W6 Maintenance Report
For
Modern Power Marine Services Co.
MTU Diesel Engine Type 12V396TE94
Order Number: AU22/1489
Engine Serial No: 5583791
Table of Content
List of Figures ................................................................................................................................... 3
1.
Technical Detail................................................................................................................. 4
2.
Maintenance........................................................................................................................ 5
2.1.
Group 01 – Crankcase ................................................................................. 5
2.2.
Group 02 – Gear Train ................................................................................ 8
2.3.
Group 03 – Running Gear ............................................................................ 8
2.4.
Group 04 – Cover Plate at KGS .................................................................. 12
2.5.
Group 05 – Cylinder head ......................................................................... 13
2.6.
Group 06 – Control System ....................................................................... 15
2.7.
Group 07 – Engine Governor ..................................................................... 18
2.8.
Group 09 – Exhaust Turbocharge .............................................................. 19
2.9.
Group 10 – Charge Air Piping – Exhaust Piping ......................................... 21
2.10. Group 11 – Injection System ..................................................................... 23
2.11. Group 12 – Fuel System ............................................................................ 25
2.12. Group 13 – Water Pump ............................................................................ 27
2.13. Group 14 – Coolant System ....................................................................... 28
2.14. Group 15 – Oil Pump................................................................................. 30
2.15. Group 16 – Oil System .............................................................................. 30
2.16. Group 18 – Starting Equipment ................................................................. 31
2.17. Group 19 – Engine Mounting..................................................................... 32
2.18. Group 84 – Monitoring Equipment ............................................................ 32
2.19. Group 86 – Accessories (electric, pneumatic) ............................................ 33
2.20. Group 88 – Accessories (mechanical) ........................................................ 34
3.
Performance Test .......................................................................................................... 36
4.
Pictures of complete Engine ..................................................................................... 38
5.
Annex A ............................................................................................................................. 42
6.
Measurement Reports ................................................................................................. 43
7.
Test Run Report ............................................................................................................. 44
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1: Crankcase after machining........................................................................ 5
2: Crankcase after machining (2)................................................................... 6
3: Crankshaft Bearings .................................................................................. 7
4: Crankshaft ................................................................................................ 9
5: Six Pistons and connecting Rods ............................................................. 11
6: Engine KGS View ..................................................................................... 12
7: Machined and mounted Cylinder Head .................................................... 13
8: Cylinder Heads while assembly ............................................................... 14
9: Replaced Gear Case ................................................................................ 16
10: Gear Case on top of Cylinder Heads ...................................................... 17
11: Engine Governor mounted to Injection Pump ........................................ 18
12: Fully mounted Turbocharger ................................................................. 19
13: Replaced Components inside the Turbocharger .................................... 20
14: Carrier Housing .................................................................................... 21
15: Turbocharger mounted to Carrier Housing ............................................ 22
16: Mounted overhauled Injection Pump ..................................................... 24
17: Fuel System with Fuel System Pipes ....................................................... 26
18: Assembled Water Pump ........................................................................ 27
19: Plate Cooler .......................................................................................... 28
20: Mounted and assembled Plate Cooler.................................................... 29
21: Overhauled and painted Starting Equipment ......................................... 31
22: Replaced Cover Plate............................................................................. 32
23: Actuator ............................................................................................... 33
24: Overhauled Coupling (Back Side) ........................................................... 34
25: Overhauled Coupling (Front Side) .......................................................... 35
26: Engine on the Test Bench ...................................................................... 37
27: Engine prepared for Painting ................................................................. 39
28: Final painted Engine.............................................................................. 40
29: Final painted Engine (2) ........................................................................ 41
30: Painted Details ...................................................................................... 41
3
1. Technical Detail
Manufacturer
MTU
Model
12V396TE94
Serial No.:
5583791
Application area
Coast Guard
Rotational speed
2000 1/min
Power
1680 kW
4
Maintenance
2. Maintenance
In the following section, maintenance is divided into individual assemblies.
2.1.





Group 01 – Crankcase
Disassembly of crankcase
Cleaning crankcase
Inspection of crankcase in respect of cracks
o No damage found
Dimensional inspection of main bearing bore, cylinder liner bore and
camshaft bores. (Refer to attached measurement report)
o All main bearing pockets without defects
o Both top decks have been surface milled
o Cylinder liner bore has been drilled to stage 1-1
Inspection of cylinder liners
o Damage found
o All cylinder liners have been replaced
Figure 1: Crankcase after machining
5
Maintenance
Figure 2: Crankcase after machining (2)
6
Maintenance
Figure 3: Crankshaft Bearings
7
Maintenance
2.2.





Disassembly of gear train
Cleaning of gear train components
Inspection of gear wheels in respect of damages
o No Damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of gear train
2.3.



Group 02 – Gear Train
Group 03 – Running Gear
Disassembly of running gear
Cleaning of running gear components
Replacement of all standard W6 components
o Refer to ANNEX A
8
Maintenance
Crankshaft

Inspection of crankshaft dimensions, crack test and hardness (refer to
attached measurement report).
o No damage found
Figure 4: Crankshaft
9
Maintenance
Pistons




Disassembly of pistons
Cleaning
Inspection of all pistons
o Damage found
o Replacement of all 12 pistons necessary, refer to inspection report
All 12 pistons were replaced
Connecting Rods

Dimensional inspection of all connecting rods
o No damage found
o Refer to attached measurement report
10
Maintenance
Figure 5: Six Pistons and connecting Rods
11
Maintenance
Vibration Damper


Disassembling of the vibration damper
Dimensional inspection of all parts
o No damage found
2.4.




Group 04 – Cover Plate at KGS
Disassembly of cover plate
Cleaning of all cover plate components
Inspection of cover plate components
Replacement of all standard W6 components
o Refer to ANNEX A
Figure 6: Engine KGS View
12
Maintenance
2.5.







Group 05 – Cylinder head
Disassembly of cylinder heads
Cleaning of cylinder heads and components
Visual inspection of cylinder heads (Refer to attached measurement report)
Dimensional machining of surfaces and valve seats
Replacement of all valve guides
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of cylinder head
Figure 7: Machined and mounted Cylinder Head
13
Maintenance
Figure 8: Cylinder Heads while assembly
14
Maintenance
2.6.






Group 06 – Control System
Disassembly of camshafts
Cleaning of all control system component
Camshaft bearings were replaced
One Gear Case were replaced
Replacement of all standard W6 components
o Refer to ANNEX A
Assembly of control system components
15
Maintenance
Figure 9: Replaced Gear Case
16
Maintenance
Figure 10: Gear Case on top of Cylinder Heads
17
Maintenance
2.7.






Group 07 – Engine Governor
Disassembly of engine governor
Cleaning of all governor components
Visual inspection of all components
Actuator has been replaced
Replacement of all standard W6 components
o Refer to ANNEX A
Assembly of engine governor
Figure 11: Engine Governor mounted to Injection Pump
18
Maintenance
2.8.







Group 09 – Exhaust Turbocharge
Disassembly of turbochargers
Cleaning of all turbocharger components
Visual inspection of all components
Cracks in the turbocharger housings have been welded
Radiant disc and compressor wheels have been replaced
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 12: Fully mounted Turbocharger
19
Maintenance
Figure 13: Replaced Components inside the Turbocharger
20
Maintenance
2.9.






Group 10 – Charge Air Piping – Exhaust Piping
Disassembly of all components
Cleaning of all components
Visual inspection of all components
Replacement of charge air manifold
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 14: Carrier Housing
21
Maintenance
Figure 15: Turbocharger mounted to Carrier Housing
22
Maintenance
2.10.






Group 11 – Injection System
Disassembly of all unit injectors
Cleaning of all components
Inspection and overhaul of all injectors
Inspection of fuel delivery pump
o Valves have been replaced
o Fuel delivery pump has been overhauled
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
23
Maintenance
Figure 16: Mounted overhauled Injection Pump
24
Maintenance
2.11.






Group 12 – Fuel System
Disassembly of fuel system components
Cleaning of fuel system components
Visual inspection
Machining of gear pump shaft
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
25
Maintenance
Figure 17: Fuel System with Fuel System Pipes
26
Maintenance
2.12.






Group 13 – Water Pump
Disassembly of coolant and seawater pump
Cleaning of all water pump components
Visual inspection
Replacement of seawater impeller and drive shaft
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 18: Assembled Water Pump
27
Maintenance
2.13.





Group 14 – Coolant System
Disassembly of coolant system
Cleaning of all components
Visual inspection
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 19: Plate Cooler
28
Maintenance
Figure 20: Mounted and assembled Plate Cooler
29
Maintenance
2.14.




Disassembly of oil pump
Cleaning of all components
Visual inspection
o No damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
2.15.




Group 15 – Oil Pump
Group 16 – Oil System
Disassembly of the oil system
Cleaning of all components
Visual inspection
o No damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
30
Maintenance
2.16.




Group 18 – Starting Equipment
Disassembly of the starting equipment
Cleaning of all components
Inspection and overhaul of the starter
Replacement of all standard W6 parts
o Refer to ANNEX A
Figure 21: Overhauled and painted Starting Equipment
31
Maintenance
2.17.



Group 19 – Engine Mounting
Disassembly of the engine mounting
Cleaning of all components
Visual inspection
o Cover plate has been replaced
Figure 22: Replaced Cover Plate
2.18.



Group 84 – Monitoring Equipment
Disassembly of the monitoring equipment
Cleaning of all components
Checking of all cables and sensors
o No damage found
32
Maintenance
2.19.


Group 86 – Accessories (electric, pneumatic)
Disassembly of the actuator
Cleaning of all components
o Actuator has been replaced
Figure 23: Actuator
33
Maintenance
2.20.



