflow method (control travel >30 mm) or pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner 20.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of TDC mark according to job card AA-MF-510 Adjustment of start of fuel delivery of the injection pump see chapter “Injection Pump”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

252

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO II 480/500 kW/cyl. (RM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 5.5° (-1.0°) CA bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. LT cooling water temperature LT water inlet temperature: Desired value: 38 °C (±2 °C) 3. HT cooling water temperature HT water inlet temperature: Desired value: 85 °C (±5 °C) 4. Charge air temperature Desired value:

45 °C (±5 °C)

5. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner 17.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of TDC mark according to job card AA-MF-510 Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment EPG / Family Concept 480 kW/cyl. 720/750 rpm (VM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 13° (+0.5° -1°) before TDC Measured according to: Overflow method, control travel 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 20.0 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

3. Max. ignition pressure Ignition pressure: 198 bar ± 3% in the combustion chamber Measuring value 206 bar ± 3% at the indicator (+ 8 bar due to pipe resonances in the indicator hole) Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

253

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO I Family Concept (VM) 480 kW/cyl. 720 rpm 500 kW/cyl. 750 rpm 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 10° (-1.0°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner 20 mm (±1 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment IMO II 460 mm stroke (with / without FCT) (VM) 480 kW/cyl. 720 rpm 500 kW/cyl. 720/750 rpm 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value without FCT: 9.5° (-1°) before TDC Desired value with FCT: 8.5° (-1°) before TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 15.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Application of the IMO marking see below in this chapter. Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

254

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO I 480 kW/cyl. 720 rpm (VM) Engine adjustment IMO I 500 kW/cyl. 750 rpm (VM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 9° (+ 1.0° -1.0°) or 10.5° (+ 1.0° -1.0°) before TDC The acceptance test record of the engine indicates which value is applicable. Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. LT cooling water temperature LT water inlet temperature: Desired value: 38 °C (±2 °C) 3. HT cooling water temperature HT water inlet temperature: Desired value: 90 °C (±2 °C) 4. Charge air temperature Desired value:

45 °C (±5 °C)

5. Piston clearance Clearance: Piston - cylinder liner: Desired value: 17.0 mm (±1.0 mm) or 20.0 mm (±1.0 mm) The acceptance test record of the engine indicates which value is applicable. Measured: Edge of bowl - top edge of sealing ring Adjustment of TDC mark according to job card AA-MF-510 Adjustment of start of fuel delivery of the injection pumps: If start of delivery is 10.5° before TDC: See chapter “Injection Pump” If start of delivery is 9.0° before TDC: See job card AA-MF-511 Application of the IMO identification: If start of delivery is 10.5° before TDC: See below If start of delivery is 9.0° before TDC: See job card AA-MF-509

Engine adjustment EPG 480 kW/cyl. 720/750 rpm (VM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 14.0° (+1° -1°) before TDC Measured according to: Overflow method, control travel 30 mm or: Pre-lift dimension 6.2 mm or 8 mm at the auxiliary device The acceptance test record of the engine indicates the applicable pre-lift dimension. 2. Piston clearance Clearance: Piston - cylinder liner: Desired value: 20 mm (±1.0 mm) Measured: Edge of bowl - top edge of sealing ring Adjustment of TDC mark according to job card AA-MF-505 Adjustment of start of fuel delivery of the injection pumps: If pre-lift dimension is 8 mm: See job card AA-MF-506 If pre-lift dimension is 6.2 mm: See chapter “Injection Pump” Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

255

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO I DNV Clean (VM) 480 kW/cyl. 720 rpm 500 kW/cyl. 750 rpm 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 9.0° (-1.0°) before TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 17.0 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Engine adjustment WB2 460 mm stroke 480/500 kW/cyl. 720/750 rpm (VM) 1. Start of fuel delivery Start of fuel delivery as arithmetic mean value over all cylinders Desired value: 11.5° (-1°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Charge air temperature Desired value:

45 °C (±5 °C)

3. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 15.5 mm (±1.0 mm) Edge of bowl - top edge of sealing ring

Application of the IMO marking see below in this chapter. Adjustment of start of fuel delivery of the injection pumps see chapter “Injection Pump”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

256

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment RM 32 E IMO II 550 kW/cyl. 720 rpm (part load optimized with FCT) Engine adjustment 6 M 32 E IMO II 720/750 rpm (part load optimized) Engine adjustment 6 M 32 E IMO II 2330 kW at 750 rpm (part load optimized) 1. Start of fuel delivery Start of fuel delivery adjusted at cylinder 1 Desired value: 9.0° (-3.0°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner X = 15.5 mm (±1.0 mm), see drawing Edge of bowl - top edge of sealing ring

Engine adjustment RM 32 E IMO II 550 kW/cyl. 720/750 rpm (part load optimized with FCT and CBV) 1. Start of fuel delivery Start of fuel delivery adjusted at cylinder 1 Desired value: 6.5° (-3.0°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner X = 15.5 mm (±1.0 mm), see drawing Edge of bowl - top edge of sealing ring

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

257

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment RM 32 E IMO II 550 kW/cyl. 720/750 rpm (standard engine) 1. Start of fuel delivery Start of fuel delivery adjusted at cylinder 1 Desired value: 9.2° (-3.0°) bef. TDC Measured according to: Overflow method, control travel > 30 mm or: Pre-lift dimension 6.2 mm at the auxiliary device 2. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner X = 15.5 mm (±1.0 mm), see drawing Edge of bowl - top edge of sealing ring

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

258

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment (non IMO and IMO I) RM 32 CCR 480 kW/cyl. and 500 kW/cyl. 1. Pre-adjustment of camshaft and timing wheel Bar the crankshaft to ignition TDC at cylinder 1. Bar camshaft to ignition TDC at cylinder 1. Take up camshaft gear wheel in device and insert it. Bar the engine until the check bore of the thrust washer is aligned with the marking of the adjusting angle (1.90.791.91.02-01) (see figure). Block the camshaft. Pump up the oil press fit at the camshaft gear wheel. Check bore for pre-adjustBar the crankshaft to ignition TDC of cylinder 1. ment of camshaft Pre-adjust and fasten the timing wheel depending on the direction of rotation of the engine: CCW rotation: Align the ACCW marking on the timing wheel horizontally: CW rotation: Align the ACW marking on the timing wheel horizontally. Attention: The ICW marking on an engine with clockwise rotation and ICCW on an engine with counter-clockwise rotation must not be covered at any time by a clamping piece of the timing wheel fastening screws. The marking is important for checking the engine adjustment after installing the pump drive. Align the clamping pieces and tighten the screws for fastening of the timing wheel with 60 Nm and Molykote.

2. Valve timing Inlet opens 45° before TDC / inlet closes 05° after BDC Exhaust opens 40° before BDC / exhaust closes 45° after TDC Instruction for adjustment: Provide the engine with cylinder heads and valve drive. Adjust valve clearance. Install dial gauge with feeler on cylinder head of cylinder 1 so that the stroke of the inlet valve can be measured. Take into account the direction of rotation of the engine and the cam ramp. Bar the engine until a value of 12.6 ± 0.1 mm* is adjusted. Block the camshaft. Pump up the oil press fit on the camshaft gear wheel. Bar crankshaft to TDC of cylinder 1. Attention: Cylinder 1 is at gas exchange TDC! Release the oil press fit. * This value applies for camshaft sections 1.93.7-31.20.01-06 1.93.7-31.20.01-26 1.94.7-31.20.01-07 1.94.7-31.20.01-27

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

259

m

Engineer’s Handbook IMO Adjustment

M 32

c2

3. Timing wheel Instruction for adjustment: Adjust camshaft according to point 2. Loosen all screws for fastening of the timing wheel. Bar the crankshaft to ignition TDC of cylinder 1. Adjust the timing wheel depending on the direction of rotation by means of mandrel 1.90.7-91.90.02-01 (1) and adjusting angle 1.1.90-7.91.91-01 (2): CCW rotation: Marking ACCW on the timing wheel (see Detail V). CW rotation: Marking ACW on the timing wheel (seeDetail W)

V

W

Align the clamping pieces (3) and tighten the screws (4) for fastening of the timing wheel with 60 Nm and Molykote. Make sure that the markings ICW and ICCW are not covered. 4. Crankshaft speed pick-up Instruction for adjustment - non IMO: Bar the crankshaft to ignition TDC of cylinder 1. Check the adjustment of the flywheel depending on the direction of rotation of the engine. Loosen and shift pick-up bracket until measuring mandrel 1.90.7-91.90.01-01 engages in the Ø 8 H12 bore of the flywheel. Tighten the screws for the pick-up bracket. Pin pick-up bracket with spring dowel pins of Ø 6 mm. Instruction for adjustment IMO I: Bar the crankshaft to ignition TDC of cylinder 1. Check the adjustment of the flywheel depending on the direction of rotation of the engine. Loosen and shift pick-up bracket until adjusting tool 1.90.7-91.90.00-01 engages in the Ø 8 H12 bore of the flywheel. Tighten the screws for the pick-up bracket. Read off the adjusted value of “Pick-up position TDC” at the scale and enter on the testbed record. Start the engine and indicate the cylinder pressures of all cylinders. If the cylinder pressure mean value is higher than the value under point 9. (see below), adjust it by shifting the pick-up bracket. Read off the adjusted value of “Pick-up position final” at the scale and enter on the testbed record. Attention: The value of “Pick-up position final” may deviate 1° crank angle from “Pickup position TDC”! Pin pick-up bracket with spring dowel pins of Ø 6 mm. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

260

m

Engineer’s Handbook IMO Adjustment

M 32

c2

5. Cooling water temperature LT (not applicable for IMO I engines) LT water inlet temperature: Desired value: 30 °C (± 2 °C) with PI control valves Working range: 20 - 30 °C with P control valves 6. Cooling water temperature HT (not applicable for IMO I engines) HT engine outlet temperature: 90 °C (± 2 °C) with PI control valves Desired value: Working range: 82 - 92 °C with P control valves 7. Charge air temperature Desired value:

45 °C (± 5°C)

8. Piston clearance Clearance: Desired value: Measured:

Piston - cylinder liner: 20.5 mm (±1.0 mm) From edge of bowl to cylinder liner landing

9. Averaged cylinder pressure (IMO I only) 480 kW/cylinder: 190 bar ± 3% The pressure of an individual cylinder must not exceed 195 bar. 500 kW/cylinder:

198 bar ± 3%

The pressure of an individual cylinder must not exceed 205 bar. Adjustment of TDC mark according to job card AA-MF-505 (non IMO engines only)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

261

m

Engineer’s Handbook IMO Adjustment

M 32

c2

Engine adjustment IMO II CCR 480/500 kW/cyl. (RM) 1. Pre-adjustment of camshaft and timing wheel Bar the crankshaft to ignition TDC of cylinder 1. Bar camshaft to ignition TDC of cylinder 1. Take up camshaft gear wheel in device and insert it. Bar the engine until the check bore of the thrust washer is aligned with the marking of the adjusting angle (1.90.7-91.91.02-01) (see figure). Block the camshaft. Pump up the oil press fit at the camshaft gear Check bore for pre-adjustwheel. ment of camshaft Bar the crankshaft to ignition TDC of cylinder 1. Pre-adjust and fasten the timing wheel depending on the direction of rotation of the engine: CCW rotation: Align the ACCW marking on the timing wheel horizontally. CW rotation: Align the ACW marking on the timing wheel horizontally. Attention: The ICW marking on an engine with clockwise rotation and ICCW on an engine with counter-clockwise rotation must not be covered at any time by a clamping piece of the timing wheel fastening screws. The marking is important for checking the engine adjustment after installing the pump drive. Align the clamping pieces and tighten the screws for fastening of the timing wheel with 60 Nm and Molykote. 2. Valve timing Inlet opens 47.5° before TDC / inlet closes 20° before BDC Exhaust opens 40° before BDC / exhaust closes 47.5° after TDC Instruction for adjustment: Provide the engine with cylinder heads and valve drive. If the engine is equipped with FCT, turn the cam follower shaft to “Normal” position and fix it. Adjust valve clearance. Install dial gauge with feeler on cylinder head of cylinder 1 so that the stroke of the inlet valve can be measured. Take into account the direction of rotation of the engine and the cam ramp. Bar the engine until a value of 13.5 ± 0.1 mm* is adjusted. Block the camshaft. Pump up the oil press fit on the camshaft gear wheel. Bar crankshaft to TDC of cylinder 1. Attention: Cylinder 1 is at gas exchange TDC. Release the oil press fit. * This value applies for camshaft sections with FCT: 1.93.7-31.20.01-14 1.93.7-31.20.01-34 1.94.7-31.20.01-14 1.94.7-31.20.01-34

without FCT: 1.93.7-31.20.01-15 1.93.7-31.20.01-35 1.94.7-31.20.01-15 1.94.7-31.20.01-35

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

262

m

Engineer’s Handbook IMO Adjustment

M 32

c2

3. Timing wheel Instruction for adjustment: Adjust camshaft according to point 2. Loosen all screws for fastening of the timing wheel. Bar the crankshaft to ignition TDC of cylinder 1. Adjust the timing wheel depending on the direction of rotation by means of mandrel 1.90.7-91.90.02-01 (1) and adjusting angle 1.1.90-7.91.91-01 (2): CCW rotation: Marking ACCW on the measuring wheel (see detail V). CW rotation: Marking at timing wheel ACW (see Detail W)

V

W

Align the clamping pieces (3) and tighten the screws (4) for fastening of the timing wheel with 60 Nm and Molykote. Make sure that the markings ICW and ICCW are not covered. 4. Crankshaft speed pick-up Instruction for adjustment: Bar the crankshaft to ignition TDC of cylinder 1. Check the adjustment of the flywheel depending on the direction of rotation of the engine. Loosen and shift pick-up bracket until adjusting tool 1.90.7-91.90.00-01 engages in the Ø 8 H12 bore of the flywheel. Tighten the screws for the pick-up bracket. Read off the adjusted value of “Pick-up position TDC” at the scale and enter on the testbed record. Start the engine and indicate the cylinder pressures of all cylinders. If the cylinder pressure mean value is higher than the value under point 9. (see below), adjust it by shifting the pick-up bracket. Read off the adjusted value of “Pick-up position final” at the scale and enter on the testbed record. Attention: The value of “Pick-up position final” may deviate 1° crank angle from “Pick-up position TDC”! Pin sensor bracket with spring dowel pins of Ø 6 mm. 5. Charge air temperature Desired value:

45 °C (± 5°C)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

263

m

Engineer’s Handbook IMO Adjustment

M 32

6. Piston clearance Clearance: Desired value: Measured:

c2

Piston - cylinder liner: 20.5 mm (±1.0 mm) From edge of bowl to cylinder liner landing

7. Averaged cylinder pressure 480 kW/cylinder: ⇒

Ask the Technical Customer Service Support for the value! Either 190 bar ± 3% (variant -19) or 200 bar ± 3% (variant -15)

The pressure of an individual cylinder must not exceed 205 bar in the combustion chamber. The individual ignition pressure value at the indicator must not exceed 208 bar.

500 kW/cylinder: ⇒

Ask the Technical Customer Service Support for the value! Either 198 bar ± 3% (variant -19) or 205 bar ± 3% (variant -15)

The pressure of an individual cylinder must not exceed 210 bar (variant -15) or 205 bar (variant -19) in the combustion chamber. The individual ignition pressure value at the indicator must not exceed 213 bar (variant -15) or 208 bar (variant -19).

IMO adjustment: Check (M 32 C) Remove the eccentric screw plug on the camshaft cover at driving end. Turn the IMO check bore (thrust washer) so that it is positioned directly over the groove (cover) and both line up with each other. Check the IMO notch at the dead centre indicator of the flywheel.

IMO adjustment: Marking of the flywheel (M 32 C) Marking is only allowed when changing the flywheel. Adjust the engine in accordance with the testbed record. Make sure the IMO timing values are kept! Turn the IMO check bore (thrust washer) so that it is positioned directly over the groove (cover) and both line up with each other. The new position corresponds to about 3° crank angle before TDC (CW rotation) or after TDC (CCW rotation). Stamp the IMO notch at the dead centre indicator of the flywheel.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

264

m

Engineer’s Handbook IMO Adjustment

M 32

c2

IMO check bore

Groove

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

265

m

Engineer’s Handbook IMO Adjustment

M 32

c2

CCR: Check of the position of the timing wheel on the camshaft Bar the crankshaft to ignition TDC of cylinder 1. Remove the screw plug from the transmission. Marking at the timing wheel depending on the direction of rotation of the engine: Engine turning clockwise: Marking at the timing wheel ICW Engine turning counter-clockwise: Marking at the timing wheel ICCW

CCR: Check of pick-up position adjustment at the crankshaft. Bar the crankshaft to ignition TDC of cylinder 1. Check screws (M10x65 8.8) for pick-up bracket for proper fit. Check the four Ø 6 mm spring dowel pins. Read off the scale value of “Pick-up position final” at the scale and compare to the testbed record value for “Pick-up position final.

IMO adjustment: Check (M 32) Remove the eccentric screw plug on the camshaft cover at driving end. Bar the engine until the bore in the helical gear is centrical with regard to the groove in the cover (see drawing). Check at the flywheel whether the IMO marking coincides with the dead centre indicator. After checking screw the screw plug into the cover again.

IMO adjustment: Marking of the flywheel (M 32) Marking is only allowed when changing the flywheel. Adjust the engine in accordance with the testbed record. Make sure the IMO timing values are kept! Turn the IMO check bore in the helical gear so that it is centrical with regard to the groove in the cover. The position corresponds to about 3° crank angle before (clockwise rotation) or after (counter-clockwise rotation) TDC. Stamp the IMO notch at the dead centre indicator of the flywheel.

Helical gear marking

Cover marking

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

266

m

Engineer’s Handbook IMO Adjustment

M 32

c2

IMO adjustment of start of fuel delivery, variant with shims (M 32 C) 1. Adjust the assembly reference dimension (78.5 mm) at all cylinders by means of spacer plates, see chapter “Injection Pump“, paragraph “Adjustment and determination of the injection pump spacer plate thickness“. The lower valve drive is installed with basic spacer plates according to the table (see below). 2. Turn camshaft in direction of rotation of the engine until the injection pump of cylinder 1 is at start of fuel delivery. 3. Loosen the camshaft gear wheel and bar the engine until the graduated disc indicates the corresponding engine adjustment value (see above in this chapter). Lock the camshaft gear wheel. 4. Bar the engine so that the other cylinders are at the same position and check the start of fuel delivery. Correct the start of fuel delivery on the lower valve drive as follows only if required: a. For this purpose, unscrew the lower screw (1) (M20 x 180). Unscrew the upper “outer” screw (2) by max. 3 mm. b. Replace the spacer plates (3). c. If a subsequent check shows that the adjustment with respect to cylinder 1 is not okay, repeat the adjustment starting from step 2. Starting from step 3 turn the camshaft again counter-clockwise/clockwise until all cylinders are within the tolerance range with respect to cylinder 1. d. Tighten screws (1) and (2) with M = 300 Nm Molykote 5. Check the adjustment of ignition by measuring the injection points (needle bounces) with the injection point tester (as mean value over all cylinders) according to the engine adjustment, see above in this chapter. Spacer plates are available in the following thickness increments: 2.4 mm, 2.7 mm, 3.0 mm, 3.3 mm, and 3.6 mm. Guide value: a thickness increment of ±0.3 mm corresponds to a change in crank angle of about ±0.5°.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

267

m

c2

Engineer’s Handbook IMO Adjustment

M 32

Engine adjustment for 500 kW/cyl. 6 CW rotation

Start of fuel delivery

8 CCW rotation

CW rotation

9 CCW rotation

CW rotation

CCW rotation

Adjust the upper tolerance from engine adjustment according to order list

Plate thickness as basic adjustment Plate cam follower cyl. 1

3.3

2.7

3.6

2.4

3.3

2.7

Plate cam follower cyl. 2

3

3

3.3

3

3.3

3

Plate cam follower cyl. 3

3

3

3

2.7

3

2.7

Plate cam follower cyl. 4

3

3

3.3

3.3

3.3

3

Plate cam follower cyl. 5

2.7

3.3

2.7

3

2.7

3

Plate cam follower cyl. 6

2.7

3.3

3

3.6

3

3

Plate cam follower cyl. 7

2.4

3.3

2.7

3

Plate cam follower cyl. 8

2.4

3.6

3

3.6

2.7

3.3

Plate cam follower cyl. 9

Engine adjustment for 480 kW/cyl. 6 CW rotation Start of fuel delivery

8 CCW rotation

CW rotation

9 CCW rotation

CW rotation

CCW rotation

Adjust the upper tolerance from engine adjustment according to order list

Plate thickness as basic adjustment Plate cam follower cyl. 1

3

2.7

3.3

2.7

3.3

2.7

Plate cam follower cyl. 2

3

3

3.3

3

3

3

Plate cam follower cyl. 3

3

3

3

2.7

3

2.7

Plate cam follower cyl. 4

2.7

3

3.3

3.3

3

3

Plate cam follower cyl. 5

2.7

3

2.7

3

2.7

3

Plate cam follower cyl. 6

2.4

3.3

3

3.3

3

3.3

Plate cam follower cyl. 7

2.7

3.3

2.7

3

Plate cam follower cyl. 8

2.7

3.3

3

3.6

2.7

3.3

Plate cam follower cyl. 9

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

268

m

Engineer’s Handbook IMO Adjustment

M 32

c2

IMO adjustment of start of fuel delivery, variant with FCT (CCW and CW rotation / by means of miniature eccentric) Attention! When installing a new cam follower take note of the adjustment according to the testbed record and adjust the new cam follower accordingly. 1. Adjust the assembly reference dimension 78.5 mm with spacer plates at all cylinders. 2. Check the position of the cam follower shaft. For engines turning counter-clockwise: Limit stop of cylinder 1 points downward. For engines turning clockwise: Limit stop of cylinder 1 points upward. Check whether the cam follower shafts have the same fitting length (comparison of position of limit stop of cylinder 1 with direction of the 8 mm hole in the cam follower shafts). Fix the full load condition of the cam follower shaft by applying compressed air (max. 7.5 bar) to the pneumatic drive unit. 3. Rotate the camshaft in direction of rotation of the engine until the injection pump of cylinder 1 is at start of fuel delivery. After that, block the camshaft. 4. Loosen the camshaft gear wheel by pumping up and bar the engine until the graduated disc indicates the corresponding engine adjustment value for cylinder 1. Block the camshaft gearwheel. 5. Bar the other cylinders to the same position and check the start of fuel delivery. Adjust the start of fuel delivery on the lower valve drive as follows only if required: 6. Screw the pressure connections into the cam follower and pump up by means of highpressure pump until oil leaks out laterally. 7. Insert a mandrel into the holes of the miniature eccentric and turn it until the corresponding injection pump is at start of fuel delivery (max +/- 90°). In doing so, the following must to be taken into account (viewing from driving end).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