Group 88 – Accessories (mechanical)
Disassembly of the coupling
Cleaning of all components
Inspection and overhaul of the coupling
Figure 24: Overhauled Coupling (Back Side)
34
Maintenance
Figure 25: Overhauled Coupling (Front Side)
35
Performance Test
3. Performance Test
36
Performance Test
Test Run
The engine test run at test bench facilities of Zeppelin Power Systems CAT in Achim,
Germany was performed successfully on 17. May 2023. Test Run report attached in
Chapter “6. Test Run Report”.
Figure 26: Engine on the Test Bench
37
Complete Engine
4. Pictures of complete Engine
38
Complete Engine
Figure 27: Engine prepared for Painting
39
Complete Engine
Figure 28: Final painted Engine
40
Complete Engine
Figure 29: Final painted Engine (2)
Figure 30: Painted Details
41
Annex A
5. Annex A
42
Pos.-No.
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
700429340000
5580130580
700429270001
5580140580
5500140280
271511022001
271511022000
5580110380
5550140380
700429050003
700429166000
5909970440
0000110032
700429075002
5550114610/87
5550110159
5500110680
700429037001
700429105001
700429100001
5500140380
700327018000
700429020000
700429015000
700429105000
700368035001
900288046008
700368028002
900288037003
700327035000
0000181802
0009813527
205412223003
700429084000
0009818801
205412203014
700429105001
700429175001
5550307540
5550302160
0080376419
0080376319
0090378518
5559901919
5550330130
5509810725
700429330000
8700380171
700429045000
700429400000
700429220001
5591870680
5550161420
O-RING
GASKET
O-RING
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
O-RING
O-RING
SEALING RING
COVER
O-RING
CYLINDER LINER
SIZE 0-0
SEALING RING
FOR CYLINDER LINER
GASKET
O-RING
O-RING
O-RING
GASKET
GROMMET
O-RING
O-RING
O-RING
SLEEVE RUBBER
CLAMP
RUBBER SLEEVE
CLAMP
GROMMET
OIL FILL CAP
ANGLR-CONT BALL BRG
CYL.ROLLER BEARING
O-RING
CYL ROLLER BEARING
CYL ROLLER BEARING
O-RING
O-RING
CRANKSHAFT BEARING SIZE 0-0
CONROD BEARING
SIZE 0-0
RECTANGLR-SECT RING
TAPER FACE COMP RING
OIL CONTROL RING
SCREW
CRANKSHAFT BEARING SIZE 0-0
GROOVED BALL BEARING SIZE 0
O-RING
CONROD BOLT
O-RING
O-RING
O-RING
GASKET
CYLINDER HEAD GASKET
Qty.
1
3
1
2
2
1
4
1
1
2
1
2
12
2
12
12
1
4
1
1
6
2
2
2
1
1
2
1
2
3
2
2
2
1
1
1
1
1
7
12
12
12
12
24
1
1
1
24
2
1
1
1
12
Pos.-No.
Part No.
Description
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
5500160432
5500160119
700429009002
700429036001
700429040003
700429021000
700429014000
0029977940
5559970344
5500170260
0000170660
700429033000
0000533635
5500530020
5500530022
0000530126
700429030001
5550510118
8695860397
700429009002
700429260000
5500160121
700429006000
0009940254
5050613280
700217014004
200625900002
5550630180
700429084000
700429013001
916016012200
700429032000
0005332275
700429168001
X00043045
700429031000
5100200212
700429105001
700429005001
5100850160
5100850260
5090850060
XT1310100444
700429210000
700429042001
X00011067
5110200412
5110850560
5110850460
5100850060
XT3510100217
700429270001
5119940330
PIPE
SEALING RING
O-RING
O-RING
O-RING
O-RING
O-RING
SEALING RING
SEALING RING
SUPPORT RING
RING
O-RING
VALVE ROTATOR
VALVE SPRING
OUTER
VALVE SPRING
INNER
VALVE COLLET
O-RING
CAMSHAFT BEARING
SIZE 0-0
REPAIR KIT
O-RING
O-RING
GASKET
O-RING
CLAMPING RING
GASKET
SHAFT SEAL
GROOVED BALL BEARING
GASKET
O-RING
O-RING
CLAMP
O-RING
CLAMP
O-RING
BEARING BUSHING
O-RING
THRUST BEARING
O-RING
O-RING
PISTON RING
PISTON RING
PISTON RING
MAGNETIC NUT
O-RING
O-RING
BEARING BUSHING
THRUST BEARING
RING SEAL
PISTON RING
RING SEAL
MAGNETIC NUT
O-RING
TAB WASHER
Qty.
96
96
24
24
24
28
16
48
12
12
12
24
48
48
48
96
12
2
24
24
12
12
24
24
2
2
3
2
3
4
2
1
1
1
2
1
1
3
1
1
1
2
1
1
2
4
2
2
2
4
2
2
12
Pos.-No.
Part No.
Description
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
700429120002
700429126000
700429017000
700429083000
700429115000
700429108000
700429120001
5601400441
5101400241
700429100000
700429188001
700429032000
5590981380
700429142000
700429270001
5590982680
5590982580
700327010000
5530981580
0229979982
5500980280
700429028001
5500981680
0039970490
0019960040
0030947404
8699970084
0009966445
0009966345
X00048307
5569940330
700429032003
X00048305
0049976736
5841420857
114C62033/1
700429006002
700429172000
700429190001
700429162000
5591420451
700429015000
5531420158
0001401487
0035317483
700386017000
700429025001
700429020000
8690940016
700429009002
700429019000
700429120001
700429042001
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
CLAMP
CLAMP
O-RING
O-RING
O-RING
SEALING RING
O-RING
O-RING
GASKET
GASKET
GROMMET
GASKET
AIR HOSE
GASKET
O-RING
GASKET
V-BAND COUPLING
ARTICULATED BEARING
AIR FILTER ELEMENT
O-RING
SWIVEL HEAD
SWIVEL HEAD
RTV
TAB WASHER
O-RING
SEALANT
VALVE DRAIN
SEALING RING
SEALING RING
O-RING
O-RING
O-RING
O-RING
RING SEALING
O-RING
CENTERING RING
DAMPER ELEMENT
GASKET
SEAL SHAFT AS
O-RING
O-RING
CARTRIDGE
O-RING
O-RING
O-RING
O-RING
Qty.
4
6
42
2
2
8
8
2
2
2
2
2
2
2
2
2
2
3
2
1
12
12
4
6
2
1
2
1
1
1
24
16
1
2
2
2
8
2
4
4
1
1
2
4
4
4
4
2
1
2
2
1
1
Pos.-No.
Part No.
Description
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
208
209
210
211
212
213
0020172112
0009922130
700429105001
200625906316
700429075002
8695860101
8699970117
8699970098
8699810014
8699970115
0149974747
8690740143
8699970101
8699970102
8690740312
700429019000
700429024000
0049979447
700429105001
700429009002
700429015000
5550900350
5550780538
5500781253
5500781253
700429004000
5370780038
700327006000
8699970630
8591810110
8591810140
8699970053
700327012000
0002375712
735038006102
700327008000
700429014002
700429027001
0049976736
700429038001
8499970970
0000921705
700294014005
700294125000
700327018000
700327015000
8699970231
8699970231
8690920032
0000925105
8690920039
8690920033
8690920038
HOLE-TYPE NOZZLE
CLAMPING ELEMENT
O-RING
GROOVED BALL BEARING
O-RING
SET OF SHIMS
O-RING
O-RING
TAPERED ROLLER BRG
O-RING
SEALING RING
SHAFT SEAL
O-RING
O-RING
GASKET
O-RING
O-RING
SHAFT SEAL
O-RING
O-RING
O-RING
FUEL PRIMING PUMP
DAMPER STRIP
SLEEVE
SLEEVE
O-RING
DAMPER STRIP
GROMMET
RADIAL-LIP OIL SEAL
BEARING BUSH
BEARING BUSH
SEALING RING
GROMMET
BUFFER
HOSE
GROMMET
O-RING
O-RING
VALVE DRAIN
O-RING
GASKET
FUEL FILTER ELEMENT
O-RING
O-RING
GROMMET
GROMMET
SEALING RING
GASKET
FILTER ELEMENT
GASKET
GASKET
COCK
Qty.
12
2
4
1
1
12
12
12
2
1
1
1
4
12
1
2
1
1
1
1
6
1
12
3
80
12
12
9
1
4
1
2
13
4
1
8
1
2
1
3
1
2
2
2
2
3
1
1
2
2
8
2
2
Pos.-No.
Part No.
Description
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
X00E50203662
705100502035
5502010280
700429100001
700429085000
0002017519
0079977247
0009813527
270952035101
700429046000
0002010418
700429150001
000625900175
0049979947
8692040020
700429057000
5552040580
0039978648
8692040050
5562031180
5582031580
000625900178
0079978047
700429165000
700429083000
5582031680
0002040479
0002040263
0002040716
0039977848
700429230000
705100502035
5502010280
700429100001
700429085000
0002017519
0079977247
0009813527
270952035101
700429046000
0002010418
700429150001
000625900175
0049979947
8692040020
700429057000
5552040580
0039978648
8692040050
5562031180
5582031580
000625900178
0079978047
LEVEL MONITOR
BEARING CYLINDRICAL ROLLER
GASKET
O-RING
O-RING
ROTARY SEAL
SHAFT SEAL
ANGLR-CONT BALL BRG
TAB WASHER
O-RING
COUNTERRING
O-RING
BEARING BALL GROOVED 62
SEAL SHAFT
GAITER
O-RING
GASKET
SEAL ROTARY PUMP
GASKET
GASKET
GASKET
GROOVED BALL BRG
SHAFT SEAL
O-RING
O-RING
GASKET
GAITER
COUNTERRING
ROTARY SEAL
O-RING
O-RING
BEARING CYLINDRICAL ROLLER
GASKET
O-RING
O-RING
ROTARY SEAL
SHAFT SEAL
ANGLR-CONT BALL BRG
TAB WASHER
O-RING
COUNTERRING
O-RING
BEARING BALL GROOVED 62
SEAL SHAFT
GAITER
O-RING
GASKET
SEAL ROTARY PUMP
GASKET
GASKET
GASKET
GROOVED BALL BRG
SHAFT SEAL
Qty.
2
2
1
2
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
Pos.-No.
Part No.
Description
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
700429165000
700429083000
5582031680
0002040479
0002040263
0002040716
0039977848
700429230000
5552031150
700429075002
700429070000
5502030060
5502032080
5552031780
5552031880
700429024002
700429028002
5552031980
5562030980
700327010000
700368042004
900288054005
700327006000
700429060000
700429055001
5562030880
700429056001
5562031380
700429048001
5592032680
0002035483
0002035583
0002035183
700429065000
5502035880
5501425880
700429042000
5552000188
700429010000
700429090000
0049979040
0002033288
700429075001
700429080005
700429175000
700429006003
700429011001
5592001351
5592010180
5582004658
5582001263
0049976736
5532031880
O-RING
O-RING
GASKET
GAITER
COUNTERRING
ROTARY SEAL
O-RING
O-RING
BUSHING
O-RING
O-RING
SIGHT GLASS
GASKET
GASKET
GASKET
O-RING
O-RING
GASKET
GASKET
GROMMET
SLEEVE RUBBER
CLAMP
GROMMET
O-RING
O-RING
GASKET
O-RING
GASKET
O-RING
GASKET
RUBBER BELLOWS
BELLOWS RUBBER 125 D N 210 BOLT CIRCLE
RUBBER BELLOWS
O-RING
GASKET
GASKET
O-RING
STRAINER
O-RING
O-RING
OIL CONTROL RING
ACTUATOR
O-RING
O-RING
O-RING
O-RING
O-RING
VENT PIPE
GASKET
VENT LINE
DRAIN LINE
VALVE DRAIN
GASKET
Qty.
1
1
1
1
1
1
1
1
3
6
3
2
4
3
1
1
1
3
1
11
1
2
7
1
8
2
1
1
8
1
1
1
1
4
4
2
4
2
1
5
2
1
4
2
1
1
5
1
3
1
1
1
1
Pos.-No.
Part No.
Description
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
700429057001
700429045000
700429040003
700368042002
900288053004
700327022000
5582031280
0039977748
5582031380
0002033980
8499970052
8499970053
202690040000
8692030074
8699970175
8699970176
700429031000
0011808901
700429042000
700429037001
700429030004
735038025103
735038016103
8695860309
8695860311
700429070002
8699970277
8699970140
8699970278
700292004300
700429037001
0002373726
0139971982
0139972982
0009975389
0009975489
705057013000
700429028002
0002372011
735038008118
735038008106
700327010000
0001840681
700294115001
0001847780
735038020104
5501870980
700327012000
700429015004
700327006000
700327004000
700429017000
700429021000
O-RING
O-RING
O-RING
RUBBER SLEEVE
CLAMP
GROMMET
GASKET
O-RING
GASKET
SEALING RING
GASKET
GASKET
GASKET
GASKET
GASKET
GLAND PACKING
O-RING
OIL PUMP
O-RING
O-RING
O-RING
HOSE
HOSE
GASKET KIT
COMPLETE
PARTS KIT
COMPLETE
O-RING
SEALING RING
O-RING
SEALING RING
TAB WASHER
O-RING
RESILIENT ELEMENT
HOSE
HOSE
QUICK-DISCONNECT CPL
SEALING NIPPLE
RING SEALING A13 X18 CU
O-RING
RESILIENT ELEMENT
HOSE
HOSE
GROMMET
GAITER
O-RING
GASKET
HOSE
GASKET
GROMMET
O-RING
GROMMET
GROMMET
O-RING
O-RING
Qty.
1
4
4
1
2
3
1
2
1
3
34
33
4
3
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
3
2
3
1
5
4
1
1
12
1
1
1
1
1
4
4
10
2
5
2
Pos.-No.
Part No.
Description
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
5550740780
5500180280
5600511280
700429126000
700429063000
5501800016
8699970059
5582031880
700429020003
0049976736
700429060000
700429042000
700429042001
700429032003
700429036001
700429055001
5591880180
5591880280
700429030004
700429033001
5551880980
700429030002
700429055002
700429009005
8691840024
700429006001
700327006000
700327012000
0019970648
700429090002
5561750680
8691700001
0001750080
8691700170
11.28068-2001
0005863615
0005863215
0001515214
000625916011
0019819325
0001510085
0001510185
0019972747
0029816501
5559970344
700327022000
5901700016/87
735038020105
5582370012
0002370612/87
X59623300108/87
700327010000
916016006202
GASKET
GASKET
GASKET
O-RING
O-RING
OIL FILTER ELEMENT
SEAL RING
GASKET
O-RING
VALVE DRAIN
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
GASKET
GASKET
O-RING
O-RING
GASKET
O-RING
O-RING
O-RING
RATCHET
O-RING
GROMMET
GROMMET
O-RING
O-RING
GASKET
DISTRIBUTOR DISC
GASKET
BUSHING
BUSHING
PARTS KIT
PARTS KIT
CARBON BRUSH KIT
GROOVED BALL BEARING
BALL BEARING
GAITER
LUBRICATING WICK
OIL SEAL
CYL ROLLER BEARING
SEALING RING
GROMMET
SOLENOID VALVE
HOSE
RUBBER RING
CONICAL BEARING
STOP PLATE
GROMMET
CLAMP
Qty.
1
2
1
4
4
4
4
1
10
2
3
6
8
2
2
4
2
2
2
2
2
4
2
4
2
2
18
68
1
1
2
1
1
1
2
2
2
1
1
1
1
1
1
1
12
1
2
1
4
8
4
6
15
Pos.-No.
Part No.
Description