269

m

c2

Engineer’s Handbook IMO Adjustment

M 32

Engine turning CW

Engine turning CCW

Min. eccentric turned CCW 90° 75° 60° 45° 30° 15° 0° 15° 30° 45° 60° 75° 90° Min. eccentric turned CW

°CA

normal normal normal normal normal normal early early early early early early

0.99 0.96 0.86 0.71 0.50 0.26 0.00 0.26 0.50 0.70 0.86 0.96 1.00 °CA

Min. eccentric turned CCW 90° 75° 60° 45° 30° 15° 0° 15° 30° 45° 60° 75° 90°

°CA

early early early early early early normal normal normal normal normal normal

Min. eccentric turned CW

0.99 0.96 0.86 0.71 0.50 0.26 0.00 0.26 0.50 0.70 0.86 0.96 1.00 °CA

8. After the adjustment remove the pressure connections. 9. Subsequent check of the start of fuel delivery!(In the event of changed adjustment of the miniature eccentric) If the start of fuel delivery is not within the tolerance range with respect to cylinder 1, readjust starting from assembly step 2. Starting from step 3, the camshaft is again turned counter-clockwise / clockwise until all cylinders are within the tolerance range with respect to cylinder 1. On the engine testbed the position of the miniature eccentric should not be changed. Check of the adjustment of ignition by measuring the injection points (needle bounces) with the injection point tester (as mean value over all cylinders) according to the engine adjustment.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

270

m

c2

Engineer’s Handbook Miscellaneous

M 32

Miscellaneous Control shaft Link lever, older variant: Tighten screw (2) with Molykote Link lever, current variant: Tighten screw (2) with Molykote

⇒

M = 60 Nm

⇒

M = 15 Nm

Always tighten the screws in the control linkage with Molykote and the corresponding standard torques for the respective strength class. Installation instructions for the shaft on RM: 1. Grease the bearing points of the shafts and insert them. Do not use Molykote. 2. Check the shafts for ease of movement. 3. Connect the control stand. 4. Screw the articulated lever (8) onto the shaft. Installation instructions for the shafts on VM: 1. Grease the bearing points of the shafts and insert them. Do not use Molykote. 2. Check the shafts for ease of movement. 3. Bolt down the articulated lever. 4. Connect the intermediate shaft (5) at the face end with the control shafts (2) on A and B side. Tighten connections A between intermediate shaft (5) and control shafts (2) with ⇒ M = 130Nm Molykote Note: In the past, the following was applicable for these connections: “Grease and loosen by 1/4 turn”. Installation instructions for the articulated levers (RM and VM): Insert bolts, spacer bushes, extension sleeves, and nuts at B with grease. Do not use Molykote. Tighten the connections so as to be finger tight and loosen them by 1/4 turn. Check if the washer is movable.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

271

m

c2

Engineer’s Handbook Miscellaneous

M 32

Note: Adjusting rings (20) were replaced by adjusting rings (14) in December 2011. Tighten the headless screws in the old adjusting rings (20) with ⇒ Molykote In doing so, adjust a clearance of ⇒ Drill the centring upon installation and secure by centre punch. Tighten screws (27) in the new set collars (14) with Molykote In doing so, adjust a clearance of Drill the centring after adjustment.

M = 15 Nm 0.20

mm

⇒

M = 45 Nm

⇒

0.40

mm

⇒ M = 8 Nm Tighten headless screw (4) with Molykote Drill the centring upon installation and secure by centre punch. Note: Headless screw (4) was replaced by a continuous spring dowel pin in April 2009.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

272

m

Engineer’s Handbook Miscellaneous

M 32

c2

For the control linkage of VM 32 C crude oil engines take into account the following special feature: At central position of the governor adjust to 35° (see figure) to ensure the clearance to the leak fuel pipe at each operating condition.

Leak fuel pipe

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

273

m

c2

Engineer’s Handbook Miscellaneous

M 32

Starting fuel limiter Tighten hexagon socket screws (2) with Tighten throttle screw (1) and screws (3) with

⇒ ⇒

M = 20 Nm M = 20 Nm

Governor arrangement Observe the adjustment data of the governor data sheet. Change the governor adjustment only in exceptions and only after consulting the Technical Customer Service. Lubricating oil nozzles for gear wheels Tighten the screws notched in the threaded area (M16x120 10.9) for the lubricating oil nozzles with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 160 Nm

274

m

c2

Engineer’s Handbook Miscellaneous

M 32

Fuel rack position transmitter Adjust the cam (1) so that in stop position the centre of the fuel rack transmitter aligns with centre punch mark (2).

Master starting valve Tighten bolts and nuts (1) and (2) with

⇒

M = 12 Nm

Tighten screws (3) with

⇒

M = 2.5 Nm

Tighten hexagon nut (4) with

⇒

M = 40 Nm

Tighten the screws for the pilot valve with

⇒

M = 24Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

275

m

c2

Engineer’s Handbook Miscellaneous

M 32

Oil sump - installation of normal oil pan with drain Tighten screws (30) from the engine block to the oil pan with Oil

⇒

M = 170 Nm

VM only: Tightening torque for screw plug DIN 910-G1A at the face end see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Normal oil pan with drain ↓

Deep oil pan ↓

Oil sump - installation of deep oil pan Tighten screws (1) and (2) from the engine block to the oil pan progressively with 1. M = 200 Nm 2. M = 280 Nm 3. M = 300 Nm Oil Always tighten these screws starting from the centre and proceeding towards the outside. Tighten screws (3) (for fastening the reinforcing sheets) with Oil

⇒

M = 75 Nm

⇒

M = 300 Nm

Tighten screws for blank flanges (4) and (6), screws for expansion joints (incl. those on the pan) (7), and screws for pipe socket base (5), with standard tightening torques. Molykote Tighten reducers for connecting the sensors in the face ends of the oil pan with Oil

Tightening torque for screw plugs M18x1.5 of these reducers see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs“.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

276

m

Engineer’s Handbook Miscellaneous

M 32

c2

Oil sump - Installation of oil pan for resiliently mounted engines (RM) Avoid engine incline to prevent the gasket from shifting. Cut out gasket visible at the four corners. Tighten studs M30 (4) in the oil pan so as to be finger tight. Tighten screws M16-8.8 (7) for engine fixation in steps of 1. 20 % 2. 60 % 3. 100 % with Molykote

⇒

M = 130 Nm

Tighten nuts M30-10.9 (5) for engine fixation in steps of 1. 20 % 2. 60 % 3. 100 % with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 1300 Nm

277

m

Engineer’s Handbook Miscellaneous

M 32

c2

Lubricating oil pipes (RM and VM) RM: Coat the threaded connections and fastenings of the lubricating oil pipe with Molykote and tighten with the applicable standard torques. Insert the O-rings with Petro Gel Amber or Vaseline. Tightening torque for screw plug G1/4 (20) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

VM: For threaded connections and fastenings of the lubricating oil pipe use Molykote. Tightening torque for screw plugs G1/4 (40) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Lubricating oil pipes at ABB TPL 65: Tighten screws (15) with ⇒ Insert gaskets (5) with grease.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 75 Nm

278

m

c2

Engineer’s Handbook Miscellaneous

M 32

Lubricating oil pipes (RM 32 E) Tighten bolts and nuts M 16 (28), (26), (30), (27), (24) with ⇒ M = 130 Nm Tighten bolts and nuts M12 (39) with ⇒ M = 52 Nm Tighten bolts and nuts M8 with ⇒ M = 15 Nm Tightening torques for screw plugs G3/8 (44) and G1/2-SW19 (17) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Lubricating oil pipes 3200.7-84.94.00-XX (RM 32 E) 6 M 32 E: Union M27x2 (7) (engine block connection) Tighten variant -03 with Tighten variants -06 and -08 with Oil Union G1/2A (5) (turbocharger connection) Tighten variant -03 with Tighten variants -06 and -08 with Oil

⇒ ⇒

M = 220 Nm M = 230 Nm

⇒ ⇒

M = 120 Nm M = 155 Nm

Tightening torques for screw plugs G1/4 (23) and G1/2A-SW19 (22) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

279

m

c2

Engineer’s Handbook Miscellaneous

M 32

8/9 M 32 E: Union M27x2 (7) (engine block connection) Tighten variant -04 with Tighten variants -07 and -09 with Oil Union G3/4A (5) (turbocharger connection) Tighten variant -04 with Tighten variants -07 and -09 with Oil

⇒ ⇒

M = 130 Nm M = 230 Nm

⇒ ⇒

M = 130 Nm M = 230 Nm

Tightening torques for screw plugs G1/4 (23) and G1/2-SW19 (22) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

280

m

c2

Engineer’s Handbook Miscellaneous

M 32

Supply and disposal pipes at the free end (stationary VM - CPGS) Tighten all threaded connections with Molykote and the standard torques applicable for the respective strength and thread size. Observe the “Installation instructions for rubber expansion joints” in the “General Part” of the Engineer’s Handbook! Brackets for supply and disposal pipes at the free end Tighten screws (1) with Molykote

⇒

M = 900 Nm

Tighten screws (2) with Nm. Molykote

⇒

M = 900

Tighten screws (3) with Molykote

⇒

M = 260 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

281

m

c2

Engineer’s Handbook Miscellaneous

M 32

Lubricating oil, cooling water, and fuel leakage pipes (VM 32 C, flat oil pan) With the exceptions listed below, tighten the threaded connections with Molykote and the standard torques applicable for the respective strength and thread size. Observe the “Installation instructions for rubber expansion joints” in the “General Part” of the Engineer’s Handbook! Tighten the threaded connections M12 (88) with Molykote

⇒

M = 55

Nm

Tighten the threaded connections M16 (41) with Molykote

⇒

M = 80

Nm

Tighten the threaded connections M16 (45) with Molykote

⇒

M = 100 Nm

Tighten the threaded connections M20 (51) with Molykote

⇒

M = 100 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

282

m

c2

Engineer’s Handbook Miscellaneous

M 32

Fuel filter pipe, nozzle leakage pipe - crude oil engine (VM 32) Tighten screws (21) with ⇒ Molykote

M = 30 Nm

Tighten screws (23) 12.9 with Molykote

⇒

M = 55 Nm

Tighten orifice screws (12) with Molykote

⇒

M = 130 Nm

Insert O-rings (14) and (16) with Petro Gel Amber. Apply a thin coat of Petro Gel Amber to the surfaces at F (O-ring).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

283

m

Engineer’s Handbook Miscellaneous

M 32

c2

Fuel filter pipe (RM 32 E) Tightening torques for screw plugs G1/2A-SW19 (55) and M33x2 (56) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

63 a and 63b

284

m

c2

Engineer’s Handbook Miscellaneous

M 32

Fuel pipe - crude oil engine (RM 32 C) Tighten threaded connections (1) with Molykote

⇒

M = 25 Nm

Double stop pipe (RM 32 E) Tighten screws (34) with Loctite 243

⇒

M = 4 Nm

Fuel leakage pipe - crude oil engine (VM) Install sealing ring in flange (2) with Loctite 577 pipe sealant, align it and lock by means of nut (3).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

285

m

Engineer’s Handbook Miscellaneous

M 32

c2

Tighten threaded connections (6) with Molykote and the applicable standard torques. Insert O-rings with Petro Gel Amber. Screw on flange (44) with Hylomar sealing compound. When fitting blocks (2) make sure that the O-rings (48) and (49) are not interchanged: (48) = 22.4 mm inside Ø, (49) = 23.6 mm inside Ø Tightening torque for screw plugs M22x1.5 (4) in the blocks see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten screws (5) with ⇒ M = 26 Nm Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

286

m

c2

Engineer’s Handbook Miscellaneous

M 32

Fuel leakage pipe - crude oil engine (RM) When fitting blocks (2) make sure that the O-rings (48) and (49) are not interchanged: (48) = 22.4 mm inside Ø, (49) = 23.6 mm inside Ø Insert O-rings with Petro Gel Amber. Tightening torque for screw plugs M22x1.5 (4) in the blocks (2) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten screws (5) with Nm Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 26

287

m

c2

Engineer’s Handbook Miscellaneous

M 32

RM 32 - VM 32 - M 32 C Fuel distributing and collecting pipe: End flanges PEO-U131 for RM 32 and VM 32 (1.90.7-85.17.00-06) Tighten screws (1) with Tighten screws (2) with Tighten screws (3) with Loctite hydraulic seal 0566

PEO-U107 for RM 32 (1.90.7-85.17.00-05) Tighten screws (1) with In doing so, counterhold pos. (3) at the slot. Tighten screw (2) with

PEO-U198 for RM 32 C (1.90.7-85.17.00-09) Tighten screws (1) with Tighten screw plug PEO-T473 (2) with Loctite hydraulic seal 0566 Tighten screws (3) with Install screw plug D901-R1/4Z (15) (only sketched) optionally on the engine and tighten with

⇒ ⇒ ⇒

M = 60 M = 65 M = 80

⇒

M = 100 Nm

⇒

M = 65

Nm

⇒ ⇒

M = 35 M = 80

Nm Nm

⇒

M = 35

Nm

⇒

M = 50

Nm

M = 80

Nm

Nm Nm Nm

Cost-optimized flange (RM and VM) Cost-optimized flange (with new leakage pipe for discharging fuel) for injection pump variant - 93 (IMO I) and injection pump variant - 19 (IMO II). Install O-rings (8) and (9) with Petro Gel Amber. Tighten hexagon socket head cap screw (6) with

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

288

m

c2

Engineer’s Handbook Miscellaneous

M 32

Hydraulic seal Loctite 542 brown Tighten screws for fastening of tubes (1) and (2) with Molykote paste G Rapid Plus

⇒

M = 25

Nm

Tighten hexagon socket head cap screws (17) with Molykote paste G Rapid Plus

⇒

M = 35

Nm

1

2

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

289

m

Engineer’s Handbook Miscellaneous

M 32

c2

Fuel distributing and collecting pipe (RM and VM) Preparation: Remove the tubes to be replaced. Remove old joint and guide rings and clean the pipe connections on the pumps. Apply grease to sealing faces (1) of tubes (2). Check sliding pieces (3) for ease of movement. For better installation of the tubes loosen the fixing screws of the pumps. After installing the new tubes tighten the fixing screws of the pumps again in accordance with the applicable instructions. Tighten screws (4) on the flanges between the injection pumps with Molykote (This tightening torque also applies for the flexible pipes on VM 32)

Old version

M = 25 Nm

New version

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

290

m

c2

Engineer’s Handbook Miscellaneous

M 32

Fuel distributing and collecting pipe (RM 32) Tighten screws (1) in 2 steps with

⇒

M = 130 Nm

Old design

New design

Bracket with fuel inlet, new design: Tighten 6 screws (2) (M16 x 90) with Molykote

⇒

M = 130 Nm

4 mm reference dimension for all throttle tubes

Freeze fit throttle tubes at -110 °C

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

291

m

c2

Engineer’s Handbook Miscellaneous

M 32

Pipe assembly, fuel supply (VM 32) Tighten threaded rods (1) (M16 thread) with Molykote

⇒

M = 130 Nm

Tighten threaded rods (1) (M12 thread) with Molykote

⇒

M = 52 Nm

Tighten orifice screws (2) with Molykote

⇒

M = 130 Nm

Tighten all other threaded connections with Molykote and the applicable standard torques.

View onto free end

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

292

m

c2

Engineer’s Handbook Miscellaneous

M 32

Media guide (RM 32 C) Tighten threaded connections on the media blocks with Molykote and the applicable standard torques. Insert the screw plugs M10x1 into the medial blocks with Loctite 243. Degrease both threads before.

Plate at normal bearing of the crankshaft (VM 32 C) Tighten screws (1) with Oil

⇒

M = 280 Nm

Tighten screws (2) with Oil

⇒

M = 250 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

293

m

c2

Engineer’s Handbook Miscellaneous

M 32

Cooling water pipe (RM) Insert the screws into the cooling water pipes with Molykote and tighten with the corresponding standard torque. Insert the gaskets with grease and the O-rings with Petro Gel Amber. Observe the “Installation instructions for rubber expansion joints” in the General Part of the Engineer’s Handbook! Tightening torques for screw plugs for drainage and venting of the system see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Pretighten screws (2) to the cooling water blocks with After that, finally tighten with Molykote G Rapid Plus Pretighten screws (1) with After that, finally tighten with Molykote G Rapid Plus

⇒

⇒

⇒ ⇒

M = 65 Nm M = 130 Nm M = 100 Nm M = 260 Nm

Insert O-rings (3) with Petro Gel Amber.

Driven in until reaching end stop

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

294

m

c2

Engineer’s Handbook Miscellaneous

M 32

Cooling water pipe (RM 32 E) Put in place the gaskets with grease. Insert O-rings with Petro Gel Amber. Tightening torques for screw plugs (36), (4) and others see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Insert studs M16 (49) with Molykote G Rapid Plus Tighten nuts M16 (51) with Molykote G Rapid Plus

⇒

M = 25

Nm

⇒

M = 130

Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

295

m

c2

Engineer’s Handbook Miscellaneous

M 32

Cooling water pipe (VM) Observe the “Installation instructions for rubber expansion joints” in the General Part of the Engineer’s Handbook! Pretighten screws (1) with After that, finally tighten with Molykote paste G Rapid Plus

⇒ ⇒

M = 50 Nm M = 105 Nm

Pretighten screws (2) with After that, finally tighten with Molykote paste G Rapid Plus

⇒ ⇒

M = 65 Nm M = 130 Nm

Pretighten screws (3) with After that, finally tighten with Molykote paste G Rapid Plus

⇒ ⇒

M = 100 Nm M = 260 Nm

Drive in spring dowel pin (4) as far as it will go. Insert the gaskets at D with a thin coat of Petro Gel Amber.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

296

m

c2

Engineer’s Handbook Miscellaneous

M 32

Tightening torques for screw plugs G1/2A (19) and (12), M26x1.5 (30) and G1A (13) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

44

Tighten screws (1) (M16 x 330) with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 130 Nm

297

m

c2

Engineer’s Handbook Miscellaneous

M 32

Lashing device When using RUD attachment points observe the installation instructions and the instructions for use for RUD attachment points. Use only by authorized and instructed persons and in accordance with UVV VBG 9a. The load rings must be adjusted in direction of tension and freely movable. They must not rest on edges. Make sure the bolting surfaces are level. Tighten the screws for installing the lifting eyes with the following torques. The max. allowable tensile load is 5 t per lifting eye. Tighten screws M 16 with Molykote

⇒

M = 100 Nm

Tighten screws M20 with Molykote

⇒

M = 100 Nm

Tighten screws 36x2 with Molykote

⇒

M = 150 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

298

m

Engineer’s Handbook Miscellaneous

M 32

c2

Barring gear RM 32 Lock the the screw for parallel key (38) with Loctite 243 Degrease both threads before. Before installation, apply Molykote to hollow shaft and threaded spindle at (B). Fill the shaft relief with lubricating grease. Tighten locking pin (44) and nut with ⇒ M = 100 Nm Loctite 243

Barring gear RM 32 + RM 32 C Put in place the barring gear with liquid sealing compound. Tighten nuts (1) with ⇒ Molykote paste G Rapid Plus

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 130 Nm

299

m

c2

Engineer’s Handbook Miscellaneous

M 32

End clearance of the tapered roller bearings of the worm: Preload of the grooved ball bearings of the worm gear: Apply sealing compound to surfaces at T. Insert lever (10) with Loctite 638.

⇒ ⇒

0 - 0.05 mm 0.05 - 0.15 mm

Tighten screws (59) with Loctite 243

⇒

M = 6.5 Nm

Tighten screws (55) with Loctite 243

⇒

M = 78

Nm

Tighten screws (58) and (63) with Loctite 243

⇒

M = 32

Nm

Tighten screws (55) with Loctite 243

⇒

M = 55

Nm

Tighten screws (51) with Loctite 270

⇒

M = 52

Nm

Insert headless screw (67) with Loctite 243 and tighten nuts (57) with M = 56 Nm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

300

m

c2

Engineer’s Handbook Miscellaneous

M 32

Barring gear VM 32 C Apply sealing compound to surfaces at T. Refill oil at O. Tighten studs at (1) with Molykote paste G Rapid Plus Tighten nuts (1) with Molykote Tighten screws (2) with Loctite 243 Tighten screws (3) and (6) as well as nut (5) with Loctite 243 Tighten nuts (4) with Tighten screws (7) with Loctite 243

⇒

M = 40

⇒

M = 130 Nm

⇒

M = 56

Nm

⇒

M = 45

Nm

⇒ ⇒

M = 56 Nm M = 6.5 Nm

End clearance of the tapered roller bearings of the worm: ⇒ End clearance of the tapered roller bearings of the worm gear: ⇒

0 - 0.05 mm 0 - 0.05 mm

Nm

Insert studs (8) with Loctite 270. Insert lever (10) with Loctite 638. Insert headless screws with chamfered end (9) with Loctite 222.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

301

m

c2

Engineer’s Handbook Miscellaneous

M 32

Barring gear VM 32 Lock the the screw for parallel key (38) with Loctite 243 Degrease both threads before. Fill the shaft relief at (A) with lubricating grease. Before installation, apply Molykote paste G Rapid Plus to hollow shaft and threaded spindle at (B). Tighten locking pin (44) and nut with Loctite 243

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 100 Nm

302

m

Engineer’s Handbook Miscellaneous

M 32

c2

Big-end bearing temperature monitoring Distance between the elements 20 ± 5 mm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

303

m

c2

Engineer’s Handbook Miscellaneous

M 32

Brackets for main bearing temperature monitoring Note: The figures below represent different attachments in an exemplary manner, also on the RM 32 engine. Tighten (short and long) screw plugs (1) with Molykote

⇒

M = 70

Tighten screws (2) with Molykote

⇒

M = 150 Nm

Before installing screws (3) degrease the threads. Then tighten screws (3) with ⇒ Loctite 243 Thereafter, secure the screws with wire. Screws with flat head without wire hole are not to be secured with wire.