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
916016008202
916016010203
916016012201
916016018202
0002372712
916016024201
916016016201
0139972382
0009975389
916016008200
916016010205
916016014201
916016014200
916016020202
916016022202
916016028200
0005353960
0005356760
X00006134
0005350703
0005350132
0000940568
0005352730
0055351331
700386060000
207753310000
0052501101
X00E50210016
XP55800600012
8695860331
700429017001
700429009004
0002346203
700429100001
700429220001
0189978747
700429270001
0149975547
700429380000
700429300000
700429330000
700429610000
200628070000
5582534542
0189978947
700429260000
700429160001
5500180280
5500100061
700429050004
700429040004
700429006001
8695860331
CLAMP
CLAMP
CLAMP
CLAMP
RUBBER MOUNT
CLAMP
CLAMP
HOSE
QUICK-DISCONNECT CPL
CLAMP
CLAMP
CLAMP
CABLE CLAMP BRSGU 14/25
CLAMP
CLAMP
CLAMP
THERMOCOUPLE
THERMOCOUPLE
PRESSURE MONITOR
LEVEL MONITOR
LEVEL MONITOR
CONTAM. INDICATOR
TEMPERATURE SENSOR
PRESSURE SENSOR
SHAFT SEAL
V-BELT KIT
COUPLING
POSITION MONITOR
ROTOR
COMPLETE
REPARATURSATZ
O-RING
O-RING
COUPLING
O-RING
O-RING
RADIAL-LIP SHFT SEAL
O-RING
RADIAL-LIP SHFT SEAL
O-RING
O-RING
O-RING
O-RING
ANG. CONT. BALL BRG.
RING
SEAL REAR CRANKSHAFT
O-RING
O-RING
GASKET
OIL SEPARATOR
O-RING
O-RING
O-RING
REPARATURSATZ
Qty.
25
5
14
5
7
5
10
1
1
1
5
4
2
5
1
1
8
4
2
1
1
1
3
2
2
1
1
1
1
1
2
4
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
2
2
1
Pos.-No.
Part No.
Description
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
007603038101
700429030004
007993040200
5550111070
5550111170
COPPER SEALING RING
O-RING
SNAP RING
STUD
STUD
Kurbelgehäuse vermessen
Kurbelwelle vermessen
CAMSHAFT BEARING
CYLINDER LINER
SIZE 1-1
SNAP RING
VALVE
STRESS BOLT
DRIVE SHAFT
IMPELLER
GAITER
O-RING
O-RING
O-RING
TAPERED ROLLER BRG
O-RING
SEALING RING
SHAFT SEAL
O-RING
O-RING
VALVE
STRESS BOLT
STRESS BOLT
TAB WASHER
GASKET
VALVE GUIDE
EXHAUST, SIZE 0
INLET VALVE
EXHAUST VALVE
PROTECTIVE SLEEVE
O-RING
VALVE STEM SEAL
VALVE ROTATOR
SEALING RING
WASHER
STRESS BOLT
PRESSURE SLEEVE
PIPE
PISTON
VIBRATION DAMPER
O-RING
COMPRESSOR WHEEL
COMPRESSOR WHEEL
HEAT SHIELD
HEAT SHIELD
COVER PLATE
CRANKSHAFT BEARING SIZE 0-0
CONROD BEARING
SIZE 0-0
PISTON
SWIVEL HEAD
5500511710
5550114910
007993040200
5110200278
5509901019
5582000002
5582040406
0002040479
700429042001
700429120001
700429009004
8699810014
8699970115
0149974747
8690740143
8699970102
8699970117
8690740393
8389900919
8389901019
070952024100
5532031880
5550532744
5500530401
5550530105
5550170053
700429030001
0000530361
0000533635
5561420157
5561420276
5509901019
5550170553
5501872401
5550301618
5560301003
700429017000
5110258201
5100253901
5100810903
5100820626
5502370865
5550307540
5550302160
5550301618
0009966345
Qty.
1
1
1
14
14
1
1
13
12
1
6
1
1
1
1
1
1
4
2
2
1
1
12
12
12
9
10
1
1
24
24
24
12
12
24
48
2
1
1
2
3
5
1
6
1
1
1
1
1
7
12
7
2
Pos.-No.
Part No.
Description
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
28360750150/0
000931010257
206925006000
5590900375
000912010016
200625906316
735080012201
700327018000
5561880280
8699970226
0020172112
0115319783
0005353960
5500110559
X00E50214448
007993014100
5500110071
0000745884
000007012221
0009966445
000094002064
0000911010
0000746184
8372010166
5550330130
8699970630
700429009002
000094002064
5550160095
700429006000
8699970153
8699970152
5502035880
0020172112
705057013000
735028010000
200625906316
700429015004
000988010000
0000170023
700429115000
700429120001
700429108000
0002372712
BUSHING
HEX SCREW
HEX NUT
NON-RETURN VALVE
BOLT HEX SOC HD
GROOVED BALL BEARING
NON-RETURN VALVE
GROMMET
GASKET
SEALING RING
HOLE-TYPE NOZZLE
MALE CONNECTOR
THERMOCOUPLE
O-RING
ACTUATOR
SNAP RING
SCREW
VALVE
DOWEL PIN
SWIVEL HEAD
PIN SPLIT
VALVE
VALVE
SCREW-FITTING UNION
CRANKSHAFT BEARING SIZE 0-0
RADIAL-LIP OIL SEAL
O-RING
PIN SPLIT
SPACER PLATE USED
O-RING
GASKET
GASKET
GASKET
HOLE-TYPE NOZZLE
RING SEALING A13 X18 CU
NUT
GROOVED BALL BEARING
O-RING
ADJUSTING WASHER
SPRING PIN
O-RING
O-RING
O-RING
RUBBER MOUNT
Qty.
2
1
1
1
1
1
1
3
2
6
45
1
8
1
1
4
1
1
16
1
2
1
1
2
1
1
1
1
1
4
4
4
4
100
6
1
1
4
1
1
1
2
2
7
Measurement Reports
6. Measurement Reports
43
06.1 Measurement Report Camshaft
Customer:
Engine Type:
Engine No.:
0°
90°
0°
90°
0°
90°
0°
90°
Modern Power
Our Order No.:
12V396TE94
5583791
Camshaft Outside
67,00 mm
Tolerance:
-0,08
-0,06
Nominal dim.:
1
2
3
4
5
6
7
66,94
66,94
66,94
66,94
66,93
66,93
66,94
66,94
66,94
66,94
66,93
66,93
12
End Bearing
56,93
56,93
Camshaft Bearings
Nominal dim.:
67,00 mm
Tolerance:
0,000
0,040
1
2
3
4
5
6
7
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
12
End Bearing
57,00
57,00
Crack testing:
Hardness:
AU22/1522
8
Measurement in: 0,01mm
9
10
11
8
Measurement in: 0,01mm
9
10
11
OK
OK
REMARKS
03.05.23
Date
T.T.
Checked by
Customer Representative
06.1 Measurement Report Camshaft
Customer:
Engine Type:
Engine No.:
0°
90°
0°
90°
0°
90°
0°
90°
Modern Power
Our Order No.:
12V396TE94
5583791
Camshaft Outside
67,00 mm
Tolerance:
-0,08
-0,06
Nominal dim.:
1
2
3
4
5
6
7
66,94
66,94
66,93
66,94
66,93
66,93
66,94
66,94
66,93
66,94
66,93
66,93
12
End Bearing
56,93
56,93
Camshaft Bearings
Nominal dim.:
67,00 mm
Tolerance:
0,000
0,040
1
2
3
4
5
6
7
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
67,00
12
End Bearing
57,00
57,00
Crack testing:
Hardness:
AU22/1522
8
Measurement in: 0,01mm
9
10
11
8
Measurement in: 0,01mm
9
10
11
OK
OK
REMARKS
03.05.23
Date
T.T.
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm (Outlet)
Customer:
Modern Power
Engine Type:
Engine No.:
Side:
Our Order No.:
AU22/1522
12V396TE94
5583791
A
Nominal dim.:
L
1
0°
28,01
90°
28,02
2
28,01
28,02
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,02
28,02
28,01
28,02
28,02
28,02
28,01
28,01
28,02
28,01
28,02
2
27,97
27,97
Shaft
28,00 mm
Tolerance:
-0,04
3
4
5
6
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
0,02
7
Measurement in:
9
10
0,01mm
8
-0,02
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,02
Nominal dim.:
L
1
0°
27,97
90°
27,97
28,01
28,02
28,01
28,02
28,01
28,02
R
0°
90°
27,96
27,96
27,97
27,97
27,96
27,97
27,97
27,97
REMARKS
06.05.2023
Date
C.G.
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm (Inlet)
Customer:
Modern Power
Engine Type:
Engine No.:
Side:
Our Order No.:
AU22/1522
12V396TE94
5583791
A
Nominal dim.:
L
1
0°
28,01
90°
28,02
2
28,01
28,02
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,01
28,01
28,01
28,02
28,02
28,02
28,02
28,01
28,02
28,01
28,02
2
27,97
27,97
Shaft
28,00 mm
Tolerance:
-0,04
3
4
5
6
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
0,02
7
Measurement in:
9
10
0,01mm
8
-0,02
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,02
Nominal dim.:
L
1
0°
27,97
90°
27,97
28,01
28,02
28,01
28,02
28,01
28,02
R
0°
90°
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
REMARKS
06.05.2023
Date
T.T.
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm (Outlet)
Customer:
Modern Power
Engine Type:
Engine No.:
Side:
Our Order No.:
AU22/1522
12V396TE94
5583791
B
Nominal dim.:
L
1
0°
28,02
90°
28,02
2
28,01
28,01
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,01
28,02
28,02
28,01
28,01
28,02
28,02
28,01
28,01
28,01
28,01
2
27,97
27,97
Shaft
28,00 mm
Tolerance:
-0,04
3
4
5
6
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
0,02
7
Measurement in:
9
10
0,01mm
8
-0,02
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,02
Nominal dim.:
L
1
0°
27,97
90°
27,97
28,01
28,02
28,01
28,01
28,01
28,01
R
0°
90°
27,97
27,97
27,97
27,97
27,96
27,97
27,96
27,97
REMARKS
06.05.2023
Date
C.G.
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm (Inlet)
Customer:
Modern Power
Engine Type:
Engine No.:
Side:
Our Order No.:
AU22/1522
12V396TE94
5583791
B
Nominal dim.:
L
1
0°
28,01
90°
28,02
2
28,01
28,02
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,01
28,01
28,01
28,02
28,02
28,01
28,02
28,01
28,01
28,01
28,01
2
27,97
27,97
Shaft
28,00 mm
Tolerance:
-0,04
3
4
5
6
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
0,02
7
Measurement in:
9
10
0,01mm
8
-0,02
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,02
Nominal dim.:
L
1
0°
27,97
90°
27,97
28,02
28,02
28,01
28,02
28,01
28,01
R
0°
90°
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
REMARKS
06.05.2023
Date
C.G.
Checked by
Customer Representative
01.4 Measurement Report Cylinder Liner Installed
A0°
A90°
B0°
B90°
A0°
A90°
B0°
B90°
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583791
Nominal dim.:
1
2
165,03 165,03
165,03 165,03
165,06 165,04
165,05 165,03
Nominal dim.:
1
2
165,03 165,03
165,03 165,03
165,05 165,03
165,06 165,04
Our Order No.:
AU22/1522
165 mm
3
4
165,03 165,04
165,03 165,03
165,05 165,06
165,04 165,05
Position:
Tolernce: 0,025
5
6
165,04 165,03
165,03 165,03
165,05 165,05
165,04 165,05
1
0,060
7
8
Measurement in: 0,01mm
9
10
165 mm
3
4
165,03 165,04
165,04 165,03
165,03 165,06
165,05 165,05
Position:
Tolernce: 0,025
5
6
165,03 165,03
165,04 165,04
165,05 165,05
165,05 165,05
4
0,060
7
8
Measurement in: 0,01mm
9
10
Crack testing:
Hardness:
REMARKS
05.05.2023
Date
C.G.
Checked by
Customer Representative
01.5 Measurement Report Cylinder Liner Protrusion
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583791
Our Order No.:
AU22/1522
A-Site
1
2
3
4
Ø
Nominal dim.:
1
8,04
8,04
8,05
8,05
8,05
8,04
8,04
8,04
8,04
8,04
8,04 mm
Tolernce:
3
4
5
8,04
8,04
8,04
8,04
8,04
8,04
8,04
8,04
8,04
8,04
8,05
8,04
8,04
8,04
8,04
8,04
8,05
8,04
8,04
8,04
8,04 mm
Tolernce:
3
4
5
8,04
8,05
8,04
8,04
8,04
8,04
8,04
8,05
8,04
8,04
8,05
8,04
8,04
8,05
8,04
2
0,000
6
8,04
8,04
8,04
8,04
8,04
0,020
7
Measurement in:
9
10
0,01mm
8
0,020
7
Measurement in:
9
10
0,01mm
8
B-Site
1
2
3
4
Ø
Nominal dim.:
1
8,06
8,05
8,05
8,06
8,06
2
0,000
6
8,04
8,04
8,04
8,04
8,04
REMARKS
04.05.2023
Date
C.G.
Checked by
Customer Representative
03.1 Measurement Report: Crankshaft
Customer:
Engine Type:
Engine No.:
0°
60°
300°
0°
60°
300°
Modern Power
12V396TE94
5583791
Nominal dim.:
I
II
140,98 140,97
140,97 140,97
140,98 140,97
Main Journals
141 mm
Tolernce: -0,039 -0,014
III
IV
V
VI
VII
140,97 140,97 140,97 140,97 140,97
140,97 140,97 140,97 140,98 140,97
140,97 140,98 140,97 140,97 140,97
Nominal dim.:
1
2
104,97 104,98
104,97 104,98
104,97 104,98
Crankpins
105 mm
Tolernce: -0,034 -0,012
3
4
5
6
7
104,97 104,97 104,97 104,97
104,98 104,98 104,97 104,97
104,98 104,98 104,97 104,97
Crack testing:
Hardness:
AU22/1522
Our Order No.:
VIII
Measurement in: 0,01mm
IX
X
XI
8
Measurement in: 0,01mm
9
10
OK
OK
REMARKS
03.05.2023
Date
C.Gasperic
Checked by
Customer Representative
03.2 Measurement Report: Crankshaft Bearings
Customer:
Engine Type:
Engine No.:
0°
60°
300°
Nominal dim.:
1
2
141,11 141,11
141,12 141,13
141,12 141,12
Modern Power
Our Order No.:
AU22/1522
12V396TE94
5583791
A-Site
141,11 mm
0
Tolerance:
3
4
5
6
141,11 141,11
141,11 141,11
141,13 141,13
141,14 141,14
141,14 141,13
141,12 141,13
0,054
7
141,11
141,13
141,12
8
Measurement in: 0,01mm
9
10
8
Measurement in: 0,01mm
9
10
B-Site
0°
60°
300°
Nominal dim.:
1
2
141,11 141,11
141,12 141,13
141,13 141,13
0
141,11 mm
Tolerance:
3
4
5
6
141,11 141,11
141,11 141,11
141,13 141,13
141,14 141,14
141,14 141,13
141,12 141,13
0,054
7
141,11
141,12
141,13
REMARKS
06.05.2023
Date
C.G.
Checked by
Customer Representative
03.3 Measurement Report Connecting Rods
Customer:
Modern Power
Engine Type:
Engine No.:
Nominal dim.:
1
2
Our Order No.:
AU22/1522
12V396TE94
5583791
112,00 mm
3
4
A-Site
Tolerance:
0,00
5
6
0,022
7
8
Measurement in: 0,01mm
9
10
0,022
7
8
Measurement in: 0,01mm
9
10
Nr.:
a1
b1
c1
a2
b2
c2
112,00
112,01
112,01
112,01
112,01
112,00
112,00
112,01
112,01
112,01
112,01
112,00
Nominal dim.:
1
2
112,00
112,01
112,00
112,01
112,01
112,00
112,00
112,02
112,01
112,01
112,01
112,00
112,00 mm
3
4
112,00
112,02
112,01
112,01
112,01
112,00
112,00
112,01
112,01
112,00
112,00
112,00
Tolerance:
5
B-Site
0,00
6
112,01
112,02
112,01
112,02
112,01
112,00
112,00
112,02
112,02
112,01
112,01
112,00
Nr.:
a1
b1
c1
a2
b2
c2
112,00
112,01
112,01
112,01
112,01
112,00
112,00
112,01
112,01
112,01
112,01
112,00
112,01
112,02
112,02
112,01
112,01
112,00
112,00
112,02
112,02
112,01
112,01
112,01
REMARKS
11.04.2023
Date
T.T.
Checked by
Customer Representative
03.3 Measurement Report Connecting Rods Bearing
Customer:
Engine Type:
Engine No.:
Nr.:
a1
b1
c1
a2
b2
c2
Nr.:
a1
b1
c1
a2
b2
c2
Modern Power
Our Order No.:
AU22/1522
12V396TE94
5583791
105,00 mm
Tolerance:
Nominal dim.:
1
2
3
4
5
AB707 AB514 AB560 AB554
AB557
105,02 105,02 105,01 105,02
105,01
105,02 105,02 105,02 105,01
105,02
105,01 105,01 105,01 105,02
105,01
105,02 105,02 105,01 105,02
105,01
105,02 105,02 105,02 105,01
105,02
105,01 105,01 105,01 105,02
105,01
A-Site
0,00
6
AB689
105,01
105,01
105,02
105,01
105,01
105,02
B-Site
105,00 mm
Tolerance:
0,00
Nominal dim.:
1
2
3
4
5
6
AB530 AB497 AB534 AB539
AB529
AB536
105,02 105,02 105,01 105,02
105,02 105,02
105,01 105,02 105,01 105,02
105,02 105,01
105,02 105,02 105,02 105,01
105,02 105,02
105,02 105,02 105,01 105,02
105,02 105,02
105,01 105,02 105,01 105,02
105,02 105,01
105,02 105,02 105,02 105,01
105,02 105,02
0,046
7
0
8
0
Measurement in: 0,01mm
9
10
0
0
0,046
7
0
8
0
Measurement in: 0,01mm
9
10
0
0
REMARKS
06.05.2023
Date
T.T.
Checked by
Customer Representative
03.7 Measurement Report: Piston
Modern Power
Customer:
AU22/1522
Our Order No.:
12V396TE94
Engine Type:
5583791
Engine No.:
Position 1
Nominal dim.:
A0°
164,782 mm
Tolerance:
-0,010
+0,010
7
1
2
3
4
5
6
164,772
164,772
164,772
164,772
164,772
164,782
Measurement in:
8
9
0,01mm
10
A90°
B0°
B90°
Position 2
Nominal dim.:
1
A0°
164,845
164,835 mm
2
164,835
Tolerance:
-0,011
+0,011
7
3
4
5
6
164,825
164,825
164,825
164,835
Measurement in:
8
9
0,01mm
10
A90°
B0°
B90°
REMARKS
06.05.2023
Date
C.G.
Checked by
Customer
Representative
03.8 Measurement Report Piston Pin
Customer:
Modern Power
Engine Type:
Engine No.:
A
0°
90°
0°
90°
A
0°
90°
0°
90!
Nominal dim.:
1
2
60,00
60,00
60,00
60,00
60,00
60,00
60,00
60,00
Nominal dim.:
1
2
60,07
60,07
60,08
60,08
60,07
60,08
60,07
60,08
Our Order No.:
AU22/1522
12V396TE94
5583791
60,00 mm
3
4
60,00
60,00
60,00
60,00
60,00
60,00
60,00
60,00
60,00 mm
3
4
60,07
60,07
60,08
60,08
60,07
60,08
60,07
60,08
Piston Pin
Tolerance: -0,005
5
6
60,00
60,00
60,00
60,00
B-Site
60,00
60,00
60,00
60,00
0,000
7
Piston Pin Bearing
0,080
Tolerance: 0,070
5
6
7
60,07
60,07
60,08
60,08
B-Site
60,07
60,07
60,08
60,08
8
Measurement in: 0,01mm
9
10
8
Measurement in: 0,01mm
9
10
REMARKS
06.05.2023
Date
T.T.
Checked by
Customer Representative
03.9 Measurement Report Piston Protrusion
Customer:
H
H
Modern Power
Our Order No.:
Engine Type:
Engine No.:
12V396TE94
5583791
Nominal dim.:
1
2
8,390
8,320
8,390
8,320
8,00 mm
Tolerance:
3
4
5
8,410
8,400
8,340
8,410
8,400
8,340
A-Site
0,160
6
8,420
8,420
Nominal dim.:
1
2
8,460
8,370
8,460
8,370
8,00 mm
Tolerance:
3
4
5
8,420
8,370
8,320
8,420
8,370
8,320
B-Site
0,160
6
8,350
8,350
0,520
7
0,520
7
AU22/1522
8
Measurement in: 0,01mm
9
10
8
Measurement in: 0,01mm
9
10
REMARKS
08.05.2023
Date
R.S.
Checked by
Customer Representative
05.1 Measurement Report Cylinder Head
Customer:
Engine Type:
Engine No.:
H
O
H
O
Modern Power
Our Order No.:
AU22/1522
12V396TE94
5583791
Nominal dim.:
1
2
142,30 142,30
Nominal dim.:
1
2
28,00
28,04
A-Site
142,00 mm
Tolerance:
0,00
3
4
5
6
142,50 142,60
142,30 142,30
27,90 mm
Tolerance:
0,00
3
4
5
6
27,94
28,02
28,00
28,00
Nominal dim.:
1
2
142,20 142,30
Nominal dim.:
1
2
27,99
28,00
B-Site
0,00
6
142,20
0,00
6
28,00
142,00 mm
Tolerance:
3
4
5
142,30 142,20
142,10
27,90 mm
Tolerance:
3
4
5
28,00
28,00
28,00
1,00
7
8
Measurement in: 0,01mm
9
10
0,20
7
8
Measurement in: 0,01mm
9
10
1,00
7
8
Measurement in: 0,01mm
9
10
0,20
7
8
Measurement in: 0,01mm
9
10
REMARKS
06.05.2023
Date
T.W.
Checked by
Customer Representative
05.2 Measurement Protocol: Cylinder Head Valve Protrusion
Customer:
Modern Power
Our Order No.:
Engine Type:
Engine No.:
12V396TE94
5583791
Nominal dim.:
1
2
1,10
1,10
1,10
1,10
0,50 mm
3
4
1,10
1,10
1,10
1,10
Tolerance:
5
1,10
1,10
A-Site
-0,15
6
1,10
1,10
Nominal dim.:
1
2
0,40
0,40
E
0,40
0,40
0,00 mm
3
4
0,40
0,40
0,40
0,40
Tolerance:
5
0,40
0,40
-0,15
6
0,40
0,40
Nominal dim.:
1
2
1,10
1,10
1,10
1,10
0,50 mm
3
4
1,10
1,10
1,10
1,10
Tolerance:
5
1,10
1,10
B-Site
-0,15
6
1,10
1,10
Nominal dim.:
1
2
0,40
0,40
E
0,40
0,40
0,00 mm
3
4
0,40
0,40
0,40
0,40
Tolerance:
5
0,40
0,40
-0,15
6
0,40
0,40
I
I
AU22/1522
1,90
7
8
Measurement in: 0,01mm
9
10
2,60
7
8
Measurement in: 0,01mm
9
10
1,90
7
8
Measurement in: 0,01mm
9
10
2,60
7
8
Measurement in: 0,01mm
9
10
REMARKS
07.06.2023
Date
C.G.
Checked by
Customer Representative
Test Run Report
7. Test Run Report
44
W6 Maintenance Report
For
Modern Power Marine Services Co.
MTU Diesel Engine Type 12V396TE94
Order Number: AU22/1489
Engine Serial No: 5583792
Table of Content
List of Figures ................................................................................................................................... 3
1.
Technical Detail................................................................................................................. 4
2.
Maintenance........................................................................................................................ 5
2.1.
Group 01 – Crankcase ................................................................................. 5
2.2.
Group 02 – Gear Train ................................................................................ 8
2.3.
Group 03 – Running Gear ............................................................................ 8
2.4.
Group 04 – Cover Plate at KGS .................................................................. 13
2.5.
Group 05 – Cylinder head ......................................................................... 15
2.6.
Group 06 – Control System ....................................................................... 17
2.7.
Group 07 – Engine Governor ..................................................................... 20
2.8.
Group 09 – Exhaust Turbocharge .............................................................. 21
2.9.
Group 10 – Charge Air Piping – Exhaust Piping ......................................... 23
2.10. Group 11 – Injection System ..................................................................... 26
2.11. Group 12 – Fuel System ............................................................................ 27
2.12. Group 13 – Water Pump ............................................................................ 28
2.13. Group 14 – Coolant System ....................................................................... 29
2.14. Group 15 – Oil Pump................................................................................. 30
2.15. Group 16 – Oil System .............................................................................. 30
2.16. Group 18 – Starting Equipment ................................................................. 31
2.17. Group 19 – Engine Mounting..................................................................... 32
2.18. Group 84 – Monitoring Equipment ............................................................ 32
2.19. Group 86 – Accessories (electric, pneumatic) ............................................ 33
2.20. Group 88 – Accessories (mechanical) ........................................................ 34
3.
Performance Test .......................................................................................................... 35
4.
Pictures of complete Engine ..................................................................................... 37
5.
Annex A ............................................................................................................................. 42
6.
Measurement Report .................................................................................................... 43
7.
Test Run Report ............................................................................................................. 44
List of Figures
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
1: Crankcase after machining........................................................................ 5
2: Crankcase after machining (2)................................................................... 6
3: Crankshaft Bearings .................................................................................. 7
4: Crankshaft ................................................................................................ 9
5: Piston and connecting Rod ...................................................................... 10
6: Vibration Damper before mounting ......................................................... 11
7: Overhauled Intake of Vibration Damper .................................................. 12
8: Engine KGS View ..................................................................................... 13
9: Mounted cover plate on KGS ................................................................... 14
10: Machined and mounted Cylinder Head .................................................. 15
11: Cylinder Heads while assembly ............................................................. 16
12: Camshaft Bearing.................................................................................. 17
13: Gear Case on top of Cylinder Heads ...................................................... 18
14: Assembled Gear Case ........................................................................... 19
15: Engine Governor mounted to Injection Pump ........................................ 20
16: Fully mounted Turbocharger ................................................................. 21
17: Replaced Components inside the Turbocharger .................................... 22
18: Carrier Housing .................................................................................... 23
19: Mounted plug-in Pipes on Turbochargers .............................................. 24
20: Mounted Charge Air Manifold ............................................................... 25
21: Mounted overhauled Injection Pump ..................................................... 26
22: Fuel System Pipes ................................................................................. 27
23: Assembled Water Pump ........................................................................ 28
24: Plate Cooler .......................................................................................... 29
25: Overhauled Starting Equipment ............................................................. 31
26: Actuator ............................................................................................... 33
27: Overhauled Coupling ............................................................................ 34
28: Engine on the Test Bench ...................................................................... 36
29: Engine prepared for Painting ................................................................. 38
30: Final painted Engine.............................................................................. 39
31: Final painted Engine (2) ........................................................................ 40
32: Painted Details ...................................................................................... 41
3
1. Technical Detail
Manufacturer
MTU
Model
12V396TE94
Serial No.:
5583792
Application area
Coast Guard
Rotational speed
2000 1/min
Power
1680 kW
4
Maintenance
2. Maintenance
In the following section, maintenance is devided into individual assemblies.
2.1.