Nm

M = 170 Nm

1

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

304

m

c2

Engineer’s Handbook Miscellaneous

M 32

Level probes Tighten the level probes (1) of the electrical equipment with max. M = 50 Nm.

Pressure transmitters Tighten the Trafag 8298 pressure transmitter (2) with max.

M = 33 Nm

Pressure switches on the genset Tighten the hexagon bolts M5x40 8.8 (60) with conical spring washers with Molykote

M = 4 Nm

Operating position

Test position Test connection

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

305

m

Engineer’s Handbook Miscellaneous

M 32

c2

Installation of thermocouples 1. Slip copper ring over the thread of the protective sleeve. 2. Apply Rivolta G.W.F. to the thread of protective sleeve (1). 3. Screw in protective sleeve. The copper ring must not be squeezed out laterally (pay attention to the centring)! 4. Slip toothed lock washer (6) over thermocouple (2). 5. Insert thermocouple into protective sleeve (1). Attention! In doing so, introduce the straight grooved pin (3) of the protective sleeve (1) into the groove of the thermocouple (2). 6. Tighten male connector (7).

Adjustment of the speed pick-up Alignment of the speed pick-up in case of radial mounting position:

Permissible deviation: Red marking, at right angle to the bevel angle (countersink)

Alignment of the speed pick-up in case of axial mounting position:

Red marking, parallel to the direction of movement (countersink)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

306

m

c2

Engineer’s Handbook Miscellaneous

M 32

Speed pick-up bracket (M 32 E) (turbocharger at driving end) Tightening torque for screw plug M33x2 (6) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Connection for lubricating oil pipe

Installation of the crankcase oil mist detector For both VM and RM (incl. M 32 E) a minimum clearance of 5 mm between engine block (1) and suction funnel (2) must be ensured. If necessary, bend the tube to obtain this clearance. For VM secure the screw-in thread (3) with Loctite 243.

RM

VM

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

307

m

c2

Engineer’s Handbook Miscellaneous

M 32

Pump covering Insert the dowel pins into the pump coverings with Loctite 243. Insert all screws with Molykote and tighten them with the standard torques. Screw the flange bolts (13) with Loctite 270 into the star grips (12). In doing so, make sure that both threads are free of grease. Do not forget the conical spring washer (11)!

Oil filter, oil safety strainer Installation for RM 32: Insert studs M16 (8) with Molykote Insert nuts M16 (9) with Molykote Installation for VM 32: Insert screws M16 (5) with Molykote

⇒

M = 50

Nm

⇒

M = 130

Nm

⇒

M = 150

Nm

Tighten all other flanges with the standard torques (Molykote). Coat the flange gasket at A with Vaseline. Automatic filter for marine application (no figure): Tightening torque for screw plug G1/2A-SW19 in the pipe see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

308

m

c2

Engineer’s Handbook Miscellaneous

M 32

Brackets for TC and RTD switch boxes (RM 32 E) Tightening torque for screw plugs M48x2 (38) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”.

Brackets for lateral switch boxes (RM 32 E) Insert screws M6 (17) with Molykote

⇒

M=8

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

309

m

c2

Engineer’s Handbook Miscellaneous

M 32

Headless screw for duplex fuel filter cover plate RM 32 E: Insert headless screw for star grip (14) with Loctite 270 RM 32 C: Insert headless screw M12x50 (15) with Loctite 270

⇒

M = 35 Nm

⇒

M = 35 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

310

m

Engineer’s Handbook Pump Support with Attached Pumps

M 32

c2

Pump support with attached pumps Pump support RM 32 - VM 32 - M 32 C Before assembly degrease all flange surfaces. Position the pump mounting plate with device, pin it and screw it onto the engine block with a thin coat of sealing compound. Pumpsealing support Apply compound also around the two holes. Before assembly degrease all flange surfaces. Position the pump mounting plate with device, pin it and (1) screw it onto thewith engine block with a thin (M20 x 130) ⇒coat of sealing compound. M = 350 Nm Tighten 2 screws Molykote Tighten 2 screws (1) (M20 x 130) with ⇒ M = 350 Nm Tighten 6 screws (2) (M12 x 45) with ⇒ M = 80 Nm Molykote Molykote Tighten 6 screws (2) (M12 x 45) with ⇒ M = 80 Nm Molykote Tighten all M16 screws with ⇒ M = 130 Nm Molykote Tighten all M16 screws with ⇒ M = 130 Nm Molykote Tighten all M12 screws with ⇒ M = 60 Nm Tighten all M12 screws with ⇒ M = 60 Nm Molykote Molykote Apply a thin coat of sealing compound in the hatched areas only

Apply a thin coat of sealing compound in the hatched area only. ↓

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

311

m

Engineer’s Handbook Pump Support with Attached Pumps

M 32

c2

Pump support (RM 32 E) Tightening torques for screw plugs G1/2A-SW19 (5) and M16x1.5-SW17 (7) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Insert and check the expanders at E only according to the instructions of the manufacturer and with the tools and tests specified by the manufacturer.

Apply a thin coat of sealing compound in the hatched areas only

Cover on pump support (RM 32 E) Put in place the gasket between pump support and cover (1) with grease. Tightening torque for screw plug M45x1.5 (7) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs“. Tighten screws M12x25-8.8 (5) with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 60 Nm

312

m

Engineer’s Handbook Pump Support with Attached Pumps

M 32

c2

Lubricating oil connections for cooling water pumps, HT and LT circuit (VM 32 C) Attention! These pumps are used on VM 32 C engines only. The engines have different lubricating oil connections depending on whether they are equipped with or without power take-off (PTO). On VM 32 C engines without PTO the cooling water pump bearings are supplied through an internal hole. The corresponding hole at the pump (see the following figure) must be open. This is the hole that is closer to the mounting flange. Plug the other holes (insert headless screws M12x12 with Loctite 270).

VM 32 C without PTO: Plug

Plug Oil supply through internal hole

On VM 32 C engines with PTO the cooling water pump bearings are supplied through an external lubricating oil pipe. For this purpose the shown outer hole must be open for connecting the lubricating oil pipe (see figure below). Plug the other holes before installing the pump (insert headless screws M12x12 with Loctite 270).

VM 32 C with PTO: Plug

Oil supply through pipe Plug

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

313

m

c2

Engineer’s Handbook Pump Support with Attached Pumps

M 32

Cooling water pumps: Gear wheel installation Check the contact pattern on the related pump shaft cone with gear wheel cone covered with blue paste. Only a contact surface displaced towards the thick end is admissible. Percentage contact area at least 80 %. The cone surfaces must be free of grease and dry. RM 32: Heat the gear wheel up to 90 °C to 100 °C above temperature of the cooling water pump shaft (example: 20 °C shaft temperature → 110 °C to 120 °C gear wheel temperature) VM 32: Heat the gear wheel up to 80 °C to 90 °C above temperature of the cooling water pump shaft (example: 20 °C shaft temperature → 100 °C to 110 °C gear wheel temperature) Fit the gear wheel firmly on the related pump shaft cone as far as it will go. The slide-on distance for RM 32 is

⇒

0.43 - 0.47 mm

The slide-on distance for VM 32 is

⇒

0.51 - 0.57 mm

Tighten the screw for the gear wheel for RM 32 with ⇒ Molykote (RM 32 E and IMO II: Gear wheel at room temperature)

M = 60

Nm

Nm

Tighten the screw for the gear wheel for VM 32 with Molykote (gear wheel at room temperature)

⇒

M = 100

Backlash

⇒

0.20 - 0.45 mm

Lubricating oil pumps, suction and pressure pump Put in place the pump flange with Dirko universal sealing compound # 610.020. Backlash (all engines incl. M 32 E)

⇒

0.20 - 0.45 mm

Tightening torque for screw plugs G1/4 see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs“. Insert the studs M16-8.8 for installing the pump with Molykote

⇒

RM 32 E: Tighten the nuts M16 for installing the pump with ⇒ Apply Molykote to thread and nut contact surface

M = 60

Nm

M = 130

Nm

Fasten the lubricating oil pipes to the lubricating oil pump with Molykote and the corresponding standard torques. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

314

m

c2

Engineer’s Handbook Pump Support with Attached Pumps

M 32

Lubricating oil pump: Gear wheel installation 1. Check the contact pattern on the related pump shaft cone with gear wheel cone covered with blue paste. Percentage contact area at least 80 %. Measure and document the position of the gear wheel. 2. Heat gear wheel up to 110 °C to 120 °C above temperature of the oil pump shaft (example: 20 °C shaft temperature → 130 °C to 140 °C gear wheel temperature) and firmly fit it on the related pump shaft cone as far as it will go. The cone surfaces must be free of grease and dry. When installing the gear wheel the pump shaft must be in vertical position (cone facing upward)! 3. Tighten the screw for the gear wheel with washer promptly with 45 Nm 4. After cooling down to room temperature remove the screw with washer. 5. Check the slide-on distance: Slide-on distance for RM 32 (incl. RM 32 E)

⇒

0.58 - 0.68 mm

Slide-on distance for VM 32 and M 32 C

⇒

0.58 - 0.63 mm

Note: Some RM 32 engines equipped with pumps with a slide-on distance of 0.58 - 0.63 mm. If in doubt, contact the Technical Customer Service. 6. Tighten the screw for the gear wheel with washer with ⇒ Apply Molykote to thread and screw head contact surface.

M = 60

Nm

Nm

Fuel feed pump (RM 32) Tighten the screw for the gear wheel with Molykote

⇒

M = 60

Backlash

⇒

0.20 - 0.45 mm

Heat the coupling halves (2) up to 100 °C and shrink fit them onto the related shaft journal according to the drawing as far as they will go.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

315

m

Engineer’s Handbook Pump Support with Attached Pumps

M 32

c2

Fuel feed pump drive (RM 32) Heat gear wheel (4) up to 30 °C to 40 °C above temperature of the pump shaft (example: 20 °C shaft temperature → 50 °C to 60 °C gear wheel temperature) and firmly fit it on the related pump shaft cone as far as it will go. The slide-on distance for the gear wheel is

⇒

0.14 - 0.18 mm

Install screw (8) with washer (5) and tighten with Molykote

⇒

M = 60

Nm

Insert screw (7) with Loctite 243. Before pressing-in lightly lubricate the bush (9) with oil. The joint is located sideways. Do not use any further lubricant.

Cooling water pump drive backlash (RM 32 E) The backlash of the cooling water pump gear wheel shall be

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

0.20 - 0.45 mm

316

m

Engineer’s Handbook Flywheel

M 32

c2

Flywheel RM 32 - VM 32 - M 32 C Flywheel installation 1. Drive the spring dowel pin (1) into the flywheel hub. 2. Bar crankshaft to TDC of cylinder 1. 3. With the 14 mm fixing hole facing upward, position the flywheel in the transportation opening so that it is suspended vertically. In this position the projecting spring dowel pin (1) in the flywheel hub is aligned with the corresponding receiving hole in the flywheel.

Flywheel installation (RM 32 CCR) Engine turning clockwise: 1. Drive the spring dowel pin (1) into the flywheel hub. 2. Bar crankshaft to TDC of cylinder 1. 3. Position the flywheel in the transportation opening so that it is suspended vertically. 4. The gap of the radial hole for speed measurement is at the top. In this position the projecting spring dowel pin (1) in the flywheel hub is aligned with the corresponding receiving hole in the flywheel. Engine turning counter-clockwise: 1. Use the device for installation! 2. Drive the spring dowel pin (1) into the flywheel hub. 3. Position the flywheel in the mounting device. 4. Turn flywheel counter-clockwise by 90° from TDC. 5. The gap in the radial holes for speed measurement is at left-hand side. In this position the projecting spring dowel pin (1) in the flywheel hub is aligned with the corresponding receiving hole in the flywheel.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

317

m

c2

Engineer’s Handbook Flywheel

M 32

RM 32 - VM 32 - M 32 C - M 32 CCR - VM 32 CCR Tightening torques Tighten screws (2) with Molykote

⇒

M = 100 Nm + 120°

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

318

m

Engineer’s Handbook Flywheel

M 32

c2

Flywheel installation (VM 32 CCR) Engine turning clockwise: 1. Drive the spring dowel pin (1) into the flywheel hub. 2. Bar crankshaft to 25° before TDC of cylinder 1, bank B. 3. Position the flywheel in the Ø 65 mm transportation opening so that it is suspended vertically. 4. The gap in the radial holes for speed measurement is leading in direction of rotation. In this position the projecting spring dowel pin (1) in the flywheel hub is aligned with the corresponding receiving hole in the flywheel. Engine turning counter-clockwise: 1. Drive the spring dowel pin (1) into the flywheel hub. 2. Position the flywheel in the two Ø 65 mm transportation openings so that it is suspended vertically. 3. Bar the crankshaft 115° from TDC of cylinder 1, bank B, in counter-clockwise direction. 4. The gap in the radial holes for speed measurement is leading in direction of rotation. In this position the projecting spring dowel pin (1) in the flywheel hub is aligned with the corresponding receiving hole in the flywheel. The following illustration shows an engine turning clockwise with cylinder B1 at TDC. The gap of the radial holes for speed measurement is located at X.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

319

m

c2

Engineer’s Handbook Flywheel

M 32

Coupling adapter ring on flywheel Tighten screws (3) M24 of adapter ring (4) with Oil

⇒

M = 660 + 70 Nm

Tighten screws (3) M22 of adapter ring (4) with Oil

⇒

M = 675 + 75 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

320

m

Engineer’s Handbook Flexible Flange Connection

M 32

c2

Flexible flange connection Couplings TEF 50.000/50W-ST, TEF 63.000/50W-ST, TEF 80.000/50W-ST Coupling assembly according to the installation instructions of the manufacturer. Axial alignment Push the generator towards the engine until assembly reference dimension X1 for the respective coupling is reached (see table below).

Coupling type

Assembly reference dimension X1

TEF 50.000/50W-ST

250 mm + 0.5 mm

TEF 63.000/50W-ST

276 mm + 0.5 mm

TEF 80.000/50W-ST

298 mm + 0.5 mm

Angular alignment Shift the generator until the gap (angular displacement) is 0+0.2 mm. Radial alignment Lift the generator by means of the jacking screws so that it is positioned 0.4 mm higher than the engine. Take into account a settlement of about 0.1 mm of the Vibracon elements.

For coupling TEF 50.000/50W-ST: Tighten screws (1) with M = 270 Nm. Oil

For coupling TEF 63.000/50W-ST: Tighten screws (1) with M = 380 Nm. Oil

For coupling TEF 80.000/50W-ST: Tighten screws (1) with M = 500 Nm. Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

321

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-S 1G391W, series 2200, 1G39100032 The hub must project 75 mm beyond the generator shaft journal end (see projection Y). Push the generator with mounted hub towards the flywheel until assembly reference dimension A is reached. Install the intermediate ring and diaphragm subassembly with screws (1) and washers at the coupling hub with the tightening torque. Pull diaphragm subassembly about 10 mm towards generator (use a hoist). Suspend a single RATO-S element from above between diaphragm subassembly and flywheel and install with bolts, nuts (3) and washers at the diaphragm subassembly. Push a single RATO-S element into the recess of the flywheel and install it by means of the corresponding screws (2) and washers. Install the remaining RATO-S elements as described above. Tighten screws (2) and nuts (3) with the tightening torque. Tighten screws (1) (M36x200) with Oil Tighten screws (2) (M24x75) with Oil

⇒

M = 2250 + 250 Nm

⇒

M = 660 + 70

Nm

Tighten nuts (3) (M22) with Oil

⇒

M = 480 + 50

Nm

Assembly reference dimension A is

⇒

685 + 0.8

mm

Y

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

322

m

Engineer’s Handbook Flexible Flange Connection

M 32

c2

Vulkan RATO-DS A3415, series 2200, 1A3410A023 1. Hub is mounted on the generator journal. The hub must be flush with the generator shaft journal end. 2. RATO-DS element and chamfered ring are connected to each other by means of screws (5) and (6). Screws (4) are pre-assembled on the chamfered ring. 3. Remove screws (4) and washers and free them of any preservative. 4. Fasten RATO-DS element and chamfered ring with the corresponding screws (4) and washers to the hub. Observe the tightening torque. 5. While tightening, check whether the chamfered ring has correct metal-to-metal contact in the centring of the hub. Pay attention to the marked 0 position. 6. Tighten the pre-assembled chamfered ring with the corresponding screws (5) and (6) and washers. Observe the tightening torque. 7. Push the generator with mounted hub and RATO-DS element towards the flywheel until assembly reference dimension B is reached. In doing so, make sure that the centring is correctly seated between RATO-DS element and flywheel. Pay attention to the marked 0 position. 8. Establish threaded connection (7) between RATO-DS element and flywheel. In doing so, observe the torque. While tightening, check whether the RATO-DS element has metal-to-metal contact at the outer circumference of the centring of the flywheel. 9. Pay attention to the marked 0 position. 10. Align the generator (separate instruction). Tighten screws (4) M24x125 with ⇒ M = 660 + 70 Nm Oil ⇒ M = 660 + 70 Nm Tighten screws (5) M24x85 with Oil Tighten screws (6) M24x65 with ⇒ M = 660 + 70 Nm Oil ⇒ M = 600 Nm Tighten screws (7) M22x200 with Oil ⇒ 515 + 0.8 mm Assembly reference dimension B is

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

323

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-DS A33D0, series 2200, 1A33D0A033 Hub with ring are installed on the generator shaft journal. The hub must project 25 mm beyond the generator shaft journal end (see projection Y). Screws (9) are pre-assembled. Screws (11) are screwed into the ring. Pay attention to the marked 0 position. Both RATO-DS elements (1) and (2) and the chamfered ring are connected to each other with screws (8), (10) and (12) and pre-assembled. The flywheel fastening screws (13) are fastened in the RATO-DS element (1)by means of nuts. Pay attention to the marked 0 position. Remove RATO-DS element (2), attach it to a suitable hoist and connect it with the ring. Tighten screws (11) with the tightening torque. Remove locknuts of screws (9). Push RATO-DS element (2) with ring towards the generator. Attach RATO-DS element (1) with chamfered ring to a suitable hoist and fit to the flywheel by means of the corresponding screws (13) and washers. In doing so, observe the tightening torque. While tightening, check whether the RATO-DS element (1) has metalto-metal contact at the outer circumference of the centring of the flywheel. Pay attention to the marked 0 position. Tighten the pre-assembled chamfered ring with the corresponding screws (10) and (12) and washers. In doing so, observe the tightening torque. Push the generator with mounted hub and loose RATO-DS element (2) towards the flywheel until assembly reference dimension C is reached. In doing so, make sure that the centring is correctly seated between hub and chamfered ring. Push RATO-DS element (2) with the screwed-on ring onto RATO-DS element (1). Pay attention to the 0 position. Establish screwed connection with (8) and (9). Observe the tightening torques for screws (8) and (9). While tightening, check whether RATO-DS element (2) has metal-to-metal contact at the outer circumference in the centring of RATO-DS element (1). Tighten screws (8) M20x180 with Oil

⇒

M = 505 + 55 Nm

Tighten screws (9) M22x150 with Oil

⇒

M = 675 + 75 Nm

Tighten screws (10) M22x80 with Oil

⇒

M = 675 + 75 Nm

Tighten screws (11) M22x60 with Oil

⇒

M = 675 + 75 Nm

Tighten screws (12) M22x60 with Oil

⇒

M = 675 + 75 Nm

Tighten hexagon socket head cap screws (13) M20x160 with⇒ Oil Assembly reference dimension C is

⇒

M = 505 + 55 Nm 525 + 0.8

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

mm

324

m

Engineer’s Handbook Flexible Flange Connection

M 32

c2

Y

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

325

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-DS A34DZ/D1-D6, series 2200, 1A34D0A016 Vulkan RATO-DS A34DO/D1-D6, series 2200, 1A34D0A027 series 2200, 1A34D0 Vulkan RATO-DS A34DO Vulkan RATO-DS A34D5, series 2200, 1A34D0A016 Vulkan RATO-DS A34D5, series 2200, 1A34D0A019 Vulkan RATO-DS A34D5, series 2200, 1A34D002A2 Hub with ring are installed on the generator shaft journal. The hub must be flush with the generator shaft journal end. Screws (15) are pre-assembled. Screws (17) are screwed into the ring. Pay attention to the marked 0 position. Both RATO-DS elements (1) and (2) and the chamfered ring are connected to each other with screws (14), (16) and (18) and preassembled. The flywheel fastening screws (19) are fastened in the RATO-DS element (1) by means of nuts (except for type 1A34D002A2). Pay attention to the marked 0 position. 1. Remove RATO-DS element (2), attach it to a suitable hoist and connect it with the ring. Tighten screws (17) with the tightening torque. 2. Remove locknuts of screws (15). 3. Push element (2) with ring towards the generator. 4. For RATO-DS A34DO/D1-D6 and RATO-DS A34DO bar the engine now in such a manner that cylinder 1 of the crankshaft is at TDC. Fill generator bearing with oil and bar the generator so that the parallel key of the generator shaft is positioned vertically at the top. 5. Attach RATO-DS element (1) with chamfered ring to a suitable hoist and fit to the flywheel by means of the corresponding washers (no washers for type 1A34D002A2) and screws (19). In doing so, observe the tightening torque. 6. While tightening, make sure that the RATO-DS element (1) has metal-to-metal contact at the outer circumference of the centring of the flywheel. Pay attention to the marked 0 position. 7. Tighten the pre-assembled chamfered ring with the corresponding screws (16) and (18) and washers. Observe the tightening torque. 8. Push the generator with mounted hub and loose RATO-DS element (2) towards the flywheel until assembly reference dimension D is reached. In doing so, make sure that the centring is correctly seated between hub and chamfered ring. 9. Push RATO-DS element (2) with the screwed-on ring onto RATO-DS element (1). Pay attention to the 0 position. 10. Establish screwed connection with (14) and (15). Observe the tightening torques for screws (14) and (15). 11. While tightening, check whether RATO-DS element (2) has metal-to-metal contact at the outer circumference in the centring of RATO-DS element (1). Tighten screws (14) M22x200 with Oil Tighten screws (15) M24x160 with Oil Tighten screws (16) M24x85 with Oil Tighten screws (17) M24x65 with Oil

⇒

M = 675 + 75 Nm

⇒

M = 660 + 70 Nm

⇒

M = 660 + 70 Nm

⇒

M = 660 + 70 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

326

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

⇒

Tighten screws (18) M24x65 with Oil

M = 660 + 70 Nm

Screws (19) M22x170 have different tightening torques depending on the coupling model (see table below). Model

Tightening torque for screws (19)

Vulkan RATO-DS A34DZ/D1-D6, series 2200, 1A34D0A016

675 + 75 Nm oil

Vulkan RATO-DS A34DO/D1-D6, series 2200,1A34D0A027

675 + 75 Nm oil

Vulkan RATO-DS A34D5,

series 2200, 1A34D0A016

675 + 75 Nm oil

Vulkan RATO-DS A34D5,

series 2200, 1A34D0A019

570 + 60 Nm oil

Vulkan RATO-DS A34D5,

series 2200, 1A34D002A2

450

Assembly reference dimension D is

⇒

Nm oil

525 + 0.8 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

327

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-S G392W, series 2100, 1G39200058 Vulkan RATO-S G342Q, series 2100, 1G34200062 (G392W used for 12 M 32 C diesel generator sets) (G342Q used for 9 M 32 C engines) Hub (3) is fitted onto the generator shaft journal. For G342Q the hub must be flush with the generator shaft journal end. For G392W the hub must project 75 mm beyond the generator shaft journal end (see projection Y). Inner cover ring (4) and diaphragm subassembly (5) are fitted onto hub (3) with fasteners (9) and (11). Fasteners (6), (7), (10), (12) and (13) are pre-assembled onto diaphragm subassembly (5). Both RATO-S elements (1) are screwed to each other by means of fasteners (14), (15) and (16). The flywheel fasteners (8) and (12) are fastened in the RATO-DS element (1) by means of nuts. 1. Remove fasteners (6), (7), (10), (12), (13) of the diaphragm subassembly and fasteners (8) and (12) of the RATO-S elements. 2. Tighten fasteners (14) and (15) of RATO-S elements (1) with the tightening torque. 3. For G342Q bar the engine so that piston of cylinder 1 is at TDC position. Fill generator bearing with oil and bar the generator so that the parallel key of the generator shaft is positioned vertically at the top. 4. Attach RATO-S elements (1) to a suitable hoist, push over hub (3) and mount onto diaphragm subassembly (5) by means of the corresponding fasteners (6), (7), (10), (12), (13). 5. Tighten fasteners (7) and (10) with the tightening torque. While tightening, check whether the RATO-S element (1) has metal-to-metal contact at the outer circumference of the centring of diaphragm subassembly (5). 6. Push the generator with mounted hub (3), mounted diaphragm subassembly (5) and mounted RATO-S elements (1) towards the flywheel until assembly reference dimension E is reached. In doing so, make sure that the centring is correctly seated between RATO-S elements (1) and flywheel. 7. Mount RATO-S elements (1) with the corresponding fasteners (8) and (12) onto the flywheel. Observe the tightening torques for screws (8). While tightening, check whether the RATO-S element (1) has metal-to-metal contact at the outer circumference of the centring of the flywheel. Coupling G392W

Coupling G342Q

Position

Screw

Tightening torque

Screw

Tightening torque

(7)

M24x110

660 + 70 Nm oil

M22x100

510 + 60 Nm oil

(8)

24x75

600 + 70 Nm oil

M22x70

675 + 75 Nm oil

(9)

M36x120

2250 + 250 Nm oil

M30x100

1300 + 150 Nm oil

(15)

Nut M22

480 + 50 Nm oil

Nut M20

480 + 50 Nm oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

328

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Assembly reference dimension E for G392W is

488.2 mm + 0.8 mm

Assembly reference dimension E for G342Q is

402.9 mm + 0.8 mm

Y

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

329

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-DS A31D5, series 2400, 1A31D5A042 (Used on 16 M 32 C diesel generator sets) Hub (3) with ring (5) are mounted onto the intermediate shaft journal. Fasteners (7) and (15) are fastened to hub (3) and ring (5) by means of nuts. Fasteners (9) and (11) are screwed into ring (5). Pay attention to the marked 0 position. Hub (17) with mit disc flange (16) are mounted onto the generator shaft journal. Fasteners (18) and (19) are screwed into disc flange (16). Pay attention to the marked 0 position. Both RATO-DS elements (1) and (2) and chamfered ring (4) are screwed to each other and pre-assembled with (6), (12) and (8), (10), (11). The disc flange fastening bolts (13) and (14) are fastened by means of nuts (20) in RATO-DS element (1). Pay attention to the marked 0 position. 1. Remove RATO-DS element (2), attach it to a suitable hoist and connect it with ring (5). 2. Tighten screws (9) and (11) with the tightening torque. 3. Remove locknuts of screws (7). 4. Shift the RATO-DS element (2) with ring (5) in direction of the intermediate bearing. 5. Attach RATO-DS element (1) with chamfered ring (4) to a suitable hoist and fit to the disc flange by means of the corresponding fasteners (13), (14), and (20) and tighten with the tightening torque. While tightening, check whether the RATO-DS element (1) has metal-to-metal contact at the outer circumference of the centring of the disc flange. Pay attention to the marked 0 position. 6. Now tighten the pre-assembled chamfered ring (4) with the corresponding fasteners (8), (10), and (11) with the tightening torque. 7. Push the generator with mounted hub (17), disc flange (16), and RATO-DS element (1) towards the intermediate bearing until assembly reference dimension F is reached. In doing so, make sure that the centring is correctly seated between hub (3) and chamfered ring (4). 8. Push RATO-DS element (2) with the screwed-on ring (5) onto RATO-DS element (1). Pay attention to the 0 position. 9. Establish connection between (7), (15) and (6), (12). Observe the tightening torques for (7) and (6). While tightening, check whether RATO-DS element (2) has metal-to-metal contact at the outer circumference in the centring of RATO-DS element (1). Tighten screws (6) M18x170 with Oil

⇒

M = 350 + 40

Nm

Tighten screws (7) M20x140 with Oil

⇒

M = 505 + 55

Nm

Tighten screws (8) M20x75 with Oil

⇒

M = 505 + 55

Nm

Tighten screws (9) and (10) M20x55 with Oil

⇒

M = 505 + 55

Nm

Tighten screws (19) M27x100 with Oil

⇒

M = 960 + 110 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

330

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Tighten nuts (20) M18 with Oil

⇒

M = 350 + 40

Assembly reference dimension F is

⇒

660 mm + 0.8 mm

Nm

The hubs at Z must be flush with the shaft journal ends.

Z

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Z

331

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-DS A33D0, series 2200, 1A33D0A049 Vulkan RATO-DS A33D0, series 2200, 1A33D0 Hub (3) with ring (5) are mounted onto the generator shaft journal. The hub must be flush with the generator shaft journal end. Screws (7), (15) are pre-assembled. Fasteners (9) and (11) are screwed into ring (5). Pay attention to the marked 0 position. Both RATO-DS elements (1) and (2) and chamfered ring (4) are screwed to each other and pre-assembled with positions (6), (12), (8), (10), and (11). The flywheel fastening screws (13) and (14) are fastened in the RATO-DS element (1) by means of nuts. Pay attention to the marked 0 position. 1. Remove RATO-DS element (2), attach it to a suitable hoist and connect it with the ring (5). Tighten screws(9) and (11)with the tightening torque. 2. Remove locknuts of screws (7). 3. Push element (2) with ring (5) towards the generator. 4. Bar the engine so that the piston of cylinder 1 is at TDC position. Fill generator bearing with oil and bar the generator so that the parallel key of the generator shaft is positioned vertically at the top. 5. Attach RATO-DS element (1) with chamfered ring (4) to a suitable hoist and fit to the flywheel by means of the corresponding fasteners (13) and (14). In doing so, observe the tightening torque. While tightening, make sure that the RATO-DS element (1) has metal-to-metal contact at the outer circumference of the centring of the flywheel. Pay attention to the marked 0 position. 6. Tighten the pre-assembled chamfered ring (4) with the corresponding fasteners (8), (10) and (11). Observe the tightening torque. 7. Push the generator with mounted hub (3) and loose RATO-DS element (2) towards the flywheel until assembly reference dimension H is reached. In doing so, make sure that the centring is correctly seated between hub (3) and chamfered ring (4). 8. Push RATO-DS element (2) with the screwed-on ring (5) onto RATO-DS element (1). Pay attention to the 0 position. 9. Establish screwed connection (7), (15) and (6), 12). Observe the tightening torques for screws (7) and (6). 10. While tightening, check whether RATO-DS element (2) has metal-to-metal contact at the outer circumference in the centring of RATO-DS element (1). Tighten screws (6) M20x180 with Oil Tighten screws (7) M22x150 with Oil Tighten screws (8) M22x80 with Oil Tighten screws (9) M22x60 with Oil Tighten screws (10) M22x60 with Oil Tighten screws (14) M20x160 with Oil

⇒

M = 505 + 55 Nm

⇒

M = 675 + 75 Nm

⇒

M = 675 + 75 Nm

⇒

M = 675 + 75 Nm

⇒

M = 675 + 75 Nm

⇒

M = 505 + 55 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

332

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Assembly reference dimension H is

⇒

490 mm + 0.8 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

333

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-DS A33D0, series 2200, 1A33D0A0XX with additional mass Hub (3) with ring (5) are mounted onto the generator shaft journal. The hub (3) must be flush with the generator shaft journal end. Screws (7), (15) are pre-assembled. Fasteners (9) and (11) are screwed into ring (5). Pay attention to the marked 0 position. Both RATO-DS elements (1) and (2) and chamfered ring (4) are screwed to each other and pre-assembled with positions (6), (12), (8), (10), and (11). The flywheel fastening screws (18) and (19) are fastened in the additional mass (17) by means of nuts. Pay attention to the marked 0 position. The fastening screws for the additional mass (13) and (14) are fastened in the RATO-DS element (1) by means of nuts. Pay attention to the marked 0 position. 1. Remove RATO-DS element (2), attach it to a suitable hoist and connect it with the ring (5). Tighten screws (9) and (11) with the tightening torque. 2. Remove locknuts of screws (7). 3. Push element (2) with ring (5) towards the generator. 4. Attach the additional mass (17) to a suitable hoist and fit it to the flywheel by means of the corresponding fasteners (18) and (19). In doing so, observe the tightening torque. While tightening, make sure that the additional mass (17) has metal-to-metal contact at the outer circumference of the centring of the flywheel. Pay attention to the marked 0 position. 5. Attach the RATO-DS element (1) with chamfered ring (4) to a suitable hoist and fit it to the additional mass (17) by means of the corresponding fasteners (13) and (14). In doing so, observe the tightening torque. While tightening, make sure that the RATODS element (1) has metal-to-metal contact at the outer circumference of the centring of the additional mass (17). Pay attention to the marked 0 position. 6. Tighten the pre-assembled chamfered ring (4) with the corresponding fasteners (8), (10) and (11). Observe the tightening torque. 7. Push the generator with mounted hub (3) and loose RATO-DS element (2) towards the flywheel until assembly reference dimension I is reached. In doing so, make sure that the centring is correctly seated between hub (3) and chamfered ring (4). 8. Push RATO-DS element (2) with the screwed-on ring (5) onto RATO-DS element (1). Pay attention to the 0 position. 9. Establish screwed connection (7), (15) and (6), 12). Observe the tightening torques for screws (7) and (6). 10. While tightening, check whether RATO-DS element (2) has metal-to-metal contact at the outer circumference in the centring of RATO-DS element (1). Tighten screws (6) M20x180 with Oil Tighten screws (7) M22x150 with Oil Tighten screws (8) M22x80 with Oil Tighten screws (9) M22x60 with Oil

⇒

M = 505 + 55 Nm

⇒

M = 675 + 75 Nm

⇒

M = 675 + 75 Nm

⇒

M = 675 + 75 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

334

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Tighten screws (10) M22x60 with Oil Tighten screws (14) M20x160 with Oil

⇒

M = 675 + 75 Nm

⇒

M = 505 + 55 Nm

Tighten screws (19) M20x60 with Oil

⇒

M = 505 + 55 Nm

Assembly reference dimension I is

⇒

540 mm + 0.8 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

335

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-R G401J, series 2200, 1G4010R009 (Used on 16 M 32 C diesel generator sets) Hub (5) is fitted onto the generator shaft journal. It must be flush with the generator shaft journal end. The bushes are fastened to the RATO-R element (1) by means of tie wraps. The flywheel fasteners (20) and (39) are fastened to the RATO-R element by means of hexagon nuts. Fasteners (16), (19), (28), (22), (35), and (36) are fastened to the diaphragm subassembly (10). 1. Remove bushes, fasteners of the diaphragm subassembly (16), (19), (28), (22), (35), and (36) and the flywheel fasteners of the RATO-R element (20) and (39). 2. Bar the engine so that the piston of cylinder 1 is at TDC position. Bar the generator so that the parallel key of the generator shaft is positioned vertically at the top. 3. Fit diaphragm subassembly (10) with fasteners (22), (35), and (36) to the hub in such a way that the locating holes for the pins (55) are in horizontal position (marking by means of notches) and tighten with the tightening torque. 4. Push the generator with mounted hub (5) and fitted diaphragm subassembly (10) towards the flywheel until assembly reference dimension G is reached. 5. Attach RATO-R element (1) to a suitable hoist and push between hub (5) and flywheel. 6. Fit RATO-R element (1) with the related fasteners (20) and (39) to the flywheel so that the locating holes for the pins (55) are in horizontal position (marking by means of notches) and tighten with the tightening torque. While tightening, check wether the RATO-R element (1) has metal-to-metal contact at the outer circumference of the centring of the flywheel. 7. Centre the diaphragm subassembly (10) with 2 bushes and 2 pins (55) with RATO-R element (1). In doing so, use the existing locating holes in the RATO-R element (1). The locating holes are marked in the RATO-R element (1) and in the diaphragm subassembly (10) by means of notches (2x180°). If necessary, bar the engine until the locating holes are facing each other. 8. Mount diaphragm subassembly (10) with fasteners (16), (19), and (28) to the RATO-R element (1) and tighten with the tightening torque. 9. Tighten pins (55) by means of fasteners (16), (19), and (28) and with the tightening torque. Tighten screws (20) M24x60 with Oil

⇒

M = 660 + 70

Nm

Tighten screws (28) M24 with Oil

⇒

M = 660 + 70

Nm

Tighten screws (36) M36 with Oil

⇒

M = 2250 + 250 Nm

Assembly reference dimension G is

⇒

619 mm + 0.8 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

336

m

Engineer’s Handbook Flexible Flange Connection

M 32

c2

Assembly reference dimension

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

337

m

c2

Engineer’s Handbook Flexible Flange Connection

M 32

Vulkan RATO-R G401J, series 2200, 1G39100036 (Used on diesel generator sets with VM 32 C) Hub (5) is fitted onto the generator shaft journal. The flywheel fasteners (20) and (39) are fastened to the RATO-S element (1) by means of hexagon nuts. Fasteners (7), (22), (35), (18), (27), (40), and (42) are fastened to the diaphragm subassembly (10). 1. Remove the fasteners of the diaphragm subassembly (7), (22), (35), (18), (27), (40), (42), and the flywheel fasteners of the RATO-S element (20) and (39). 2. Bar the engine so that the piston of cylinder 1 is at TDC position. Bar the generator so that the parallel key of the generator shaft is positioned vertically at the top. 3. Attach the diaphragm subassembly (10) to a suitable hoist, push over hub (5) and fit to hub (5) by means of the corresponding fasteners (7), (22), and (35). Tighten fasteners (22) with the tightening torque. 4. Attach the RATO-S element (1) to a suitable hoist and fit to the diaphragm subassembly (10) by means of the corresponding fasteners (18), (27), (40), and (42). Tighten fasteners (27) with the tightening torque. 5. Push the generator with mounted hub (5), mounted diaphragm subassembly (10) and mounted RATO-S element (1) towards the flywheel until assembly reference dimension H is reached. In doing so, make sure that the centring is correctly seated between RATO-S element (1) and flywheel. 6. Fit RATO-S element (1) with the related fasteners (20) and (39) to the flywheel. Observe the tightening torques for screws (20). While tightening, check whether the RATO-S element (1) has metal-to-metal contact at the outer circumference of the centring of the flywheel. 7. While tightening, check whether the RATO-S element (1) has metal-to-metal contact at the outer circumference of the centring of the flywheel. Tighten screws (20) M24x70 with Oil

⇒

M = 660 + 70

Nm

Tighten nuts (27) (M22) with Oil

⇒

M = 480 + 50

Nm

Tighten screws (22) M36x100 with Oil

⇒

M = 2250 + 250 Nm

Assembly reference dimension H is

⇒

318.8 mm + 0.8 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

338

m

Engineer’s Handbook Flexible Flange Connection

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

339

m

c2

Engineer’s Handbook Charge Air

M 32

Charge air

Charge air duct drain pipe (VM) (example) Tighten screws (1) (M16-8.8) for bracket with Molykote

⇒

M = 130 Nm

Tighten screws (2) (M8-8.8) for pipe clamp with Molykote

⇒

M = 15

Nm

Bracket

Pipe clamp Tube

Differential pressure gauge on charge air cooler (VM) Tighten hexagon socket head cap screws (3) M12-8.8 for fastening of the brackets for the differential pressure gauge with ⇒ Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 50 Nm

340

m

c2

Engineer’s Handbook Charge Air

M 32

Sealing caps in the charge air cooler casing The sealing surface of the sealing caps and the corresponding hole must be clean and free of grease.Lubricate the sealing surface of the sealing caps with Loctite 270. Use the provided drive-in mandrel for installation. The sealing cap edges must be located 1.5 ± 0.5 mm deep in the casing. Installation of charge air cooler casing (VM) Applicable for turbocharger assemblies 1.91.7-72.55.00-04, -05, -06, -08 with water separator, oil return, and screws for TPL65. Tightening torque for screw plugs G1/2 A-SW19 (35) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten screws M12x45 (23) with Molykote

⇒

M = 40 Nm

Tighten screws M12x55 (24) with Molykote

⇒

M = 80 Nm

Put in place the gaskets at flanges (8) and (9) with grease.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

341

m

c2

Engineer’s Handbook Charge Air

M 32

Tighten screws M20x220 (25) with Molykote

⇒

M = 420 Nm

Tighten screws M24x110 (27) with Molykote

⇒

M = 720 Nm

Insert studs (3) with Oil

⇒

M = 220 Nm

Tighten nuts (38) with Oil

⇒

M = 455 Nm

Apply a thin coat of Petro Gel Amber to toroidal sealing rings and O-rings and insert them untwisted. Degrease flange surfaces A before assembly and apply a thin coat of DIRKO No. 610.020 sealing compound. In doing so, keep the grooves for the toroidal sealing rings free of sealing compound.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

342

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler casing, driving end (6 M 32 C) Apply a thin coat of Petro Gel Amber to the O-rings (10) and insert them untwisted. Degrease flange surfaces to the engine block before assembly and apply a thin coat of DIRKO No. 610.020 sealing compound. Note: Not all of the mentioned screws are shown in the figures. Tightening torques for screw plugs M52x2 (31), G1/2A-SW19 (not shown) and M26x1.5 (30) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten studs (5) with Molykote

⇒

M = 100 Nm

Tighten screws (42) and (45) with Molykote

⇒

M = 260 Nm

Tighten screws (44) and (46) with standard tightening torques and Molykote.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

343

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler casing, free end (6 M 32 C) Apply a thin coat of Petro Gel Amber to the O-rings (10) and insert them untwisted. Degrease flange surfaces A to the engine block before assembly and apply a thin coat of DIRKO No. 610.020 sealing compound. Note: Not all of the mentioned screws are shown in the figures. Tighten studs (5) with Molykote

⇒

M = 100 Nm

Tightening torques for screw plugs M33x2 (31), G1/2A-SW19 (not shown) and M26x1.5 (30) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten the screws for fastening on the engine block with standard tightening torques and Molykote.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

344

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler casing for TPL67, driving end and free end (8 M 32 C and 9 M 32 C) Apply a thin coat of Petro Gel Amber to the sealing ring (5). Degrease flange surfaces A to the engine block before assembly and apply a thin coat of Hylomar sealing compound for casings without hole for air injection. For casings with hole for air injection apply a thin coat of DIRKO No. 610.020 sealing compound. In both cases keep the groove for the sealing ring (5) free of sealing compound. Note: Not all of the mentioned screws are shown in the figures. Tightening torques for screw plugs M33x2 (29) and G1/2A-SW19 (28) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten screws M20 (22), (23) and (26) with Molykote

⇒

M = 420 Nm

(For installation at the free end only): Tighten screws M16 (24) and (27) with ⇒M = 190 Nm Molykote

Free end

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

345

m

Engineer’s Handbook Charge Air

M 32

c2

Driving end

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

346

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler casing for TPL65, driving end and free end (8 M 32 C with single-pipe charging) Apply a thin coat of Petro Gel Amber to the sealing ring (5). Degrease flange surfaces A to the engine block before assembly and apply a thin coat of Hylomar sealing compound. In doing so, keep the groove for the sealing ring (5) free of sealing compound. Note: Not all of the mentioned screws are shown in the figures. Tightening torques for screw plugs M33x2 (29) and G1/2A-SW19 (28) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten screws M20 (22), (23) and (26) with Molykote

⇒

M = 420 Nm

Insert studs M20 (19) with Oil

⇒

M = 220 Nm

Tighten nuts M20 (20) with Oil

⇒

M = 455 Nm

(For installation at free end only): Tighten screws M16 (24) and (27) with ⇒ M = 190 Nm Molykote

Free end

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

347

m

Engineer’s Handbook Charge Air

M 32

c2

Driving end

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

348

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler casing, driving end and free end (RM 32 E) Apply a thin coat of Petro Gel Amber to the toroidal sealing ring (4) before insertion. Degrease sealing surface A before assembly and apply a thin coat of Dirko 610.020 sealing compound. Keep the groove for toroidal sealing ring (4) free of sealing compound. Tightening torques for screw plugs M52x1.5 (19) and M48x2 (20) (the latter for installation at driving end only) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Screw plug tightening torques”. ⇒

M = 260 Nm

6 M 32 E: Screws M20-10.9 (15) with Rivolta G.W.F.

⇒

M = 480 Nm

8/9 M 32 E: Tighten screws M24-10.9 (15) with Rivolta G.W.F.