Group 01 – Crankcase
Disassembly of crankcase
Cleaning crankcase
Inspection of crankcase in respect of cracks
o No damage found
Dimensional inspection of main bearing bore, cylinder liner bore and
camshaft bores. (refer to attached measurement report)
o All main bearing pockets without defects
o Both top decks have been surface milled
o Cylinder liner bore has been drilled to stage 1-1
Inspection of cylinder liners
o Damage found
o All cylinder liners have been replaced
Figure 1: Crankcase after machining
5
Maintenance
Figure 2: Crankcase after machining (2)
6
Maintenance
Figure 3: Crankshaft Bearings
7
Maintenance
2.2.





Disassembly of gear train
Cleaning of gear train components
Inspection of gear wheels in respect of damages
o No Damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of gear train
2.3.



Group 02 – Gear Train
Group 03 – Running Gear
Disassembly of running gear
Cleaning of running gear components
Replacement of all standard W6 components
o Refer to ANNEX A
8
Maintenance
Crankshaft

Inspection of crankshaft dimensions, crack test and hardness (refer to
attached measurement report).
o No damage found
Figure 4: Crankshaft
9
Maintenance
Pistons




Disassembly of pistons
Cleaning
Inspection of all pistons
o Damage found
o Replacement of all 12 pistons necessary, refer to inspection report
All 12 pistons were replaced
Connecting Rods

Dimensional inspection of all connecting rods
o No damage found
o Refer to attached measurement report
Figure 5: Piston and connecting Rod
10
Maintenance
Vibration Damper


Disassembling of the vibration damper
Dimensional inspection of all parts
o No damage found
Figure 6: Vibration Damper before mounting
11
Maintenance
Figure 7: Overhauled Intake of Vibration Damper
12
Maintenance
2.4.




Group 04 – Cover Plate at KGS
Disassembly of cover plate
Cleaning of all cover plate components
Inspection of cover plate components
Replacement of all standard W6 components
o Refer to ANNEX A
Figure 8: Engine KGS View
13
Maintenance
Figure 9: Mounted cover plate on KGS
14
Maintenance
2.5.








Group 05 – Cylinder head
Disassembly of cylinder heads
Cleaning of cylinder heads and components
Visual inspection of cylinder heads (Refer to attached measurement report)
Dimensional machining of surfaces and valve seats
Replacement of all valve guides
Replacement of one cylinder head
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of cylinder head
Figure 10: Machined and mounted Cylinder Head
15
Maintenance
Figure 11: Cylinder Heads while assembly
16
Maintenance
2.6.





Group 06 – Control System
Disassembly of camshafts
Cleaning of all control system component
Camshaft bearings were replaced (see figure 12)
Replacement of all standard W6 components
o Refer to ANNEX A
Assembly of control system components
Figure 12: Camshaft Bearing
17
Maintenance
Figure 13: Gear Case on top of Cylinder Heads
18
Maintenance
Figure 14: Assembled Gear Case
19
Maintenance
2.7.






Group 07 – Engine Governor
Disassembly of engine governor
Cleaning of all governor components
Visual inspection of all components
Actuator has been replaced
Replacement of all standard W6 components
o Refer to ANNEX A
Assembly of engine governor
Figure 15: Engine Governor mounted to Injection Pump
20
Maintenance
2.8.







Group 09 – Exhaust Turbocharge
Disassembly of turbochargers
Cleaning of all turbocharger components
Visual inspection of all components
Cracks in the turbocharger housings have been welded
Radiant discs and compressor wheels have been replaced
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 16: Fully mounted Turbocharger
21
Maintenance
Figure 17: Replaced Components inside the Turbocharger
22
Maintenance
2.9.





Group 10 – Charge Air Piping – Exhaust Piping
Disassembly of all components
Cleaning of all components
Visual inspection of all components
o No damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 18: Carrier Housing
23
Maintenance
Figure 19: Mounted plug-in Pipes on Turbochargers
24
Maintenance
Figure 20: Mounted Charge Air Manifold
25
Maintenance
2.10.






Group 11 – Injection System
Disassembly of all unit injectors
Cleaning of all components
Inspection and overhaul of all injectors
Inspection of fuel delivery pump
o Valves have been replaced
o Fuel delivery pump has been overhauled
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 21: Mounted overhauled Injection Pump
26
Maintenance
2.11.






Group 12 – Fuel System
Disassembly of fuel system components
Cleaning of fuel system components
Visual inspection
Replacement of both fuel pipes and oil return line
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 22: Fuel System Pipes
27
Maintenance
2.12.






Group 13 – Water Pump
Disassembly of coolant and seawater pump
Cleaning of all water pump components
Visual inspection
Replacement of seawater impeller and drive shaft
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 23: Assembled Water Pump
28
Maintenance
2.13.





Group 14 – Coolant System
Disassembly of coolant system
Cleaning of all components
Visual inspection
Replacement of all standard W6 parts
o Refer to ANNEX A
Assembly of all components
Figure 24: Plate Cooler
29
Maintenance
2.14.




Disassembly of oil pump
Cleaning of all components
Visual inspection
o No damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
2.15.




Group 15 – Oil Pump
Group 16 – Oil System
Disassembly of the oil system
Cleaning of all components
Visual inspection
o No damage found
Replacement of all standard W6 parts
o Refer to ANNEX A
30
Maintenance
2.16.




Group 18 – Starting Equipment
Disassembly of the starting equipment
Cleaning of all components
Inspection and overhaul of the starter
Replacement of all standard W6 parts
o Refer to ANNEX A
Figure 25: Overhauled Starting Equipment
31
Maintenance
2.17.



Disassembly of the engine mounting
Cleaning of all components
Visual inspection
o Cover plate has been replaced
2.18.



Group 19 – Engine Mounting
Group 84 – Monitoring Equipment
Disassembly of the monitoring equipment
Cleaning of all components
Checking of all cables and sensors
o No damage found
32
Maintenance
2.19.


Group 86 – Accessories (electric, pneumatic)
Disassembly of the actuator
Cleaning of all components
o Actuator has been replaced
Figure 26: Actuator
33
Maintenance
2.20.