⇒

M = 800 Nm

Tighten screws (18) with Molykote G Rapid Plus

(Free end)

 

$



(Driving end)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

349

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler, driving end and free end, IMO I and WB1 (RM) Tighten screws (1) with Molykote

⇒

M = 260 Nm

Tighten screws (2) with Molykote

⇒

M = 20 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

350

m

Engineer’s Handbook Charge Air

M 32

c2

Installation: 1. Fasten angle section (3) with screws (2) onto the charge air cooler without water separator. 2. Push the charge air cooler into the casing; if necessary, jack up by means of screw (6). 3. Pull the charge air cooler with screws (4) against the sealing surface of the casing. Tighten screws (4) with ⇒ Molykote 4. Fasten the charge air cooler onto the casing with screws (5). Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 70 Nm

351

m

c2

Engineer’s Handbook Charge Air

M 32

Installation of charge air cooler GEA -13 / - 44, driving and free end, IMO II (6 M 32) Installation for charge air cooler GEA 0.00.6-41.80.00-13 (without water separator): 1. Fasten the angle section (2) on the charge air cooler (1). (figure shows installation at the free end as an example) 2. Push the charge air cooler into the casing. 3. Jack up the charge air cooler with hexagon bolt (18). 4. Pull the charge air cooler with screws (17) against the sealing surface of the casing. 5. Fasten the charge air cooler in the casing with screws (10).Molykote Installation for charge air cooler GEA 0.00.6-41.80.00-44 (with water separator): (figure shows a charge air cooler without water separator as an example) 1. Push the charge air cooler into the casing. 2. Jack up the charge air cooler with hexagon bolt (18). 4. Pull the charge air cooler with screws (17) against the sealing surface of the casing. 5. Fasten the charge air cooler in the casing with screws (10). Molykote Tighten screws M8-8.8 (15) for fastening of the angle section (2) with ⇒ Molykote G Rapid Plus

M = 20 Nm

Tighten hexagon socket head cap screws M16 (17) with Molykote G Rapid Plus

⇒

M = 70 Nm

Tighten hexagon nut M20 (20) at hexagon bolt (18) with Oil

⇒

M = 80 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

352

m

Engineer’s Handbook Charge Air

M 32

c2

Installation of charge air cooler GEA -20, driving end and free end (VM 32 C) Tightening instruction for charge air cooler GEA 0.00.6-41.80.00-20: Put in place the gasket at (2) with grease. First tighten the horizontal screws (9) with ⇒ from the centre towards the outside.Molykote G Rapid Plus Then tighten the vertical screws (8) with ⇒ Molykote G Rapid Plus

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 420 Nm M = 210 Nm

353

m

Engineer’s Handbook Charge Air

M 32

c2

Installation of charge air cooler Vestas -74, free end (RM 32 E) The following instructions apply to Vestas charge air coolers 0.00.6-41.80.00-74 for Napier NT1-10 (6 M 32 E) and NT1-12 (8 M 32 E and 9 M 32 E) turbochargers. 1. Install the support plate (3) with mounting plate (4) at the casing. 2. Screw two ISO4017-M16x65 screws into the same holes into which the screw plugs M24x1.5-SW22 (21) will be screwed until a clearance of 10 mm is reached between the screw head contact surface and the machined casting surface at the charge air cooler casing. 3. Push the charge air cooler into the casing. 4. Adjust the height of the cooler by means of the two M16x65 screws in such a way that the positions of the 12 fixing holes on the sealing surface of the cooler (towards the charge air cooler casing) coincide with the positions of the holes of the charge air cooler casing. Tighten the cooler by means of 4 screws (16) with extension sleeves (13) in the first and last hole of the upper and lower fastening row. Loosen the 4 screws again. Attention! Apply Rivolta G.W.F. to the screws (16) also under the head. 5. Tighten the charge air cooler in the casing with screws (18) and 20 Nm. Apply Rivolta G.W.F. to the threads. 6. Tighten screws (16) with extension sleeves (13) from the cooler flange surface towards the centre of the engine with 70 Nm. Apply Rivolta G.W.F. to the threads. 7. Tighten screws (18) with 130 Nm from the inside towards the outside. 8. Remove the two ISO4017-M16x65 screws (from step 2) and replace them by M24x1.5SW22 screw plugs (21) with sealing rings. Tighten the screw plugs with 105 Nm and oil. 9. Retighten screws (16) once again with 70 Nm from the cooler flange surface towards the centre of the engine. Tighten screws (15) (fastened to the turbocharger bracket) with ⇒ Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 15 Nm

354

m

Engineer’s Handbook Charge Air

M 32

c2

Installation of charge air cooler GEA -79, driving end (RM 32 E) The following instructions apply to GEA charge air coolers 0.00.6-41.80.00-79 for Napier NT1-10 (6 M32 E) and NT1-12 (8 M 32 E and 9 M 32 E) turbochargers. 1. Install the support plate (3) with mounting plate (4) at the casing. 2. Screw two ISO4017-M16x65 screws into the same holes into which the screw plugs M24x1.5-SW22 (21) will be screwed until a clearance of 10 mm is reached between the screw head contact surface and the machined casting surface at the charge air cooler casing. 3. Push the charge air cooler into the casing. 4. Adjust the height of the cooler by means of the two M16x65 screws in such a way that the positions of the 12 fixing holes on the sealing surface of the cooler (towards the charge air cooler casing) coincide with the positions of the holes of the charge air cooler casing. Tighten the cooler by means of 4 screws (16) with extension sleeves (13) in the first and last hole of the upper and lower fastening row. Loosen the 4 screws again. Attention! Apply Rivolta G.W.F. to the screws (16) also under the head. 5. Tighten the charge air cooler in the casing with screws (18) and 20 Nm. Apply Rivolta G.W.F. to the threads. 6. Tighten screws (16) with extension sleeves (13) from the cooler flange surface towards the centre of the engine with 190 Nm. Apply Rivolta G.W.F. to the threads. 7. Tighten screws (18) with 130 Nm from the inside towards the outside. 8. Remove the two ISO4017-M16x65 screws (from step 2) and replace them by M24x1.5SW22 screw plugs (21) with sealing rings. 9. Retighten screws (16) once again with 190 Nm from the cooler flange surface towards the centre of the engine. Tightening torques for screw plugs M30x2 (22) and M24x1.5-SW22 (21) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten screws (15) (fastened to the turbocharger bracket) with ⇒ Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 15 Nm

355

m

c2

Engineer’s Handbook Charge Air

M 32

Tightening torques for charge air cooler GEA -78 / -79 (RM 32 E) The following tightening torques apply to GEA charge air coolers 75/27/8+12/2+2ESV-S99-20N162 (0.00.6-41.80.00-78 and 0.00.6-41.80.00-79): Tighten M12 thread with Apply oil to head and thread or tighten M12 thread with When using Nordlock washers

⇒

M = 75 Nm

⇒

M = 90 Nm

Tighten M16 thread with Apply oil to head and thread or tighten M16 thread with When using Nordlock washers

⇒

M = 180 Nm

⇒

M = 220 Nm

Tighten M20 thread with Apply oil to head and thread or tighten M20 thread with When using Nordlock washers

⇒

M = 360 Nm

⇒

M = 430 Nm

The following three-step tightening torques apply to the graphite seal: Tighten M12 thread in three steps with Apply oil to head and thread or tighten M12 thread in three steps with When using Nordlock washers

⇒

M = 38 / 60 / 75

Nm

⇒

M = 45 / 72 / 90

Nm

Tighten M16 thread in three steps with Apply oil to head and thread or tighten M16 thread in three steps with When using Nordlock washers

⇒

M = 90 / 145 / 180 Nm

⇒

M = 110 / 175 / 220 Nm

Tighten M20 thread in three steps with Apply oil to head and thread or tighten M20 thread in three steps with When using Nordlock washers

⇒

M = 180 / 285 / 360 Nm

⇒

M = 215 / 345 / 430 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

356

m

c2

Engineer’s Handbook Charge Air

M 32

Air injection (RM 32 E) Variant 3200.7-86.75.00-02: Screw in union (11) with Oil

⇒

M = 560 Nm

⇒

M = 120 Nm

Screw throttle (12) and both unions (27) with into the solenoid valve (3). Oil

⇒

M = 30

Nm

Screw union G1/2A (26) with into the compressed air filter (2) (if provided). Oil

⇒

M = 85

Nm

Variants 3200.7-86.68.00-01/-02/-03: Screw in relief valve (19) with Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

357

m

c2

Engineer’s Handbook Charge Air

M 32

Compressor bypass valve (RM 32 E) Attention! Upon installation fit the expansion joint tube (5) unbraced! Any lateral offset at the expansion joints may lead to component failure. Put in place the flat gasket below the cover at (2) and below the compressor bypass valve (CBV) at (9) with grease. Tightening torque for screw plug M12x1.5 (26) see“General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten threaded connections M16 (21) with Rivolta G.W.F.

⇒

M = 140 Nm

Tighten screws M12 (24) with Rivolta G.W.F.

⇒

M = 60

Tighten screws M16 (24) with Rivolta G.W.F.

⇒

M = 140 Nm

Nm

In case of screws (24) = M16, align the flat A at the circumference of the flange (6) so as to be at right angle with respect to the top edge of the engine block and the outside of the engine.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

358

m

c2

Engineer’s Handbook Charge Air

M 32

Control of the compressor bypass valve (RM 32 E) The following instructions for installation and adjustment of the control of the compressor bypass valve (CBV) apply to arrangement at driving end and free end on 6 M 32 E and 8 M 32 E. 1. Unscrew the thrust rod of the actuator (1) in ccw direction until end stop is reached. 2. Screw the nut (6) onto the thrust rod until end stop is reached and mount it so as to be finger tight. 3. Screw the fork head (5) onto the thrust rod (1) until end stop is reached and lock with nut (6). 4. Preassemble the linkage: Preadjust thrust rod (3) with joint heads (12) and (13) to dimension 213 +1 mm and lock with nuts (14) and (15) so as to be finger tight. In doing so, ensure an even length of engagement and parallel alignment of the joint heads. 5. Install the linkage with fork head (5), bolt (7) and nut (20) so as to be finger tight. 6. Connect the actuator (1) and the adjusting tool electrically and activate the mode for adjustment position. In doing so, secure the fork head (5) with linkage folded down against rotation until the adjustment position is reached. 7. With control valve closed install the lever (4) together with the linkage. Align lever and shaft end with clearance 5 ± 0.5 mm (attention: special process characteristic). See section B-B. 8. Check of the adjustment: At an extension dimension of 107 -2 mm and with control valve closed adjust an angle of the lever (4) of 46.6° ± 0.5° by turning the thrust rod (3). In doing so, take care that the joint heads are aligned parallel. 9. After checking the adjustment tighten all threaded connections with the torques indicated below. Tighten screws M8 (26), (27) and (28) with Molykote G Rapid Plus

⇒

M = 20

Nm

Tighten nuts (20) with (Apply Molykote to bolts (7))

⇒

M = 60

Nm

Tighten nut (20) with Molykote G Rapid Plus

⇒

M = 40

Nm

Tighten nuts (14) and (15) with Molykote G Rapid Plus

⇒

M = 65

Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

359

m

Engineer’s Handbook Charge Air

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

360

m

c2

Engineer’s Handbook Charge Air

M 32

Air blow-off device (RM and VM) The following applies to both RM and VM. The figure shows the air blow-off device of an RM as an example. Adjust the pressure reducers (9) in such a way that the admissible ignition pressure is not exceeded. Guide value: 7.5 bar. Slightly tighten the silencer (10) with a pipe wrench. Tighten screws (33) with Molykote G Rapid Plus

⇒

M = 40

Nm

If new blow-off valves (8) are to be installed, turn the head if necessary.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

361

m

c2

Engineer’s Handbook Charge Air

M 32

Air stop valves (VM) Put in place the gaskets (18) with grease. Insert studs (32) with Molykote G Rapid Plus

⇒

M = 40

Tighten hexagon nuts (53) with Molykote G Rapid Plus

⇒

M = 110 Nm

Tighten screws (45) with Molykote G Rapid Plus

⇒

M = 50

Tighten screws (46) with Molykote G Rapid Plus

⇒

M = 435 Nm

Nm

Nm

Return screw W19 turned by 180° is open

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

362

m

c2

Engineer’s Handbook Charge Air

M 32

Air inlet casing to charge air cooler (VM) Tighten 56 screws (2) (M12x80-10.9) with extension sleeves with ⇒ Molykote

M = 80 Nm

No gaskets here

Air inlet casing to charge air cooler (RM) Tighten screws (1) with Molykote Tighten screws (2) with Rivolta G.W.F. Tighten eye bolts DIN 580 M16 with Molykote

⇒

M = 52

Nm

⇒

M = 90

Nm

⇒

M = 130 Nm

Tightening torques for screw plugs M30x1.5, G1/2 and G1/4 see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs“.

No gaskets here Fixing screws

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

363

m

c2

Engineer’s Handbook Charge Air

M 32

Air passage (RM) (1.90.7-72.41.00-*) Tightening torques for screw plugs M30x1.5 (11), G1/2A-SW19 (9), G1/4 (10) and G1/2 A-SW19 (15) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Tighten eye bolt M16 (19) with Molykote

⇒

M = 130 Nm

Tighten threaded connections M16 (16) with Molykote

⇒

M = 110 Nm

Tighten screws (14) to the charge air cooler casing with Molykote

⇒

M = 70

Nm

Tighten threaded connections M16 (12) with Molykote

⇒

M = 95

Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

364

m

c2

Engineer’s Handbook Charge Air

M 32

Air passage (RM 32 E) Tighten fittings (10) to the expansion joint with Molykote G Rapid Plus

⇒

M = 110 Nm

Tighten fittings (11) to the charge air cooler casing with Molykote G Rapid Plus

⇒

M = 190 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

365

m

c2

Engineer’s Handbook Charge Air

M 32

Air passage, driving end and free end (VM) (1.91.7-72.41.00-01 / -02), (3401.772.41.00-01) Tightening instructions for the flange to the charge air cooler casing: Put in place the gasket at (2) with grease. First tighten the horizontal screws (21) with ⇒ M = 375 Nm from the centre towards the outside. Molykote G Rapid Plus Then tighten the vertical screws (20) with ⇒ M = 190 Nm Molykote G Rapid Plus Put in place the gaskets (10) with grease. Insert studs (16) with Molykote G Rapid Plus Insert threaded connections (12) with Molykote G Rapid Plus 73, 74a, and 74b Insert threaded connections (18) with Rivolta G.W.F.

⇒

M = 40

⇒

M = 110 Nm

⇒

M = 110 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

366

Nm

m

c2

Engineer’s Handbook Charge Air

M 32

Coverings at the air inlet casing (1.9*.7-72.81.00-*) Tighten screws (1) for fastening cover sheet (3) on 8+9 M 32 C (IMO I) with Molykote

⇒

M = 85

Nm

Tighten screws (5) for fastening cover sheet on VM 32 C (IMO I) with Molykote

⇒

M = 50

Nm

Tighten screws (4) for fastening cover sheet on 6 M 32 C (IMO I) with Molykote

⇒

M = 50

Nm

On IMO II engines the cover sheet (3) has been replaced by Thermamax cladding.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

367

m

Engineer’s Handbook Charge Air

M 32

c2

6 M 32 C: Installation sequence: 1, 2, 2, 8, 10, 9, 4, 6, 7, 11, 3, 5, 12 Insert all screws with Rivolta G.W.F..

6 M 32 C: Installation sequence: 1, 2, 2, 4, 6, 7, 8, 9, 11, 5, 12, 3, 10 Insert all screws with Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

368

m

Engineer’s Handbook Charge Air

M 32

c2

8 M 32 C and 9 M 32 C: Installation sequence: 1, 2, 2, 3, 10, 5, 4, 7. Install pos. 6, 8, and 9 only after pre-assembly. Insert all screws with Rivolta G.W.F.

M 32 C and 9 M 32 C: Installation sequence: 1, 2, 2, 3, 4, 7. Install pos. 5, 6, and 8 only after pre-assembly. Insert all screws with Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

369

m

Engineer’s Handbook Charge Air

M 32

c2

9 M 32 C: Installation sequence: 1, 2, 2, 3, 10, 5, 4, 7. Install pos. 6, 8, and 9 only after pre-assembly. Insert all screws with Rivolta G.W.F.

9 M 32 C: Installation sequence: 1, 2, 2, 3, 4, 7. Install pos. 5, 6, and 8 only after pre-assembly. Insert all screws with Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

370

m

Engineer’s Handbook Charge Air

M 32

c2

8 M 32 C and 9 M 32 C with turbocharger at driving end, ABB TPL67 and air injection: Installation sequence: 1, 2, 3, 4, 10, 5, 6, 7, 9, 12, 12. Install pos. 8, 11, and 13 only after pre-assembly. Insert all screws with Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

371

m

Engineer’s Handbook Charge Air

M 32

c2

RM 32 E with Napier NT10A without blow-off: Start the installation with pos. 7, 13, 1, 2, 3, 4, 5, 6, 14. Install pos. (8) before installing the drain pipe of the turbocharger. Continue the installation with pos. 10, 9, 11, 12. For pos. 12 ensure proper installation with snug fit. Overlap towards the outside. Insert all screws with Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

372

m

Engineer’s Handbook Charge Air

M 32

c2

RM 32 E with Napier NT12A without blow-off: Start the installation with pos. 7, 13, 1, 2, 3, 4, 5, 6, 14. Install pos. (8) before installing the drain pipe of the turbocharger. Continue the installation with pos. 9, 10, 11, 12. For pos. 12 ensure proper installation with snug fit. Overlap towards the outside. Insert all screws with Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

373

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Turbocharger installation Tightening torques and notes (data valid for all engines) Before mounting, spray all connecting links with graphite or molybdenum spray. Tighten clamp screws M8 in potentially hot areas of the engine with Rivolta G.W.F.

⇒

M = 10 Nm

Tighten clamp screws M8 in non heat critical areas with Molykote

⇒

M = 15 Nm

Insert all other screws in the turbocharger assembly that are not specifically mentioned below with Molykote and tighten them with the corresponding standard tightening torques. Insert all screw plugs in the turbocharger assembly that are not specifically mentioned below with oil and tighten them according to the table in the “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs”. Insert high-temperature screws in the exhaust gas area with Rivolta G.W.F. and tighten them with the following torques: Thread

Tightening torque

M8

13 Nm

M10

27 Nm

M12

49 Nm

M14

75 Nm

M16

125 Nm

M18

170 Nm

M20

240 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

374

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Drain pipe, driving end and free end (RM 32 E) HFO Installation at the driving end: Tighten reducer (1) with Oil

⇒

M = 230 Nm

Tighten shank G1/2A (8) with Oil

⇒

M = 85 Nm

Tighten union M22x1.5 (19) with Oil

⇒

M = 90 Nm

Tighten union G1/2A (20) with Oil

⇒

M = 85 Nm

Tighten union G1 1/2A (10) with Oil

⇒

M = 550 Nm

Tighten screw plug G1/2A-SW19 (21) according to the table in the “General Part”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

375

m

Engineer’s Handbook Turbocharger Installation

M 32

Installation at the free end: Tighten union G1 1/2A (10) with Oil

⇒

c2 M = 550 Nm

Tighten screw plug G1/2A-SW19 (21) according to the table in the “General Part”.

Turbocharger bracket Any data regarding the turbocharger bracket that are not included in the turbocharger assemblies mentioned below can be found in chapter “Charge Air”, in the sections with keyword “charge air cooler casing”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

376

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Lubricating oil pipes at the turbocharger Details on the lubricating oil pipes at the turbocharger can be found in chapter “Miscellaneous”, sections “Lubricating oil pipes ....”.

Installation of turbocharger NA295, DE (driving end) and FE (free end) (6 M 32) Tighten the fixing screws (M24 8.8) with Molykote

⇒

M = 500 Nm

Installation of turbocharger NA355, DE and FE (8 M 32 and 9 M 32) Tighten the fixing screws (M24 8.8) with Molykote

⇒

M = 500 Nm

Tighten the fixing screws (M24 10.9) with Molykote

⇒

M = 640 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

377

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger NA297, DE and FE (6 M 32 C) Attention! Only for very early variants that have fixing screws of strength classes 8.8 and 10.9 (mixed) the following applies: Tighten screws (1) M20-8.8 and M20-10.9 with ⇒ M = 260 Nm Molykote Tighten M20 screws (1) new variants: strength class 12.9 with Molykote old variants: strength class 10.9 with Molykote Tighten screws (2) M12-8.8 with Molykote

⇒

M = 450 Nm

⇒

M = 380 Nm

⇒

M = 52

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

378

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(NA297, DE and FE, 6 M 32 C) Tighten screw plug (if any) with Rivolta G.W.F.

⇒

M = 130 Nm

Tighten screws (2) and (3) with Rivolta G.W.F.

⇒

M = 10 Nm

Tighten screws (4) (M12-8.8 / DE+FE) with Rivolta G.W.F.

⇒

M = 36 Nm

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

⇒

M = 30 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

379

m

c2

Engineer’s Handbook Turbocharger Installation

M 32

Installation of turbocharger NA357, DE and FE, (8 M 32 C and 9 M 32 C) Attention! Only for very old variants that have fixing screws of strength classes 8.8 (or 8.8 and 10.9 mixed) the following applies: Tighten screws (1) and (2) M24-8.8 and M24-10.9 with ⇒ M = 500 Nm Molykote Tighten screws (1) and(2) new variants: only strength class 12.9 with Molykote old variants: only strength class 10.9 with Molykote

⇒

M = 750 Nm

⇒

M = 640 Nm

Tighten screws (3) with Molykote

⇒

M = 52 Nm

Tighten bolts and nuts on the expansion joint with Molykote

⇒

M = 52 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

380

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(NA357, DE and FE, 8 M 32 C and 9 M 32 C) Tighten screws (1) and (3) with Rivolta G.W.F.

⇒

M = 10 Nm

Tighten screw plugs (2) (if any) with Rivolta G.W.F.

⇒

M = 130 Nm

⇒

M = 90 Nm

⇒

M = 30 Nm

Tighten screws (4) for the bracket of the cleaning device with Rivolta G.W.F. Tighten screws (5) (M10-10.9) with Rivolta G.W.F.

Note: The figures below show an installation at driving end.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

381

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPS61, DE and FE (6 M 32 C) Pretighten screws (1) with After that, finally tighten with Oil

⇒ ⇒

M = 400 Nm M = 780 Nm

Tighten bolts and nuts (2) on the expansion joint with Molykote

⇒

M = 110 Nm

Tighten screws (3), strength class 8.8, with Tighten screws (3), strength class 10.9, with Molykote

⇒ ⇒

M = 52 Nm M = 70 Nm

⇒

M = 375 Nm

⇒

M = 640 Nm

Screws on turbocharger foot (4): Tighten screws M20-10.9 with Molykote Tighten screws M24-10.9 with Molykote Note: The figure shows an installation at driving end

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

382

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPL65-A, DE (8 M32 C) Note: The tightening torques apply to turbocharger installation at both driving end and free end. The illustrations below show an installation at driving end. Before assembly degrease flange surfaces A. Apply a thin layer of Hylomar sealing compound to the sealing surfaces. Keep the groove for the sealing ring free of sealing compound. For sealing ring, O-rings, and at V use Petro Gel Amber. Insert studs at (1) with Oil

⇒

M = 220 Nm

Tighten nuts at (1) with Oil

⇒

M = 455 Nm

Tighten bolts and nuts (2) on the expansion joint with Molykote

⇒

M = 110 Nm

Tighten screws (3) with Molykote

⇒

M = 190 Nm

Corner valve (5) must be marked with number “5.0”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

383

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL65-A, DE, 8 M 32 C) Tighten screws (4) on the upper flange of the drain pipe with Rivolta G.W.F. Tighten screws (6) with ⇒ Molykote Tighten screws (7) with ⇒ Molykote Replace screws (8) by current screws and extension sleeves and tighten with ⇒ Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 50 Nm M = 420 Nm M = 290 Nm

M = 70 Nm

384

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL65-A, DE, 8 M 32 C) Tighten screws (9) with Molykote Tighten screws (10) with Molykote Tighten screws (11) with Molykote

⇒

M = 190 Nm

⇒

M = 80 Nm

⇒

M = 420 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

385

m

c2

Engineer’s Handbook Turbocharger Installation

M 32

Installation of turbocharger A145, DE and FE (6 M 32 C) There are 3 different possibilities for fastening screws (1). Mechanical tightening with hexagon head screws: Pretighten hexagon head screws (1) M30x420-10.9 with ⇒ Then tighten with ⇒ and finally tighten with ⇒ Oil

M = 600 M = 1200 M = 1900

Nm Nm Nm

Hydraulic tightening with studs and round nuts (no figure provided): Insert studs at (1) with ⇒ Molykote

M = 100

Nm

Pretighten round nuts at (1) with Then finally tighten round nuts with Molykote (piston area 66 cm2)

⇒ ⇒

Installation with studs and clamping collars (ABB scope of supply): Insert studs at (1) with ⇒ Molykote

M = 100 Nm P = 600 + 25 bar

M = 100

Nm

Attention! It is imperative to observe the disassembly notes on the next page! 1. Clean the threads of the studs (1) and the contact surface. 2. Apply grease to thread (1). 3. Put on thrust washer (2). 4. Make sure that thrust screws (4) are not projecting from clamping nut (3) in direction of the thrust washer (2). 5. Tighten clamping nut (3) by hand and screw back ¼ turn. 6. The distance between thrust washer (2) and clamping nut (3) is now about 1 mm. 7. Tighten thrust screws crosswise by hand. 8. Tighten two opposite thrust screws with 21.5 Nm. 9. Tighten two other opposite thrust screws with 43 Nm. 10. Tighten all thrust screws in circular sequence with 43 Nm. 11. Repeat until all thrust screws are evenly tightened (less than 20° residual movement).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

386

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Disassembly (loosen clamping nut): Attention! Do not completely relieve any individual screws. This could compress the thrust screws and make their loosening impossible. It is absolutely necessary to proceed as follows when loosening the clamping nut: 1. Break away all thrust screws (4) of the clamping nut (3) in circular sequence. 2. Loosen each thrust screw in circular sequence by about ¼ turn. 3. Repeat the aforementioned step until all thrust screws are relieved. 4. Loosen clamping nut (3) by hand.

Tighten screws (2) on the expansion joint with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 110 Nm

387

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(A145, DE and FE, 6 M 32 C) Tighten screws (3) with Molykote Tighten screws (4) with Molykote Tighten screws (5) with Molykote Tighten screws (6) with Molykote Tighten screws (7) with Molykote In case of installation at the driving end: Tighten screws (8) for the pipe brackets with Molykote In case of installation at the free end: Tighten screws (8) for the pipe brackets with Molykote

⇒

M = 640 Nm

⇒

M = 375 Nm

⇒

M = 130 Nm

⇒

M = 70 Nm

⇒

M = 260 Nm

⇒

M = 52 Nm

⇒

M = 70 Nm

(The illustration below shows an installation at driving end) Shown without air inlet casing:

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

388

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPL67-C, DE and FE (8 M 32 C, 9 M 32 C) Turbocharger installation: 1. Place bronze slide plates underneath the turbine side (TS) foot. These plates allow sliding due to heat expansion. 2. Insert screws at compressor side (CS) (3, 4, 5, 6) with a washer each and pretighten with 160 Nm. 3. Insert the bushes into the turbine side foot. Marking TOP to point upwards. 4. Insert the turbine side screws without disc springs into the bushes. 5. Check position and clearance (W = min. 3.0 mm) of bushes (B):

6. Grease the contact surfaces of the disc springs at the turbine side foot. (Do not grease the bush surface!) 7. Insert five disc springs per screw at the turbine side foot. 8. Pretighten the turbine side screws (1, 2, 7, 8) with 160 Nm. 9. Tighten all screws in sequence (1, 2, 3, 4, 5, 6, 7, 8) with 800 Nm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

389

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL67-C, DE and FE, 8 M 32 C, 9 M 32 C) Before assembly degrease flange surfaces A. Apply a thin layer of Hylomar sealing compound to the sealing surfaces. Keep the groove for the sealing ring free of sealing compound. Apply a thin coat of Petro Gel Amber to toroidal sealing ring and O-ring. Tighten screws (1) on the expansion joint with Molykote

⇒

M = 110 Nm

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

⇒

M = 50 Nm

Tighten screws at (3) with Molykote

⇒

M = 80 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

390

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL67-C, DE and FE, 8 M 32 C, 9 M 32 C) Tighten screws (4) with Molykote

⇒

M = 190 Nm

Tighten screws (5) with Molykote Tighten screws (6) with Molykote

⇒

M = 80 Nm

⇒

M = 420 Nm

⇒

M = 70 Nm

Replace screws (11) by current screws and extension sleeves. Tighten these with Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

391

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL67-C, DE and FE, 8 M 32 C, 9 M 32 C) Tighten screws (7) (if pipe with flange is provided) with Molykote

M = 35 Nm

Tighten screws (8) with Molykote

⇒

M = 420 Nm

Tighten screws (9) with Molykote

⇒

M = 290 Nm

Corner valve (10) must be marked with number “5.0”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

392

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger NA297, FE (12 M 32 C) (variant -10) Attention! Certain screws have been replaced by screws of higher strength. The corresponding tightening torques have been adjusted up. Upon reassembly, replace these screws by screws of higher strength. In order to identify these screws and in case no replacement is possible, the tightening torques for all strengths are indicated for these screws. Before assembly, degrease flange face (5). Apply a thin film of Hylomar high-temperature sealing compound to the sealing face.Keep the groove for sealing rings free of sealing compound. Before installing the turbocharger insert two sealing rings (Al or Cu) into the turbocharger foot. Tightening torques for screw plugs (2) and (3) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs“. Tighten screws (1), strength class 12.9, with Molykote

⇒

M = 450 Nm

Tighten screws (1), strength class 10.9, with Molykote

⇒

M = 375 Nm

Tighten screws (4) with Molykote

⇒

M = 130 Nm

Tighten screws (6) with Molykote

⇒

M = 40 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

393

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(NA297, FE, 12 M 32 C)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

394

m

c2

Engineer’s Handbook Turbocharger Installation

M 32

(NA297, FE, 12 M 32 C) Tighten screws (7) of the drain pipe flanges with Rivolta G.W.F. Put in place the gaskets with grease.

⇒

M = 30

Nm

Tighten screws (25) of the drain pipe clamps with Molykote

⇒

M = 30

Nm

Tighten screws (8), strength class 8.8, with Molykote

⇒

M = 50

Nm

Tighten screw plugs M33x2 (9) according to the table in the “General Part”. Tighten screws (10), strength class 8.8, with Molykote Tighten screws (10), strength class 10.9, with Molykote

⇒

M = 130 Nm

⇒

M = 190 Nm

Tighten screws (11), strength class 8.8, with Molykote Tighten screws (11), strength class 10.9, with Molykote

⇒

M = 130 Nm

⇒

M = 210 Nm

Tighten screws (12), strength class 8.8, with Molykote Tighten screws (12), strength class 10.9, with Molykote

⇒

M = 260 Nm

⇒

M = 375 Nm

Tighten screws (13), strength class 8.8, with Molykote Tighten screws (13), strength class 10.9, with Molykote

⇒

M = 260 Nm

⇒

M = 420 Nm

Tighten screws (14), strength class 8.8, with Molykote Tighten screws (14), strength class 10.9, with Molykote

⇒

M = 260 Nm

⇒

M = 420 Nm

Tighten screws (15), strength class 8.8, with Molykote Tighten screws (15), strength class 10.9, with Molykote

⇒

M = 520 Nm

⇒

M = 720 Nm

Tighten screws (16), strength class 8.8, with Molykote

⇒

M = 520 Nm

Tighten screws (17), strength class 10.9, with Molykote

⇒

M = 640 Nm

Tighten screws (18), strength class 12.9, with Molykote

⇒

M = 450 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

395

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(NA297 FE, 12 M 32 C)

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

396

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(NA297 FE, 12 M 32 C) Tighten screws (19), strength class 8.8, with Molykote

⇒

M = 50

Nm

Tighten screws (20), strength class 8.8, with Molykote

⇒

M = 55

Nm

Tighten screws (21), strength class 8.8, with Molykote

⇒

M = 110 Nm

Tighten screws (22), strength class 12.9, with Molykote Tighten screws (22), strength class 10.9, with Molykote

⇒

M = 450 Nm

⇒

M = 375 Nm

Tighten screws (23) for the cleaning device with Molykote

⇒

M = 85

Tighten screws (24), strength class 8.8, with Molykote Tighten screws (24), strength class 10.9, with Molykote

⇒

M = 260 Nm

⇒

M = 420 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

397

m

c2

Engineer’s Handbook Turbocharger Installation

M 32

Installation of turbocharger NA297 FE with air stop valves (12 M 32 C) (variant -14) For the NA297 turbocharger with air stop valves the same tightening torques are applicable as for installation of the normal NA297 (variant -10, see above). Use Petro Gel Amber at V. Furthermore, the following applies: Tightening torques for screw plugs G1/2A (25) and M33x2 (26) see “General Part” of the Engineer’s Handbook, chapter “General Installation Instructions”, section “Tightening torques for screw plugs“. Insert studs at (27) and (29) with Molykote

⇒

M = 50

Tighten screws (28) and nuts (27) and (29) with Molykote

⇒

M = 110 Nm

⇒

M = 435 Nm

⇒

M = 4 Nm

Replace screws (30) by hexagon head bolts ISO4014 M20x70 12.9. Tighten these with Molykote Tighten screws (3) with Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

398

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger NA297,FE, stationary applications with HFO (12 M 32 C) (variant -09) For NA297 with intake socket instead of filter the same tightening torques are applicable as for installation of the normal NA297 (variant -10, see above). Furthermore, the following applies: Tighten screws M16x45-8.8 (42) with Molykote G Rapid Plus

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 110 Nm

399

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPL65, DE and FE (VM 32 C) Attention! Certain screws of strength 8.8 have been replaced by screws of strength 10.9. The corresponding tightening torques have been adjusted up. Upon reassembly, replace these screws by corresponding screws of higher strength. In order to identify these screws and in case no replacement is possible, the tightening torques for both strength classes (8.8 and 10.9) are indicated for these screws. Before assembly, degrease flange face (7). Apply a thin film of universal sealing compound to the sealing surface. Keep the groove for sealing rings free of sealing compound. Insert studs (1) with ⇒ M = 220 Nm Oil Tighten nuts (2) with ⇒ M = 455 Nm Oil Attention! The only exception is: Engine 034001: Tighten studs (1) and nuts (2) with ⇒ M = 150 Nm Molykote

Tighten screws (3), strength class 8.8, with Molykote Tighten screws (3), strength class 10.9, with Molykote Tighten screws (4) and (6) with NmMolykote Tighten screws (1), strength class 8.8, with Molykote

⇒

M = 260 Nm

⇒

M = 420 Nm

⇒

M = 130

⇒

M = 520 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

400

Engineer’s Handbook Turbocharger Installation

c2

⇒

M = 720 Nm

⇒

M = 130 Nm

Tighten screws (3), strength class 8.8, and (4) 8.8 with Molykote Tighten screws (3) strength class 10.9, with Molykote

⇒

M = 130 Nm

⇒

M = 210 Nm

Tighten screws (4), strength class 10.9, with Molykote

⇒

M = 190 Nm

Tighten screws (5), strength class 8.8, with Molykote Tighten screws (5), strength class 10.9, with Molykote

⇒

M = 260 Nm

⇒

M = 375 Nm

Tighten screws (6) of the drain pipe flanges with Rivolta G.W.F. Put in place the gaskets with grease.

⇒

M = 50 Nm

Tighten bolts and nuts (8) with Molykote

⇒

M = 110 Nm

Insert studs (8) with Oil Tighten nuts (9) with Oil

⇒

M = 220 Nm

⇒

M = 455 Nm

m M 32

Tighten screws (1), strength class 10.9, with Molykote Tighten screws (2) with Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

401

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPL65, DE and FE (VM 32 C) Tighten screws (1) with Molykote Tighten screws (2), strength class 8.8, with Molykote Tighten screws (2), strength class 10.9, with Molykote Tighten screws (2a) with Molykote

⇒

M = 40 Nm

⇒

M = 50 Nm

⇒

M = 80 Nm

⇒

M = 50 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

402

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL65, DE and FE, VM 32 C) Free end: Tighten screws (1) for drain pipe flanges with Rivolta G.W.F. Put in place the gaskets with grease.

⇒

M = 50 Nm

Tighten screws (2) with Molykote

⇒

M = 60 Nm

Tighten screws (3) for drain pipe clamps with Molykote

⇒

M = 30 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

403

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL65, DE and FE, VM 32 C) Tighten screw plugs (3) according to the table in the “General Part”. Tighten nuts (4) with Molykote

⇒

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 110 Nm

404

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL65, DE and FE, VM 32 C) Tighten screws (5), strength class 8.8, with Molykote Tighten screws (5), strength class 10.9, with Molykote Tighten screws (6), strength class 8.8, with Molykote Tighten screws (6), strength class 10.9, with Molykote

⇒

M = 260 Nm

⇒

M = 420 Nm

⇒

M = 260 Nm

⇒

M = 375 Nm

View from below:

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

405

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPL65 with air stop valves (VM 32 C) (variants -05 and -08) For TPL65 with air stop valves the same tightening torques are applicable as for the installation shown above without air stop valves. Furthermore, the following applies: Tighten bolts and nuts (1) at the flanges of the air stop valve (2) with Molykote Replace screws (3) by hexagon head bolts ISO4014 M20x70 12.9. Tighten these with ⇒ Molykote

M = 110 Nm

M = 435 Nm

Tighten screws (4) with

⇒

M = 50 Nm

Tighten screws (5) with

⇒

M = 375 Nm

Tighten screw plugs G1/2 (6) and M33x2 (7) according to the table in the “General Part”.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

406

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPL65 with flange on the air inlet casing (VM 32 C) (variant -07) Before assembly, degrease flange face A. Apply a thin layer of Hylomar sealing compound. Keep the groove for toroidal sealing ring free of sealing compound. Tighten screws (M16x60-8.8) on the expansion joints between air inlet nozzle and turbocharger (no fig.) with ⇒ Molykote

M = 110 Nm

Tighten screws at (1) with Molykote

⇒

M = 40 Nm

Tighten screws at (2) with Molykote

⇒

M = 720 Nm

Tighten screws (3) with Molykote

⇒

M = 420 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

407

Engineer’s Handbook Turbocharger Installation

c2

Tighten screws (4) for the air inlet nozzles with Molykote Tighten screws (5) with Molykote

⇒

M = 110 Nm

⇒

M = 80 Nm

Tighten screws (5) with Molykote Insert studs (6) with Oil Tighten nuts (7) with Oil Tighten screws (8) with Molykote Tighten screws (9) with Molykote Insert studs (10) with Oil Tighten nuts (11) with Molykote Tighten screws (12) with Molykote

⇒

M = 80 Nm

⇒

M = 220 Nm

⇒

M = 455 Nm

⇒

M = 60 Nm

⇒

M = 420 Nm

⇒

M = 70 Nm

⇒

M = 50 Nm

⇒

M = 210 Nm

⇒

M = 190 Nm

m M 32

Tighten screws (15) with Molykote

Tighten screw plugs G1/2 (13) according to the table in the “General Part”. Tighten screws (14) with Molykote and the standard torques corresponding to the respective strength class.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

408

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPL65 with flange on the air inlet casing, VM 32 C) Tighten screws (16) (top view) with ⇒ M = 720 Nm Molykote Tighten screws (17) with ⇒ M = 50 Nm Molykote Tighten positions (19) with Molykote and the standard torques corresponding to the respective strength class. Insert positions (18) with Petro Gel Amber.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

409

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

Installation of turbocharger TPS61 (12 M 32 C) (variant -13) Before assembly degrease flange surface (F). Apply a thin layer of Hylomar sealing compound. Keep the groove for toroidal sealing ring free of sealing compound. Use Petro Gel Amber at V. Tighten screws (1) with Molykote Tighten screws (2) with Molykote Tighten screws (3) with Molykote Tighten screws (4) with Molykote Tighten screws (5) with Molykote

⇒

M = 420 Nm

⇒

M = 640 Nm

⇒

M = 720 Nm

⇒

M = 210 Nm

⇒

M = 375 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

410

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPS61, 12 M 32 C) Tighten screws (6) with Molykote

⇒

M = 190 Nm

Pretighten screws (8) with Then finally tighten with Oil

⇒ ⇒

M = 400 Nm M = 780 Nm

Tighten screws (9) and screws M8 8.8 on the pipe clamps with Molykote

M = 15

Nm

Tighten screw plugs (7) according to the table in the “General Part”. Use Petro Gel Amber at V.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

411

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPS61, 12 M 32 C) Tighten bolts and nuts (10) with Molykote

⇒

M = 110 Nm

Tighten screws (11) with Molykote Tighten screws (12) with Molykote Use Petro Gel Amber at V.

⇒

M = 720 Nm

⇒

M = 420 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

412

m

Engineer’s Handbook Turbocharger Installation

M 32

c2

(TPS61, 12 M 32 C) Tighten bolts and nuts (13) with Molykote

⇒

M = 50 Nm

Tighten screws (14) with Molykote Tighten screws (15) with Molykote Tighten screws (16) with Molykote Use Petro Gel Amber at V.

⇒

M = 130 Nm

⇒

M = 640 Nm

⇒

M = 80 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

413

m

c2

Engineer’s Handbook Turbocharger Installation

M 32

Installation of NT1-10 turbocharger (6M32E) Tighten screws M20-10.9 (15) of turbocharger fastening with Rivolta G.W.F.

⇒

M = 480 Nm

Tighten union G1/4A (9) of the cleaning device with Oil

⇒

M = 30 Nm

HFO engines: Tighten union G1/2A (8) and shank G1/2A (13) of cleaning device with ⇒ Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 85 Nm

414

m

c2

Engineer’s Handbook Turbocharger Installation

M 32

Installation NT1-12 turbocharger (8M32E and 9M32E) Tighten screws M24-10.9 (15) of turbocharger fastening with Rivolta G.W.F.