Group 88 – Accessories (mechanical)
Disassembly of the coupling
Cleaning of all components
Inspection and overhaul of the coupling
Figure 27: Overhauled Coupling
34
Perormance Test
3. Performance Test
35
Perormance Test
Test Run
The engine test run at test bench facilities of Zeppelin Power Systems CAT in Achim,
Germany was performed successfully on 17. May 2023. Test Run Report attached in
Chapter “6. Test Run Report”.
Figure 28: Engine on the Test Bench
36
Complete Engine
4. Pictures of complete Engine
37
Complete Engine
Figure 29: Engine prepared for Painting
38
Complete Engine
Figure 30: Final painted Engine
39
Complete Engine
Figure 31: Final painted Engine (2)
40
Complete Engine
Figure 32: Painted Details
41
Annex A
5. Annex A
42
Pos.-No.
Part No.
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
700429340000
5580130580
700429270001
5580140580
5500140280
271511022001
271511022000
5580110380
5550140380
700429050003
700429166000
5909970440
0000110032
700429075002
5550110159
5500110680
700429037001
700429105001
700429100001
5500140380
700327018000
700429020000
700429015000
700429105000
700368035001
900288046008
700368028002
900288037003
700327035000
0000181802
0009813527
205412223003
700429084000
0009818801
205412203014
700429105001
700429175001
0080376419
0080376319
0090378518
5559901919
5550330130
5509810725
700429330000
8700380171
700429045000
700429400000
700429220001
5591870680
5550161420
5500160432
5500160119
700429009002
O-RING
GASKET
O-RING
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
O-RING
O-RING
SEALING RING
COVER
O-RING
SEALING RING
FOR CYLINDER LINER
GASKET
O-RING
O-RING
O-RING
GASKET
GROMMET
O-RING
O-RING
O-RING
SLEEVE RUBBER
CLAMP
RUBBER SLEEVE
CLAMP
GROMMET
OIL FILL CAP
ANGLR-CONT BALL BRG
CYL.ROLLER BEARING
O-RING
CYL ROLLER BEARING
CYL ROLLER BEARING
O-RING
O-RING
RECTANGLR-SECT RING
TAPER FACE COMP RING
OIL CONTROL RING
SCREW
CRANKSHAFT BEARING SIZE 0-0
GROOVED BALL BEARING SIZE 0
O-RING
CONROD BOLT
O-RING
O-RING
O-RING
GASKET
CYLINDER HEAD GASKET
PIPE
SEALING RING
O-RING
Qty.
1
3
1
2
2
1
4
1
1
2
1
2
12
2
12
1
4
1
1
6
2
2
2
1
1
2
1
2
3
2
2
2
1
1
1
1
1
12
12
12
24
1
1
1
24
2
1
1
1
12
96
96
24
Pos.-No.
Part No.
Description
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
700429036001
700429040003
700429021000
700429014000
0029977940
5559970344
5500170260
0000170660
700429033000
0000533635
5500530020
5500530022
0000530126
0000530361
700429030001
5550510118
8695860397
700429009002
700429260000
5500160121
700429006000
0009940254
5050613280
700217014004
200625900002
5550630180
700429084000
700429013001
916016012200
700429032000
0005332275
700429168001
X00043045
700429031000
5100200212
700429105001
700429005001
5100850160
5100850260
5090850060
XT1310100444
700429210000
700429042001
X00011067
5110200412
5110850560
5110850460
5100850060
XT3510100217
700429270001
5119940330
700429120002
700429126000
O-RING
O-RING
O-RING
O-RING
SEALING RING
SEALING RING
SUPPORT RING
RING
O-RING
VALVE ROTATOR
VALVE SPRING
OUTER
VALVE SPRING
INNER
VALVE COLLET
VALVE STEM SEAL
O-RING
CAMSHAFT BEARING
SIZE 0-0
REPAIR KIT
O-RING
O-RING
GASKET
O-RING
CLAMPING RING
GASKET
SHAFT SEAL
GROOVED BALL BEARING
GASKET
O-RING
O-RING
CLAMP
O-RING
CLAMP
O-RING
BEARING BUSHING
O-RING
THRUST BEARING
O-RING
O-RING
PISTON RING
PISTON RING
PISTON RING
MAGNETIC NUT
O-RING
O-RING
BEARING BUSHING
THRUST BEARING
RING SEAL
PISTON RING
RING SEAL
MAGNETIC NUT
O-RING
TAB WASHER
O-RING
O-RING
Qty.
24
24
28
16
48
12
12
12
24
48
48
48
96
3
12
2
24
24
12
12
24
24
2
2
3
2
3
4
2
1
1
1
2
1
1
3
1
1
1
2
1
1
2
4
2
2
2
4
2
2
12
4
6
Pos.-No.
Part No.
Description
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
700429017000
700429083000
700429115000
700429108000
700429120001
5601400441
5101400241
700429100000
700429188001
700429032000
5590981380
700429142000
700429270001
5590982680
5590982580
700327010000
5530981580
0229979982
5500980280
700429028001
5500981680
0039970490
0019960040
0030947404
8699970084
0009966445
0009966345
X00048307
5569940330
700429032003
X00048305
0049976736
5841420857
114C62033/1
700429006002
700429172000
700429190001
700429162000
5591420451
700429015000
5531420158
0001401487
0035317483
700386017000
700429025001
700429020000
8690940016
700429009002
700429019000
700429120001
700429042001
0020172112
0009922130
O-RING
O-RING
O-RING
O-RING
O-RING
CLAMP
CLAMP
O-RING
O-RING
O-RING
SEALING RING
O-RING
O-RING
GASKET
GASKET
GROMMET
GASKET
AIR HOSE
GASKET
O-RING
GASKET
V-BAND COUPLING
ARTICULATED BEARING
AIR FILTER ELEMENT
O-RING
SWIVEL HEAD
SWIVEL HEAD
RTV
TAB WASHER
O-RING
SEALANT
VALVE DRAIN
SEALING RING
SEALING RING
O-RING
O-RING
O-RING
O-RING
RING SEALING
O-RING
CENTERING RING
DAMPER ELEMENT
GASKET
SEAL SHAFT AS
O-RING
O-RING
CARTRIDGE
O-RING
O-RING
O-RING
O-RING
HOLE-TYPE NOZZLE
CLAMPING ELEMENT
Qty.
42
2
2
8
8
2
2
2
2
2
2
2
2
2
2
3
2
1
12
12
4
6
2
1
2
1
2
1
24
16
1
2
2
2
8
2
4
4
1
1
2
4
4
4
4
2
1
2
2
1
1
12
2
Pos.-No.
Part No.
Description
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
700429105001
200625906316
700429075002
8695860101
8699970117
8699970098
8699810014
8699970115
0149974747
8690740143
8699970101
8699970102
8690740312
700429019000
700429024000
0049979447
700429105001
700429009002
700429015000
5550900350
5550780538
5500781253
700429004000
5370780038
700327006000
8699970630
8591810110
8591810140
8699970053
700327012000
0002375712
735038006102
700327008000
700429014002
700429027001
0049976736
700429038001
8499970970
0000921705
700294014005
700294125000
700327018000
700327015000
8699970231
8690920032
0000925105
8690920039
8690920033
8690920038
X00E50203662
705100502035
5502010280
700429100001
O-RING
GROOVED BALL BEARING
O-RING
SET OF SHIMS
O-RING
O-RING
TAPERED ROLLER BRG
O-RING
SEALING RING
SHAFT SEAL
O-RING
O-RING
GASKET
O-RING
O-RING
SHAFT SEAL
O-RING
O-RING
O-RING
FUEL PRIMING PUMP
DAMPER STRIP
SLEEVE
O-RING
DAMPER STRIP
GROMMET
RADIAL-LIP OIL SEAL
BEARING BUSH
BEARING BUSH
SEALING RING
GROMMET
BUFFER
HOSE
GROMMET
O-RING
O-RING
VALVE DRAIN
O-RING
GASKET
FUEL FILTER ELEMENT
O-RING
O-RING
GROMMET
GROMMET
SEALING RING
GASKET
FILTER ELEMENT
GASKET
GASKET
COCK
LEVEL MONITOR
BEARING CYLINDRICAL ROLLER
GASKET
O-RING
Qty.
4
1
1
12
12
12
2
1
1
1
4
12
1
2
1
1
1
1
6
1
12
83
12
12
9
1
4
1
2
13
4
1
8
1
2
1
3
1
2
2
2
2
3
2
2
2
8
2
2
2
2
1
2
Pos.-No.
Part No.
Description
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
700429085000
0002017519
0079977247
0009813527
270952035101
700429046000
0002010418
700429150001
000625900175
0049979947
8692040020
700429057000
5552040580
0039978648
8692040050
5562031180
5582031580
000625900178
0079978047
700429165000
700429083000
5582031680
0002040479
0002040263
0002040716
0039977848
700429230000
705100502035
5502010280
700429100001
700429085000
0002017519
0079977247
0009813527
270952035101
700429046000
0002010418
700429150001
000625900175
0049979947
8692040020
700429057000
5552040580
0039978648
8692040050
5562031180
5582031580
000625900178
0079978047
700429165000
700429083000
5582031680
0002040479
O-RING
ROTARY SEAL
SHAFT SEAL
ANGLR-CONT BALL BRG
TAB WASHER
O-RING
COUNTERRING
O-RING
BEARING BALL GROOVED 62
SEAL SHAFT
GAITER
O-RING
GASKET
SEAL ROTARY PUMP
GASKET
GASKET
GASKET
GROOVED BALL BRG
SHAFT SEAL
O-RING
O-RING
GASKET
GAITER
COUNTERRING
ROTARY SEAL
O-RING
O-RING
BEARING CYLINDRICAL ROLLER
GASKET
O-RING
O-RING
ROTARY SEAL
SHAFT SEAL
ANGLR-CONT BALL BRG
TAB WASHER
O-RING
COUNTERRING
O-RING
BEARING BALL GROOVED 62
SEAL SHAFT
GAITER
O-RING
GASKET
SEAL ROTARY PUMP
GASKET
GASKET
GASKET
GROOVED BALL BRG
SHAFT SEAL
O-RING
O-RING
GASKET
GAITER
Qty.
1
1
1
2
1
1
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
Pos.-No.
Part No.
Description
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
0002040263
0002040716
0039977848
700429230000
5552031150
700429075002
700429070000
5502030060
5502032080
5552031780
5552031880
700429024002
700429028002
5552031980
5562030980
700327010000
700368042004
900288054005
700327006000
700429060000
700429055001
5562030880
700429056001
5562031380
700429048001
5592032680
0002035483
0002035583
0002035183
700429065000
5502035880
5501425880
700429042000
5552000188
700429010000
700429090000
0049979040
0002033288
700429075001
700429080005
700429175000
700429006003
700429011001
5592001351
5592010180
5582004658
5582001263
0049976736
5532031880
700429057001
700429045000
700429040003
700368042002
COUNTERRING
ROTARY SEAL
O-RING
O-RING
BUSHING
O-RING
O-RING
SIGHT GLASS
GASKET
GASKET
GASKET
O-RING
O-RING
GASKET
GASKET
GROMMET
SLEEVE RUBBER
CLAMP
GROMMET
O-RING
O-RING
GASKET
O-RING
GASKET
O-RING
GASKET
RUBBER BELLOWS
BELLOWS RUBBER 125 D N 210 BOLT CIRCLE
RUBBER BELLOWS
O-RING
GASKET
GASKET
O-RING
STRAINER
O-RING
O-RING
OIL CONTROL RING
ACTUATOR
O-RING
O-RING
O-RING
O-RING
O-RING
VENT PIPE
GASKET
VENT LINE
DRAIN LINE
VALVE DRAIN
GASKET
O-RING
O-RING
O-RING
RUBBER SLEEVE
Qty.
1
1
1
1
3
6
3
2
4
3
1
1
1
3
1
11
1
2
7
1
8
2
1
1
8
1
1
1
1
4
4
2
4
2
1
5
2
1
4
2
1
1
5
1
3
1
1
1
1
1
4
4
1
Pos.-No.
Part No.
Description
324
325
326
327
328
329
330
331
332
333
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
900288053004
700327022000
5582031280
0039977748
5582031380
0002033980
8499970052
8499970053
202690040000
8692030074
8692030074
8699970175
8699970176
700429031000
0011808901
700429042000
700429037001
700429030004
735038025103
735038016103
8695860309
8695860311
700429070002
8699970277
8699970140
8699970278
700292004300
700429037001
0002373726
0139971982
0139972982
0009975389
0009975489
705057013000
700429028002
0002372011
735038008118
735038008106
700327010000
0001840681
700294115001
0001847780
735038020104
5501870980
700327012000
700429015004