⇒

M = 800 Nm

Tighten union G1/4A (9) of the cleaning device with Oil

⇒

M = 30 Nm

HFO engines: Tighten union G1/2A (8) and shank G1/2A (13) of cleaning device with ⇒ Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 85 Nm

415

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Exhaust manifold Expansion joint installation Install the expansion joints without gaskets. Pay attention to the mounting direction/flow direction (arrow on the flange) of the expansion joints. Insert the screws from expansion joint side. Insert all screws with Rivolta G.W.F. If new expansion joints are to be installed in older exhaust manifolds with gaskets at the expansion joint outlet side, these are not necessary any more.

Tightening torques Insert all screws in the exhaust manifold with Rivolta G.W.F. Before mounting, spray all connecting links with graphite or molybdenum spray. Tighten screws M12 in the exhaust manifold with Rivolta G.W.F.

⇒

M = 60 Nm

Tighten screws M16 in the exhaust manifold with Rivolta G.W.F.

⇒

M = 140 Nm

When using clamps (see figure above): Tighten hexagon head bolts (1) (ISO4014 M16x200-8.8) with ⇒ Rivolta G.W.F.

M = 150 Nm

Tighten screw plugs (2) (G1/2A-SW19) with Rivolta G.W.F.

⇒

M = 180 Nm

Tighten screw plugs DIN 908 M64x2 in the exhaust tube Rivolta G.W.F.

⇒

M = 450 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

416

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Single-pipe charging (RM) Tighten M20 hexagon head bolts and nuts for 6 M 32 to fasten the expansion joint to the turbocharger with Rivolta G.W.F. Tighten hexagon head bolts (5) (M20-8.8) for 8 M 32 and 9 M 32 to fasten the shown bracket (6) with Rivolta G.W.F.

⇒

M = 180 Nm

⇒

M = 180 Nm

Tighten hexagon head bolts (7) (ISO 4014-M20x220-8.8) for 8 M 32 and 9 M 32 to fasten the shown bracket (6) with ⇒ Molykote

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 260 Nm

417

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Tighten M20 hexagon head bolts (3) for 6 M 32 to fasten bracket (4) (schematic diagram) with Rivolta G.W.F.

⇒

Tighten high-temperature M20 hexagon head bolts (10) and (11) for expansion joint fastening with ⇒ Rivolta G.W.F.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

M = 180 Nm

M = 110 Nm

418

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Pulse charging (RM) Tighten hexagon head bolts (8) (M20, high-temperature) for 6 M 32 to fasten the shown bracket (9) with ⇒ Rivolta G.W.F.

M = 180 Nm

Exhaust nozzle on the turbocharger Tighten screw plugs G1/2A SW19 (1) with Rivolta G.W.F.

⇒

M = 130 Nm

Tighten threaded connections M20 (2) with Rivolta G.W.F.

⇒

M = 270 Nm

Tighten threaded connections M20 (3) with Rivolta G.W.F.

⇒

M = 270 Nm

Tighten threaded connections M16 (3) with Rivolta G.W.F.

⇒

M = 140 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

419

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

RM 32 E Insert all screws in the exhaust manifold with Rivolta G.W.F. Tighten screws M16 in the exhaust manifold with Rivolta G.W.F.

⇒

M = 140 Nm

For 8 M 32 E and 9 M 32 E provide a preload of 3.3 mm at connecting links (8) and (9). Figure U shows the connection without preload. 6 M 32 E: Tighten screw plugs (24) (M18x1.5-SW17) with Oil

⇒

M = 85 Nm

8 M 32 E and 9 M 32 E: Tighten screw plugs (24) (M18x1.5-SW17) with Rivolta G.W.F.

⇒

M = 75 Nm

6 M 32 E: Tighten screw plugs (26) (G1/2A-SW19) with Oil

⇒

M = 150 Nm

8 M 32 E and 9 M 32 E: Tighten screw plugs (26) (G1/2A-SW19) with Rivolta G.W.F.

⇒

M = 130 Nm

8

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

420

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Wastegate installation (RM 32 E) Tighten threaded connections M16 (12) with Rivolta G.W.F.

⇒

M = 140 Nm

Installation of wastegate control (RM 32 E) 1. Unscrew the thrust rod of the actuator (1) in counter-clockwise direction until end stop is reached. 2. Screw the nut (11) onto the thrust rod until end stop is reached and mount it so as to be finger tight. 3. Screw the fork head (9) onto the thrust rod (1) until end stop is reached and lock with nut (11). 4. Preassemble the linkage: Adjust the thrust rod (7) with joint heads (20) and (21) to dimension 213 +1 mm and lock with nuts (22) and (23) so as to be finger tight. In doing so, ensure an even length of engagement and parallel alignment of the joint heads. 5. Install the linkage with fork head (9), bolt (15) and nut (29) so as to be finger tight. 6. Establish an electrical connection between actuator (1) and adjusting tool and activate the mode for adjustment position. In doing so, secure the fork head (9) with linkage folded down against rotation until the adjustment position is reached. Insert the shaft (8) into the bearing bracket with grease and check for ease of movement. 7. Insert the shaft couplings (2) with closed wastegate. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

421

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Note: Variant -01 has a shaft coupling (2) and a compensating coupling (3). Variant -06 has two shaft couplings (2) for transmitting higher torques. Align the end of the shaft (8) and the lever (10) so as to be flush. 8. Check of the adjustment: At an extension dimension of 107 -2 mm and with closed wastegate adjust an angle of 45° at the lever (10). For this purpose, turn the thrust rod (7) and ensure parallel alignment of the joint heads. 9. After checking the adjustment tighten all threaded connections with the specified torque. Tighten screws (37) and (39) with Rivolta G.W.F.

⇒

M = 65 Nm

Tighten nuts (22) and (23) with Rivolta G.W.F.

⇒

M = 65 Nm

Tighten all screws in the compensating coupling (3) with

⇒

M = 14.5 Nm

Tighten screws (30), (36) and (40) with Rivolta G.W.F.

⇒

M = 20 Nm

Lock fork head (9) and nut (11) with against each other. Rivolta G.W.F. Tighten bolt (15) and nut (29) with Rivolta G.W.F.

⇒

M = 40 Nm

⇒

M = 80 Nm

Tighten bolt (17) and nut (18) with Rivolta G.W.F.

⇒

M = 160 Nm

Clearance at A (variant -01 with compensating coupling(3))

⇒

0.2 ± 0.05 mm

Clearance at B (variant -06 with two shaft couplings (2))

⇒

1 mm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

422

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Variant -01:

Variant -06:

Centre aligned

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

423

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Exhaust tubes with integral insulation Tighten screws M20 (28) with Rivolta G.W.F.

⇒

M = 180 Nm

Tighten screw plugs G1/2A SW19 (34) with Rivolta G.W.F.

⇒

M = 180 Nm

Tighten threaded connections M20 (30) with Rivolta G.W.F.

⇒

M = 180 Nm

Tighten screws for clamps at the cylinder outlets with Rivolta G.W.F.

⇒

M = 150 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

424

m

c2

Engineer’s Handbook Exhaust Manifold

M 32

Fixing screws (VM) Tighten the fixing screws (1) (M16x100) for the brackets with Molykote

⇒

M = 190 Nm

Tighten the fixing screws (2) (M20x180) for the brackets with Molykote

⇒

M = 400 Nm

VM 32 with turbocharger at free end Align and fix bracket (5) and bracket (8) in such a way that before tightening the three screws M16x95 (15) a clearance of 5 ± 1 mm between the two brackets (5) and (8) is created.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

425

m

Engineer’s Handbook Exhaust Manifold

M 32

c2

6 M 32 with turbocharger at driving end Install the connecting links (10) and (14) with 6 mm offset. Before mounting, spray all connecting links with graphite or molybdenum spray.

8 M 32 with turbocharger at driving end Install the connecting links (16), (14) and (17) with offset. Before mounting, spray all connecting links with graphite or molybdenum spray.

9 M 32 with turbocharger at driving end Install the connecting links (15) with 5 mm offset. Install the connecting links (13) with 4 mm offset. Before mounting, spray all connecting links with graphite or molybdenum spray.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

426

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Exhaust cladding Tightening torques Insert all screws in the exhaust cladding with Rivolta G.W.F. Tighten the high-temperature screws on the exhaust cladding with the torques indicated in the table below. When installing cladding sections of the individual cylinders leave an assembly clearance of 1 - 3 mm between the individual sections. Thread

Tightening torque

M8

11 Nm

M10

21 Nm

M12

36 Nm

M14

58 Nm

M16

90 Nm

M18

128 Nm

M20

179 Nm

M24

313 Nm

Exhaust tubes with integral insulation see chapter “Exhaust Manifold”, section “Exhaust tubes with integral insulation”

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

427

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 6 M 32 C (FE) Start the installation with pos. (30) and (14). After that, install bottom plate (13) and bracket (16). After that, install the pipe for the washing unit. Continue the installation with positions (28), (10), (11), (38), (24), (25), (7), (39), (19), (6), (5), (4), (3), (26), (27), (35), (21), (22), (23), (1), (2).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

428

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Continue with positions (15), (54), (9), (8), (43), (46), (41), (42), (40), (44).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

429

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 6 M 32 C (free end), special design for AP Möller with insulation reinforced components for a surface temperature < 60 °C Installation sequence: (30), (14), (13), (16), (28), (38), (24), (25), (7), (39), (19), (6), (5), (4), (3), (26), (27), (35). Put in place pos. (10) and (11) on the contact surface of the cooling water tube. Bolt down pos. (44) on pos. (11). Bolt together pos. (51) with pos. (10). Bolt together pos. (52) with pos. (11) and (44). Bolt together pos. (53) with pos. (13). Continue the installation with pos. (21), (22), (23), (1), (2), (47), (48), (15), (54), (9), (8), (43), (41), (42), (46), (40). Before mounting the pipe for the washing unit install the bottom plate (13) and the bracket (16).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

430

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Assembly clearance between the sections

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

431

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 6 M 32 C (DE), ABB TPS61, single-pipe charging (old) Installation sequence for the cladding plates of the exhaust cladding before turbocharger: First install (29), (27), and (28). After installation of (28) bolt down the clamp of the valve. Continue the installation with (13), (34), (12), and (16).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

432

m

Engineer’s Handbook Exhaust Cladding

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

433

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Make sure that the cladding of the bearing casing is removed. Install pos. (17). Continue the installation with (31), (30), (3), (4), (9), (8), (26), (35), (1), (10), (21), and (39).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

434

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 6 M 32 C (DE), ABB A145 and ABB TPS61, single-pipe charging (new) Start the installation with (20), (30), and (14). Install the pipe for the washing pipe at the fixation points of pos. (20). Continue with installation of the bottom plate (13) and pos. (12), (10), (11), (24), (25), (17), (19), (16), (18), (5), (6), (7), (3), (4).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

435

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Continue with pos. (26), (27), (35), (8), (9), (21), (22), (1), (2), (15), (43), (33), (39), (41), (42), (40), (44).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

436

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Finally, install pos. (45), (46), (47).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

437

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 6 M 32 E (free end), Napier NT10A, pulse charging This section also provides information on how to remove certain exhaust cladding parts and outlines the differences depending on whether or not the engine is equipped with compressor bypass valve (CBV). Removal description for cylinder head extraction Standard parts: Pos. (40), (41), (45), (1), and (22). End covering: Pos. (40), (42), (45), (1), and (23). Transition to the turbocharger: Pos. (61), (43), (45), (1), and (21). Removal description for the service case of turbocharger cartridge Pos. (38), (66), (32), (31), (64), (37), (36), (34), (30), (33), and (62). Installation sequence 1. Install pos. (3), (4), (5), (6) on the turbocharger bracket. 2. Install pos. (13) on the cooling water pipe. 3. Install pos. (14) on the turbocharger bracket. In doing so, make sure there is a clearance of 3 mm between pos. (13) and (14). 4. Install pos. (10) (4x) and (11) on the cooling water pipe. In doing so, make sure there is clearance of 4 mm between pos. (10) and (11) and pos. (10) with respect to each other. Furthermore, create a clearance of 4 mm between pos. (10) and (13). 5. Install pos. (44). 6. Install the washing unit. 7. Insert mats (65) (2x) with wire mesh oriented towards the connecting link of the bracket of the exhaust manifold. 8. Insert pos. (66) between compressor and foot of the bearing casing. 9. Install pos. (30) and (31) at the foot of the bearing casing. 10. Tighten all screws of pos. (30), (31) and (66) (tightening torques see at the very beginning of this chapter). 11. Install pos. (16) and (17) at the compressor. 12. Install the sensor. 13. Install pos. (19) and (18) at the compressor. 14. Install pos. (28) and (29) at the bearing casing. 15. Install pos. (27). 16. Install the bypass tube. 17. Insert pos. (64) between foot of the bearing casing and pos. (3). Install pos. (26) and bolt together with pos. (64). 18. Insert pos. (62) between foot of the bearing casing and pos. (5). Insert pos. (25) and bolt together with pos. (62) and (5). 19. Install pos. (39) and (24). 20. Install pos. (32) and (38) bolted together. 21. Install pos. (33), (34), (36) and (37).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

438

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

22. Install pos. (35) (2x) with wire mesh oriented towards the centre. 23. Install pos. (47) and (48). In doing so, make sure there is a clearance of 3 mm between the positions. 24. Install the actuator for the delivery valve. 25. Install pos. (49), (50), (51), (52), (53), (56), (55), (63), (57), (58), (60) and (59). 26. Pre-install pos. (21), (22) (4x) and (23) at the cylinder head. Mount pos. (41) (5x), (42) and (43). After that, align pos. (21), (22) and (23) by means of pos. (41) and then tighten. 27. Install pos. (1) (6x). In doing so, make sure there is a clearance of 3 mm between positions (1) with respect to each other and create a clearance of 2 mm between positions (1) and position (47). 28. Install pos. (15), (54), (9), (8), (61), (40) and (45).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

439

m

Engineer’s Handbook Exhaust Cladding

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

440

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for RM 32 E with CBV: Install pos. (1) in front of the CBV tube. After that, install pos. (2), (3), (4), (6), and (40).

Installation sequence for RM 32 E without CBV: Install pos. (1), (6) and (40).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

441

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Assembly sequence for 8 M 32 C (DE) Align bracket (20) with support plate (12) and then bolt down bracket (20). Install support plate (14). Install bracket of the exhaust manifold (1). Continue with installation of (18), (13), (10), (16), (17), (21), (22), (15), (19), (5), (3), (4), (31), (35), (39), (44), (24), (25), (33), (40), (41), (42).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

442

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 8 M 32 C (FE), ABB TPL67, single-pipe charging For cladding of the turbocharger start the installation with pos. (25), (16), (13), (14), (18), (20), (19), (26), (5), (3), (17), (35). When installing the cladding of the exhaust tube provide an assembly clearance of 3 mm between the individual sections.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

443

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 8 M 32 C (FE), ABB TPL67, pulse charging Start the installation with pos. (16), (13), (14), (15), (20), (18), (19), (21), (9), (8), (17), (35), (12), (11).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

444

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Continue the installation with pos. (24), (23), (22), (4), (5), (1), (2), (3), (25), (54), (37), (36), (28), (26), (34), (27), (33), (32).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

445

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 8 M 32 C (FE), ABB TPL65, single-pipe charging Start the installation with pos. (16), (17), (13), (14), (18), (20), (19), (5), (3), (35), (25),

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

446

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Continue the installation with (10), (11), (21), (22), (23), (1), (2), (15), (54), (9), (8), (43), (46), (41), (42), (40), (44).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

447

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 8 M 32 C (free end), special design for AP Möller with insulation reinforced components for a surface temperature < 60 °C Installation sequence: (25), (16), (13), (14), (18), (20), (19), (26), (5), (3), (17), (35), (5), (4), (3), (26), (27), (35). Put in place pos. (10) and (11) on the contact surface of the cooling water tube. Bolt down pos. (44) on pos. (11). Bolt together pos. (51) with pos. (10). Bolt together pos. (52) with pos. (11) and (44). Bolt together pos. (53) with pos. (13). Continue the installation with pos. (21), (22), (23), (1), (2), (31), (32), (33), (15), (54), (9), (8), (43), (41), (42), (46), (40), (56), (57).

Assembly clearance between the sections



Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

448

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 8 M 32 E (FE), Napier NT12A, single-pipe charging This section also provides information on how to remove certain exhaust cladding parts and outlines the differences depending on whether or not the engine is equipped with compressor bypass valve (CBV). Removal description for cylinder head extraction Standard parts: Pos. (40), (41), (45), (1) and (22). End covering: Pos. (40), (42), (45), (1) and (23). Transition to the turbocharger: Pos. (61), (43), (45), (1) and (21). Removal description for the service case of turbocharger cartridge Pos. (38), (66), (31), (32), (64), (37), (36), (34), (30), (33), (28) and (62). Installation sequence 1. Install pos. (3), (4), (5), (6) on the turbocharger bracket. 2. Install pos. (13) on the cooling water pipe. 3. Install pos. (14) on the turbocharger bracket. In doing so, make sure there is a clearance of 3 mm between pos. (13) and (14). 4. Install pos. (10) (6x) and (11) on the cooling water pipe. In doing so, make sure there is a clearance of 4 mm between positions (10) and (11) and positions (10) with respect to each other. Furthermore, create a clearance of 4 mm between pos. (10) and (13). 5. Install pos. (44). 6. Install the washing unit. 7. Insert mats (65) (2x) with wire mesh oriented towards the connecting link (bracket of the exhaust manifold). 8. Insert pos. (66) between compressor and foot of the bearing casing. 9. Install pos. (30) and (31) at the foot of the bearing casing. 10. Tighten all screws of pos. (30), (31) and (66) (tightening torques see at the very beginning of this chapter). 11. Install pos. (16) and (17) at the compressor. 12. Install the sensor. 13. Install pos. (19) and (18) at the compressor. 14. Install pos. (28) and (29) at the bearing casing. 15. Install pos. (27). 16. Install the bypass tube. 17. Insert pos. (64) between foot of the bearing casing and pos. (3). Install pos. (26) and bolt together with pos. (64). 18. Insert pos. (25) and bolt together with pos. (5). Insert pos. (62) between foot of the bearing casing and pos. (5). Bolt together pos. (62) with pos. (25). Bolt together pos. (67) with pos. (25). 19. Install pos. (39) and (24). 20. Install pos. (32) and (38) bolted together. 21. Install pos. (33), (34), (36) and (37). 22. Install pos. (35) (2x) with wire mesh oriented towards the centre. 23. Install pos. (47) and (48). In doing so, make sure there is a clearance of 2.5 mm between the positions. Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

449

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

24. Install the actuator for the delivery valve. 25. Install pos. (49), (50), (51), (53), (55), (63), (57) and (58). 26. Pre-install pos. (21), (22) (6x) and (23) at the cylinder head. Mount pos. (41) (7x) and (43). After that, align pos. (21), (22) and (23) by means of pos. (41) and then tighten. 27. Install pos. (1) (8x). In doing so, make sure there is a clearance of 3 mm both between positions (1) with respect to each other and between positions (1) and (47). 28. Install pos. (15), (54), (9), (8), (61), (40) (7x), (42) and (45) (8x).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

450

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for RM 32 E with CBV: Install pos. (1) in front of the CBV tube. After that, install pos. (2), (3), (4), (6), and (40).

Installation sequence for RM 32 E without CBV: Install pos. (1), (6) and (40).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

451

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 9 M 32 C (DE) Align bracket (20) with support plate (12) and then bolt down bracket (20). Install support plate (14). After that, install the bracket of the exhaust manifold (1). Continue the installation with (18), (16), (19), (13), (23), (26), (27), (17), (5), (3), (39), (35), (24), (25), (33).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

452

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 9 M 32 C (FE), single-pipe charging Installation sequence for the individual items of the exhaust cladding before turbocharger: (25), (16), (13), (14), (18), (20), (19), (26), (5), (3), (17), (35).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

453

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 9 M 32 C (FE), pulse charging (var. 12) Installation sequence for the individual items of the exhaust cladding before turbocharger: (16), (13), (14), (15), (20), (18), (19), (21), (9), (8), (17), (35), (33).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

454

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 9 M 32 C (FE), pulse charging (var. 13) Installation sequence: (16), (13), (14), (15), (20), (18), (19), (21), (9), (8), (17), (35), (12), (11), (24), (23), (22), (4), (5), (1), (2), (3), (25), (54), (37), (36), (28), (26), (34), (27), (33), (32).

Assembly clearance between the cladding sections





Assembly clearance between the support plate sections Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

455

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence for 12 M 32 C (DE) Bank A Install rear panels (11), (10) (4x) and (12) on the cylinder heads. Provide a gap of 1.3 mm between the individual sections and a gap of 2.1 mm between the last section and the end cladding (6). (Do not yet install the end cladding (6).) Fit cover plate (38) (5x) to the rear panels. Bank B Proceed the same way for bank B. Now fit the end cladding (6) to the rear panels of bank A and B. Fit the centre panels (30) and (31) between the cooling water tubes. Bring in insulating piece (32), see detail Q. Screw on bracket (33) for fixation of insulating piece (32). Install cover plates (36) and (37) as cover above the cooling water tubes.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

456

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Loosely preassemble all following positions in the indicated sequence: First, preassemble central support plate (15). Bank A Support plate between exhaust bracket and cooling water tube (18). Support plate between exhaust bracket and turbocharger (16). Push in turbocharger connection cladding (40) from the front below the transition to the turbocharger. Press the insulation piece into the recess of the turbocharger. Push in turbocharger connection cladding (41) from above over the transition to the turbocharger. Press the insulation piece into the recess of the turbocharger. Bank B Support plate between exhaust bracket and cooling water tube (19). Support plate between exhaust bracket and turbocharger (17). Push in turbocharger connection cladding (42) from the front below the transition to the turbocharger. Press the insulation piece into the recess of the turbocharger. Push in turbocharger connection cladding (43) from above over the transition to the turbocharger. Press the insulation piece into the recess of the turbocharger.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

457

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Now insert the central rear panel (22) from above. The cleaning pipe to the A side should be preassembled. Bank B Put on cladding (7). Fit thermocouple before. Bank A Put on cladding (8). Fit thermocouple before. Cylinder sections Screw 24 pcs. threaded hooks (50) into the cladding segments. Put on first cylinder cladding segment (3). Put on cladding (2) with the opening for the handling device. Put on 2 pcs. claddings (1) between the handling device openings. Put on cladding (2) with the opening for the handling device. Put on cladding (5) for the last cylinder. Preassemble cover plate (24). Bank A Preassemble cover plates (25) and (27). Screw on two cover plates (35) for the thermocouple. Bank B Proceed the same way for bank B. Finally, preassemble the cover plate (29) for the transition. Tighten all screws with the corresponding torques (please refer to the beginning of this chapter).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

458

m

Engineer’s Handbook Exhaust Cladding

M 32

c2

Installation sequence 12 M 32 C (FE) Put into position cover plates (29) and (30) and bolt them together. Installation with brackets (11) and (14), support plates (17), (18) and (19). For the time being preassemble bracket (25) just loosely. Continue the installation with (31), (21), (22). After installation of support plate (22) firmly bolt down bracket (25). Install support plate (24). Put hexagon head bolt M12x50 (69) into sleeve and then assemble support plate (23). Bolt together support plate (23) and cover sheets (30/29) with hexagon head bolt M12x50 (69). Then install brackets (32) and (26). Loosen the preassembled cover plate at A and install cladding (16). Then bolt down cover plate again. Continue with the following positions: (8), (15), (7), (35), (27), (28), (33), (10), (12), (13), (4), (36), (37), (3), (2), (1), (6), (20), and (38).

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

459

m

Engineer’s Handbook Exhaust Cladding

M 32

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

c2

460

m

c2

Engineer’s Handbook Diesel Generator Set

M 32

Diesel Generator Set Engine and generator fastening The tightening torques for the engine and generator fixing screws are cost unit specific. If in doubt, please contact the Technical Customer Service Support to obtain the values applicable for your case. Apply the tightening torques for the fixing screws in three steps: 1. step: 20% 2. step: 60% 3. step: 100% The values in the following tables are the tightening torques in Nm for the screws indicated in the headers (strength class 8.8**). Insert all screws with oil! Engine / Generator

M10

M12

M16

Engine

M30

M30 Gen.

6 M 32 C with Siemens 1F J3 904-12

40

70

180

1300

1460

8 M 32 C with Siemens 1DK4637-8BF06-Z

40

70

180

1300

1460

9 M 32 C with Siemens 1DK4637-8BF06-Z

40

70

180

1300

1460

9 M 32 C with Siemens 1F J3 1004-12

40

70

180

1300

1460

8 M 32 C with Siemens 1FJ3

40

70

180

1300

1460*

8 M 32 C with Hyundai HFJ7 914-12P

40

70

180

1300

1460

9 M 32 C with Siemens 1DK4533-8AD05-Z

40

70

180

1300

1460

9 M 32 C with Siemens 1DK4639-8AL06-Z

40

70

180

1300

1460

6 M 32 C with Siemens 1DC1240-8AY06-Z

40

70

180

1300

1460*

9 M 32 C with Hyundai HSJ7 921-10P

40

70

180

1300

1460

9 M 32 C with Siemens 1FJ3 1002-12

40

70

180

1300

1460*

6 M 32 E with Siemens 1DC1237-8AZ05-Z

40

70

180

1300

1650*

6 M 32 E with INDAR GBLS 1110

40

70

170

1300

1460*

8 M 32 E with Siemens 1FJ3 906-10

40

70

180

1300

1650*

8 M 32 E with Siemens 1DC1244-8AL05-Z

40

70

170

1300

1460*

8 M 32 E with INDAR GBLS 1210

40

70

170

1300

1460*

* alternatively: 150 Nm + 22°

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

461

m

c2

Engineer’s Handbook Diesel Generator Set

M 32

Engine / Generator

M10

M12

M16

M20

M30 Engine

M36 Gen.

12 M 32 C (engine No. 34120)

40

70

170

400

1200

2400

12 M 32 C with Siemens Generator (Engines Nos. 37186, 37187, 37188, 37189)

40

70

170

400

1200

2100

12 M 32 C with Siemens 1DK45438AL05-Z

40

70

170

400

1200

2100

12 M 32 C with Siemens 1DK41438AD04-Z

40

70

170

400

1200

2100

16 M 32 C with Siemens 1DK44428AD04-Z

40

70

170

400

1200

2100

16 M 32 C with Siemens GE 5663398

2100

** Strength class 8.8 is not applicable for the following table! Lubricate all threads with oil: M10

M16

Engine / Generator

M22 Flange connection

Engine

M30

M30 Gen.

8 M 32 + ABB 3AFP5109216/261214-216

36

150

500

1200

1465

6 M 32 C + ABB HSG 900SH12/261 213/ 215

36

150

500

1200

1465

M10

Engine / Generator 8 M 32 C with VEM generator (Engines Nos. 38560, 38561, 38562, 38563, 38568, 38569, 38570, 38571, 38572, 38573, 38574, 38575)

Engine / Generator 12 M 32 C + Leroy Somer LSA 60 125/ 10p

M10 40

M12

M16

40

70

180

M12

M16

M20

70

170

Engine

M30

M48 Gen.

1300

5900

Engine

M30

M39 Gen.

1200

2400

400

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

462

m

c2

Engineer’s Handbook Diesel Generator Set

M 32

Engine / Generator 16 M 32 C with AvK DIG 171 o/8W 16 M 32 C (engines Nos. 34148, 34149, 34150 and 34151)

M10 40

M12 70

M16 170

M20

M30 Engine

M48 Gen.

1200

5700

400

See below: Section “Additional tightening torques for 16 M 32 C”

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

463

m

c2

Engineer’s Handbook Diesel Generator Set

M 32

Additional tightening torques for 16 M 32 C Attention! The following data apply to engines 34148, 34149, 34150 and 34151 only!

Engine 16 M 32 C

M10

M12

M16

M20

M24

M27

M30 Engine

40

70

170

400

630

900

1200

Tighten screws M20x110 10.9 on bracket (1) with Oil

Tighten screws M33x220 8.8 for fastening of the generator on the base frame with Oil

⇒

M = 375 Nm

⇒

M = 1650

Nm

Alternative procedure: Pretighten the screws with Then continue to tighten by Oil

⇒ ⇒

M = 150 M = 35°

Nm

Tighten screws (2) with Oil

⇒

M = 960 + 110 Nm

Tighten screws (3) with

⇒

M = 1200

Nm

Tighten nuts (4) with

⇒

M = 900

Nm

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

464

m

Engineer’s Handbook Diesel Generator Set

M 32

c2

Installation of PTO coupling hub (VM) Attention! This work shall only be executed by qualified MaK personnel! Contact Parts Operations in Kiel to hire the required tools and qualified professionals. Hub installation is carried out by means of an oil press fit. The oil press fit is designed specifically for each application so that no general statement about slide-on distances and oil pressures can be made. As a general rule, however, the following applies: • Push the hub onto the shaft journal without applying any pressure until the contact surfaces are close-fitting. • Normally, hydraulic oil SAE10 should be used as pressing liquid. • Oil pressure, assembly force and slide-on distance vary from application to application. Accordingly, different devices are to be used. • Relieve the assembly force earliest after one hour. • After relieving the oil press fit do not subject the hub to any load for at least 24 hours.

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

465

m

Engineer’s Handbook Diesel Generator Set

M 32

c2

Installation of PTO coupling hub (RM) 1. Clean the hub assembly (3) and (5). 2. Remove all bolts of the hub assembly (except for four bolts (7) with hexagon nuts, staggered by 90° each). For installation of the hub, the ring (5) must remain fastened to it. 3. Check the parallel key (A) for closing fit in the hub and clean again if necessary. 4. Turn the shaft until the parallel key points upwards (12:00 h). 5. Lubricate the shaft in the area of the hub seat with hydraulic oil. 6. Screw two threaded rods (A) and (B) as guiding aid into the threaded holes of the hub (3). 7. Heat the hub in an oil bath or a heating furnace evenly up to 180 °C - 200 °C above ambient temperature. 8. In the indicated temperature range match the bore of the hub to the diameter of the generator shaft journal. If the bore is too small to push the hub onto the journal, continue to heat up the hub, but do not exceed 250 °C. 9. Push the hub (3) onto the shaft (A) until it reaches the end stop and make sure that the hub abuts correctly on the end stop. 10. Maintain the axial pressure on the hub until it has cooled down. After that, recheck the connection. 11. Unscrew the threaded rods.

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

466

m

Engineer’s Handbook Diesel Generator Set

M 32

c2

Alignment instruction for diesel generator sets Alignment instructions are cost unit specific. For drawing Nos. please refer to PIDS starting with pos. 9000 (normally, pos. 9212). The values belonging to the drawing number are included in the corresponding table (see next page). In the text of the alignment instruction please replace placeholders A and B with the appropriate values from that table.

Note: In case of 8 M 32 C with Vulkan RATO-DS A33D0, series 2200, drawing numbers 1.90.7-15.33.00-08* and 1.90.7-15.33.00-06* (see table) first bar the engine in such a way that piston of cylinder 1 is at TDC. Bar the generator so that the parallel key of the generator shaft is positioned vertically at the top. 1.90.7-15.33.00-08* has flange connection 1A33D0A0XX with additional mass. 1.90.7-15.33.00-06* has flange connection 1A33D0A033.

Align the generators in cold condition with respect to the engine as follows: Axial alignment: Push the generator towards the engine until the assembly reference dimension of the coupling is A mm (see chapter “Flexible Flange Connection”). Radial alignment: Lift the generator by means of the jacking screws so that it is positioned 0.2 mm higher than the engine. In doing so, take into account a settlement of about 0.1 mm of the Vibracon elements. Angular alignment: Angular ± 0.2 mm measured at coupling outside diameter B mm. At this position place the Vibracon elements onto the top plate, put through the foundation bolts and fasten them finger tight (about 20 Nm). Centre the Vibracon elements with regard to the bolt and raise them by turning until the spherical cap fits closely without any clearance (about 20 Nm). Slacken the jacking screws and tighten the foundation bolts with the prescribed torque. After a test run of the generator sets measure and record crank web deflection at operating temperature (about 10 minutes after shutdown from full load). For notes regarding tightening torques of the coupling please refer to chapter “Flexible Flange Connection”.

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

467

m

c2

Engineer’s Handbook Diesel Generator Set

M 32

RM 32: Table with values for placeholders A and B: Engine / Coupling type

Dwg. No.

A

B

6 M 32 C with Vulkan RATO-DS 3415 A, series 2200

1.90.7-15.33.00-01

515 ± 0.8 mm

1070 mm

1.90.7-15.33.00-02 1.90.7-15.33.00-05 1.90.7-15.33.00-11

525 ± 0.8 mm

1070 mm

8 M 32 C with Vulkan RATO-DS A34D0, series 2200

1.90.7-15.33.00-03

525 ± 0.8 mm

1070 mm

8 M 32 C with Vulkan RATO-DS A33D0, series 2200

1.90.7-15.33.00-04 1.90.7-15.33.00-06*

525 ± 0.8 mm

995 mm

8 M 32 C with Vulkan RATO-DS A33D0, series 2200

1.90.7-15.33.00-08*

540 ± 0.8 mm

995 mm

9 M 32 C with Vulkan RATO-S 1G342Q, series 2100

1.90.7-15.33.00-09

402.9 ± 0.8 mm

1070 mm

6 M 32 C with Vulkan RATO-DS 1A33D0, series 2200

1.90.7-15.33.00-10

490 ± 0.8 mm

995 mm

M 32 C with Vulkan RATO-DS 1A33D0, series 2200

1.90.7-15.33.00-12

490 ± 0.8 mm

995 mm

8 M 32 C with Vulkan RATO-DS 1A34D0, series 2200

1.90.7-15.33.00-13

525 ± 0.8 mm

1070 mm

8 M 32 E with Vulkan RATO-DS 1A33D0, series 2200

1.90.7-15.33.00-13

490 ± 0.8 mm

995 mm

9 M 32 C with Vulkan RATO-DS 34D5 A, series 2200

VM 32: Table with values for placeholders A and B: Engine / Coupling type

Dwg. No.

A

B

12 M 32 C with Vulkan RATODS 34D5 A, series 2200

1.91.7-15.33.00-01

525 ± 0.8 mm

1070 mm

12 M 32 C with Vulkan RATOS 1G391W, series 2200

1.91.7-15.33.00-02

685 ± 0.8 mm

1255 mm

16 M 32 C with Vulkan RATODS A31D5, series 2400

1.91.7-15.33.00-03

660 ± 0.8 mm

935 mm

12 M 32 C with Vulkan RATOS G392W, series 2100

1.91.7-15.33.00-04

488.2 ± 0.8 mm

1240 mm

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

468

m

c2

Engineer’s Handbook Diesel Generator Set

M 32

Engine / Coupling type

Dwg. No.

A

B

16 M 32 C with Vulkan RATOR G401J, series 2100

1.91.7-15.33.00-06

441 ± 0.8 mm

1240 mm

12 M 32 C with Vulkan RATODS 34D0 A, series 2200

1.91.7-15.33.00-07

525 ± 0.8 mm

1070 mm

Last Revised. January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

469

m

Engineer’s Handbook Resilient Mounting

M 32

c2

Resilient mounting Installation (RM and VM) 1. When using pourable resin: Clean the unmachined top plates. When using steel chocks: Machine the top plates. 2. Position the engine and carry out the following alignment by means of jacking screws: Radial:

About 2.00 mm above gearbox shaft (gearbox with vertical shaft offset) About 2.20 mm above gearbox shaft (gearbox with horizontal shaft offset)

Angular:

In line with the gearbox input shaft

Axial:

Coupling axially relieved (observe assembly reference dimension)

3. Drill the top plates for fixing of the bonded rubber rails. 4. Bolt bonded rubber rails (1), (2) and (3) underneath the engine with bolts and nuts. The contact surfaces of the bonded rubber rails must show a bright metal finish. Mechanically remove any contamination by scale, rust or suchlike before bolting them down.

5. When using pourable resin: Pour the resin around the bonded rubber rails according to the instructions of the resin manufacturer (resin must not contact the rubber). Lower the engine after curing of the resin. (Relieve the jacking screws completely). Static deflection about 1.50 mm. 5.1 When using steel chocks: Measure the distance between top plate and bonded rubber rails. Manufacture steel chocks and insert them. Lower the engine according to step 5.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

470

m

Engineer’s Handbook Resilient Mounting

M 32

c2

6. Further settling (subsidence of the engine after 24 hours) about 0.40 mm. The engine will then be approximately in line with the gearbox shaft. 7. Fasten the bonded rubber rails with screws (4) and washers (5) onto the top plate.

Thread engagement > 17 mm for VM 32 27 mm - 30 mm

8. Before installing the stoppers machine a chamfer (1 x 45°) on the engine mount in the area of the stoppers over a length of 350 mm.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

471

m

c2

Engineer’s Handbook Resilient Mounting

M 32

9. Install side stopper (6) and plate (7). Fasten screws (8) finger tight. Insert screws (10) and washers (9) before screwing locking ring (11) onto stopper tube (12). Screw the locking ring (11) up until it reaches the end stop.

Adjust 2 mm upon installation

10. Measure the distance between top plate and bottom edge of locking ring (11). (Dimension H) Add 7.00 mm to the measured dimension H. The calculated dimension is the new tube length R. Manufacture the tube according to length R. 11. Remove side stopper (6) and plate (7). 12. Install side stopper (6) and plate (7) above tube (12). Fasten screws (8) finger tight. 13. Screw down locking ring (11) to centre tube (12). The conical surfaces must come to rest with a positive fit. Level any unevenness of the top plates, tack the tube and weld it.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

472

m

c2

Engineer’s Handbook Resilient Mounting

M 32

14. Remove side stopper (6) and plate (7). 15. Drill the top plates for the tie rods (13). 16. Insert rubber cladding (14) into welded tube (12). Install side stopper (6) and plate (7). 17. Screw the locking ring (11) upward until it reaches the end stop and secure it with 2 headless screws. 18. At operating temperatures the engine stands about 1.00 mm above the gearbox shaft (due to thermal expansion of bonded rubber rail, engine, gearbox, and foundation). The flexible coupling is designed to compensate this. Later re-alignment is not necessary. 19. After reaching operating temperature adjust a vertical clearance of 2 mm between side stopper (6) and nut/washer (15) / (16). Put on washer (17) and secure with nut (18). Check the vertical clearance every six months. When a vertical clearance of > 3 mm is reached, readjust the vertical clearance to 2 mm.

Tightening torques RM 32 and VM 32: Tighten screws (4) with Loctite 242 Tighten screws (10) with Loctite 242 Tighten nuts (15) with Oil Tighten nuts (19) with Oil RM 32: Tighten nuts (19) (alternatively) with Oil Tighten nuts (8)with Loctite 242 Tighten screws (20) with Loctite 242 VM 32: Tighten nuts (8) with Loctite 242 Tighten nuts (20) with Secure the related stud with Loctite 242.

⇒

M = 250

Nm

⇒

M = 650

Nm

⇒

M = 1250

Nm

⇒

M = 1250

Nm

⇒

M = 300 Nm + 60°

⇒

M = 800

Nm

⇒

M = 250

Nm

⇒

M = 1900

Nm

⇒

M = 250

Nm

If possible, oil the head contact surfaces of the screws.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

473

m

c2

Engineer’s Handbook Resilient Mounting

M 32

Locking device to be used in case of damage (not possible for all variants) 1. Remove nuts and washers (15), (16), (17), (18). 2. Loosen hexagon socket set screws M12 (not shown below). 3. Screw the locking ring (11) downward until it rests against the tube. Ø 10 mm auxiliary hole for the tool is provided in the locking ring. 4. Put washer and nut (15), (16) onto the side stopper (6) and bolt down with ⇒ Oil

M = 1250 Nm

Adjust 2 mm upon installation

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

474

m

c2

Engineer’s Handbook Resilient Mounting

M 32

Installation of the conical elements (M 32 C) Remove all jacking screws (6) after alignment and curing of the resin. Tighten nut M48x3 (1) with Oil

⇒

M = 2300 Nm + 100 Nm

Attention! In case of differing conical elements contact the Technical Customer Service Support to obtain the correct tightening value for (1). Tighten nut M33 (2) with Oil

⇒

M = 1250 Nm + 50 Nm

Tighten hexagon head bolt M24 (3) with Oil

⇒

M = 650 Nm + 50

Nm

Tighten hexagon head bolt M30 (4) with ⇒ Apply Loctite 243 to thread, oil to contact surfaces

M = 1000 Nm + 50 Nm

⇒

M = 800 Nm + 50 Nm

Tighten nut M30 (5) with Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

475

m

c2

Engineer’s Handbook Resilient Mounting

M 32

Tighten nut M33 (8) with Oil Tighten hexagon head bolt M24 (9) with Oil Tighten threaded bolt M30 (10) with Oil Tighten nut M48x3 (7) with Oil

⇒

M = 1250 Nm + 50 Nm

⇒

M = 650 Nm + 50 Nm

⇒

M = 800 Nm + 50 Nm

⇒

M = 2300 Nm + 50 Nm

Attention! In case of differing conical elements contact the Technical Customer Service Support to obtain the correct tightening value for (7). Remove all jacking screws (11) after alignment and curing of the resin.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

476

m

c2

Engineer’s Handbook Resilient Mounting

M 32

6 M 32 C and 8 M 32 C: Tighten threaded connection M30 (4) with Oil

⇒

M = 800 Nm + 50

⇒

M = 2300 Nm + 100 Nm

Tighten hexagon head bolt M30 (3) with ⇒ Apply Loctite 243 to thread, oil to contact surfaces

M = 1000 Nm + 50 Nm

Tighten nut M48x3 (1) with Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

477

m

c2

Engineer’s Handbook Resilient Mounting

M 32

12 M 32 C: Tighten hexagon head bolt M24 (8) with Oil

⇒

M = 650 Nm + 50

Tighten nut M48x3 (1) with Oil

⇒

M = 2300 Nm + 100 Nm

Tighten nut M30 (11) with Oil

⇒

M = 800 Nm + 50

Tighten hexagon head bolt M30 (9) with ⇒ Apply Loctite 243 to thread, oil to contact surfaces

Nm

Nm

M = 1000 Nm + 50 Nm

Tighten nuts M30 (16) and nuts M33 (7) with ⇒ M = 1250 Nm + 50 Nm Oil Note regarding nuts (16) and (7): Assembly support (4) and clamping plate (5) are fastened to the engine with M30 threaded connections at the level of cylinders A1 and B1. The other connections are designed as M33.

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

478

m

c2

Engineer’s Handbook Resilient Mounting

M 32

16 M 32 C: Tighten nut M33 (6) with Oil

⇒

M = 1250 Nm + 50 Nm

Tighten hexagon head bolt M24 (7) with Oil

⇒

M = 650 Nm + 50

Tighten nut M48x3 (1) with Oil

⇒

M = 2300 Nm + 100 Nm

Tighten hexagon head bolt M30 (8) with ⇒ Apply Loctite 243 to thread, oil to contact surfaces

M = 1000 Nm + 50 Nm

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

Nm

479

m

c2

Engineer’s Handbook Resilient Mounting

M 32

Installation of the conical elements (M 32 C, M 32 E) (applicable to all standard applications of propulsion engines) Remove hexagon head bolts (5) and all jacking screws (7) after alignment and curing of the resin. Tighten threaded bolt M30 (4) with Oil

⇒

M = 800 Nm + 50 Nm

Tighten screws M30x60 (3) with ⇒ Apply Loctite 243 to thread, oil to contact surfaces

M = 1000 Nm + 50 Nm

⇒

M = 2300 Nm + 100 Nm

Tighten nut M48x3 (1) with Oil

Last Revised: January 2015 Caterpillar confidential: yellow © 2016 Caterpillar Motoren GmbH & Co. KG - All rights reserved

480