700327006000
700327004000
700429017000
700429021000
5550740780
5500180280
5600511280
CLAMP
GROMMET
GASKET
O-RING
GASKET
SEALING RING
GASKET
GASKET
GASKET
GASKET
GASKET
GASKET
GLAND PACKING
O-RING
OIL PUMP
O-RING
O-RING
O-RING
HOSE
HOSE
GASKET KIT
COMPLETE
PARTS KIT
COMPLETE
O-RING
SEALING RING
O-RING
SEALING RING
TAB WASHER
O-RING
RESILIENT ELEMENT
HOSE
HOSE
QUICK-DISCONNECT CPL
SEALING NIPPLE
RING SEALING A13 X18 CU
O-RING
RESILIENT ELEMENT
HOSE
HOSE
GROMMET
GAITER
O-RING
GASKET
HOSE
GASKET
GROMMET
O-RING
GROMMET
GROMMET
O-RING
O-RING
GASKET
GASKET
GASKET
Qty.
2
3
1
2
1
3
34
33
4
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
2
2
3
2
3
1
5
4
1
1
12
1
1
1
1
1
4
4
10
2
5
2
1
2
1
Pos.-No.
Part No.
Description
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
420
421
422
423
424
425
426
427
428
429
700429126000
700429063000
5501800016
8699970059
5582031880
700429020003
0049976736
700429060000
700429042000
700429042001
700429032003
700429036001
700429055001
5591880180
5591880280
700429030004
700429033001
5551880980
700429030002
700429055002
700429009005
8691840024
700429006001
700327006000
700327012000
0019970648
700429090002
5561750680
8691700001
0001750080
8691700170
11.28068-2001
0005863615
0005863215
0001515214
000625916011
0019819325
0001510085
0001510185
0019972747
0029816501
5559970344
700327022000
735038020105
5582370012
0002370612/87
X59623300108/87
700327010000
916016006202
916016008202
916016010203
916016012201
916016018202
O-RING
O-RING
OIL FILTER ELEMENT
SEAL RING
GASKET
O-RING
VALVE DRAIN
O-RING
O-RING
O-RING
O-RING
O-RING
O-RING
GASKET
GASKET
O-RING
O-RING
GASKET
O-RING
O-RING
O-RING
RATCHET
O-RING
GROMMET
GROMMET
O-RING
O-RING
GASKET
DISTRIBUTOR DISC
GASKET
BUSHING
BUSHING
PARTS KIT
PARTS KIT
CARBON BRUSH KIT
GROOVED BALL BEARING
BALL BEARING
GAITER
LUBRICATING WICK
OIL SEAL
CYL ROLLER BEARING
SEALING RING
GROMMET
HOSE
RUBBER RING
CONICAL BEARING
STOP PLATE
GROMMET
CLAMP
CLAMP
CLAMP
CLAMP
CLAMP
Qty.
4
4
4
4
1
10
2
3
6
8
2
2
4
2
2
2
2
2
4
2
4
2
2
18
68
1
1
2
1
1
1
2
2
2
1
1
1
1
1
1
1
12
1
1
4
8
4
6
15
25
5
14
5
Pos.-No.
Part No.
Description
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
482
483
0002372712
916016024201
916016016201
0139972382
0009975389
916016008200
916016010205
916016014201
916016014200
916016020202
916016022202
916016028200
0005353960
0005356760
X00006134
0005350703
0005350132
0000940568
0005352730
0055351331
700386060000
207753310000
0052501101
X00E50210016
XP55800600012
8695860331
700429017001
700429009004
0002346203
700429100001
700429220001
0189978747
700429270001
0149975547
700429380000
700429300000
700429330000
700429610000
200628070000
5582534542
0189978947
700429260000
700429160001
5550111170
5550111070
5371810150
5371810050
0000911010
0000745884
0000746184
5590900375
700429030004
5501801015
RUBBER MOUNT
CLAMP
CLAMP
HOSE
QUICK-DISCONNECT CPL
CLAMP
CLAMP
CLAMP
CABLE CLAMP BRSGU 14/25
CLAMP
CLAMP
CLAMP
THERMOCOUPLE
THERMOCOUPLE
PRESSURE MONITOR
LEVEL MONITOR
LEVEL MONITOR
CONTAM. INDICATOR
TEMPERATURE SENSOR
PRESSURE SENSOR
SHAFT SEAL
V-BELT KIT
COUPLING
POSITION MONITOR
ROTOR
COMPLETE
REPARATURSATZ
O-RING
O-RING
COUPLING
O-RING
O-RING
RADIAL-LIP SHFT SEAL
O-RING
RADIAL-LIP SHFT SEAL
O-RING
O-RING
O-RING
O-RING
ANG. CONT. BALL BRG.
RING
SEAL REAR CRANKSHAFT
O-RING
O-RING
STUD
STUD
BUSHING
BEARING BUSHING
VALVE
VALVE
VALVE
NON-RETURN VALVE
O-RING
PRESS RELIEF VALVE
Qty.
7
5
10
1
1
1
5
4
2
5
1
1
8
4
2
1
1
1
3
2
2
1
1
1
1
1
2
4
4
1
1
1
1
1
1
1
1
1
2
1
1
1
1
14
14
1
3
1
1
1
1
1
1
Pos.-No.
Part No.
Description
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
504
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
271511022001
8699970226
5561880280
000472080000
5550302160
0019960040
5500100061
5500180280
700429050004
700429040004
700429006001
8695860331
007603038101
700429030004
007993040200
000912004002
5085301934
700429006000
5550302160
5550307540
5531870224
006885004002
5501872401
5551800022
5551800122
5501870169
000443050002
5580702373/87
5580702473/87
5371810150
5371810050
5582040406
5582000002
5509901019
5110258201
5100253901
5100810903
5100820626
5550160095
5502370865
5550301618
8591840170
X55699100239
5552035639
8699970630
700429009002
8690740393
0149974747
GASKET
1
SEALING RING
6
GASKET
2
RING SNAP
1
CONROD BEARING
SIZE 0-0
9
ARTICULATED BEARING
1
OIL SEPARATOR
1
GASKET
2
O-RING
1
O-RING
2
O-RING
2
REPARATURSATZ
1
COPPER SEALING RING
1
O-RING
1
SNAP RING
1
BOLT HEX SOC HD
8
CABLE
COMPLETE
1
O-RING
4
CONROD BEARING
SIZE 0-0
3
CRANKSHAFT BEARING SIZE 0-0
7
ELBOW
1
KEY
1
#N/A
12
OIL LINE USED
7
OELLEITUNG
1
SCREW-FITTING UNION
1
COVER
1
HP FUEL LINE
FOR CYLINDER B4
1
HP FUEL LINE
FOR CYLINDER B5
1
BUSHING
1
BEARING BUSHING
3
IMPELLER
1
DRIVE SHAFT
1
STRESS BOLT
1
COMPRESSOR WHEEL
1
COMPRESSOR WHEEL
1
HEAT SHIELD
1
HEAT SHIELD
1
SPACER PLATE USED
1
COVER PLATE
1
PISTON
12
SCREW
1
ACTUATING CYLINDER
1
FLANGE
1
RADIAL-LIP OIL SEAL
1
O-RING
1
VALVE
12
SEALING RING
1
Begutachtung Kurbelgehäuse VIERTEL-Motoren Nürnber 1
O-RING
1
RING SNAP
1
GAITER
1
O-RING
2
530
531
532
533
534
535
536
537
538
8699970115
000472080000
0002040479
700429032003
Qty.
Pos.-No.
Part No.
Description
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
70A
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
5371810150
5371810050
700429030004
271511022001
5500511710
5550114910
5110200278
5500511710
700429042001
700429120001
700429009004
5500530401
200933008008
200934008002
000835010062
000835010074
000007012221
000007012221
700429190001
700429162000
0000530361
5550534244
5559901440
007993014100
700429165000
5550532744
8389900919
8389901019
070952024100
5550534244
8372010072
5550170553
5532031880
700429100001
700429083000
5550162320
5550533244
5550532744
700294024000
5550105241/87
0010610200
5502035880
0000170023
5550170553
0005313185
5561420157
5559900104
700429165000
5841420753
700429017000
700429006001
206925006000
5590900375
BUSHING
BEARING BUSHING
O-RING
GASKET
CAMSHAFT BEARING
CYLINDER LINER
SIZE 1-1
VALVE
CAMSHAFT BEARING
O-RING
O-RING
O-RING
INLET VALVE
HEX SCREW
HEX NUT
STUD
STUD
DOWEL PIN
DOWEL PIN
O-RING
O-RING
VALVE STEM SEAL
VALVE GUIDE
INLET, SIZE 0
ADJUSTING WASHER
SNAP RING
O-RING
VALVE GUIDE
EXHAUST, SIZE 0
STRESS BOLT
STRESS BOLT
TAB WASHER
VALVE GUIDE
INLET, SIZE 0
BRACKET
PRESSURE SLEEVE
GASKET
O-RING
O-RING
CYLINDER HEAD GASKET
VALVE GUIDE
INLET, SIZE 0
VALVE GUIDE
EXHAUST, SIZE 0
O-RING
CYLINDER HEAD
W/VALVE
ACTUATOR
GASKET
SPRING PIN
PRESSURE SLEEVE
MALE CONNECTOR
SEALING RING
SCREW
O-RING
SLEEVE
O-RING
O-RING
HEX NUT
NON-RETURN VALVE
Qty.
1
3
1
1
13
12
6
1
1
1
4
24
1
1
12
8
5
2
1
1
21
4
1
4
1
4
9
10
1
1
2
3
1
1
1
12
4
3
2
2
1
4
4
3
1
2
1
1
2
6
2
1
1
Pos.-No.
Part No.
Description
591
592
593
594
595
596
597
000912010016
000931010257
0020172112
5550170553
700327018000
8699970153
8699970152
BOLT HEX SOC HD
HEX SCREW
HOLE-TYPE NOZZLE
PRESSURE SLEEVE
GROMMET
GASKET
GASKET
Qty.
1
1
5
1
3
1
1
Measurement Reports
6. Measurement Report
43
05.2 Messprotokoll: Zylinderkopf Ventilüberstand
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Our Order No.:
Nominal dim.:
1
2
1,82
1,07
1,72
1,33
0,50 mm
3
4
1,54
2,08
2,12
2,03
Tolerance:
5
1,44
1,37
A-Site
-0,15
6
1,78
1,73
Nominal dim.:
1
2
0,95
1,54
E
0,87
1,58
0,00 mm
3
4
0,65
0,83
0,91
2,04
Tolerance:
5
1,27
2,06
-0,15
6
0,55
1,86
Nominal dim.:
1
2
1,44
1,08
2,23
1,19
0,50 mm
3
4
0,57
1,78
0,55
0,93
Tolerance:
5
0,57
0,55
B-Site
-0,15
6
0,81
0,72
Nominal dim.:
1
2
0,51
2,18
E
0,24
1,61
0,00 mm
3
4
0,12
0,71
0,15
1,87
Tolerance:
5
0,13
0,15
-0,15
6
1,61
1,81
I
I
AU22/1521
1,90
7
8
Measurement in: 0,01mm
9
10
2,60
7
8
Measurement in: 0,01mm
9
10
1,90
7
8
Measurement in: 0,01mm
9
10
2,60
7
8
Measurement in: 0,01mm
9
10
REMARKS
25.04.23
Date
TW
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Side:
Our Order No.:
AU22/1521
A
Nominal dim.:
L
1
0°
28,01
90°
28,01
2
28,01
28,01
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,02
28,02
28,02
28,02
28,01
28,02
28,01
28,01
28,01
28,01
28,01
28,01
2
28,04
28,04
Shaft
28,00 mm
Tolerance:
0,04
3
4
5
6
28,04
28,05
28,04
28,04
28,04
28,05
28,04
28,04
28,04
28,04
28,05
28,05
0,02
7
Measurement in:
9
10
0,01mm
8
0,06
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,01
Nominal dim.:
L
1
0°
28,05
90°
28,05
28,01
28,01
28,01
28,01
28,01
28,01
R
0°
90°
28,04
28,04
28,04
28,04
28,05
28,05
28,05
28,05
REMARKS
25.04.2023
Date
TW
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Side:
Our Order No.:
AU22/1521
B
Nominal dim.:
L
1
0°
28,01
90°
28,01
2
28,01
28,01
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,01
28,01
28,01
28,01
28,01
28,01
28,01
28,01
28,01
28,01
28,01
2
27,96
27,96
Shaft
28,00 mm
Tolerance:
-0,04
3
4
5
6
27,97
27,96
27,97
27,97
27,97
27,96
27,97
27,97
27,97
27,97
27,96
27,96
0,02
7
Measurement in:
9
10
0,01mm
8
-0,02
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,02
28,02
Nominal dim.:
L
1
0°
27,97
90°
27,97
28,01
28,01
28,01
28,01
28,01
28,01
R
0°
90°
27,97
27,97
27,97
27,97
27,96
27,96
27,96
27,96
REMARKS
25.04.2023
Date
TW
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Side:
Our Order No.:
AU22/1521
C
Nominal dim.:
L
1
0°
28,02
90°
28,01
2
28,01
28,01
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,01
28,01
28,01
28,02
28,02
28,02
28,04
28,01
28,01
28,01
28,01
2
28,05
28,05
Shaft
28,00 mm
Tolerance:
0,04
3
4
5
6
28,06
28,05
28,05
28,05
28,06
28,05
28,05
28,05
28,06
28,06
28,06
28,06
0,02
7
Measurement in:
9
10
0,01mm
8
0,06
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,01
Nominal dim.:
L
1
0°
28,05
90°
28,05
28,01
28,02
28,01
28,01
28,01
28,01
R
0°
90°
28,05
28,05
28,04
28,04
28,05
28,05
28,05
28,05
REMARKS
25.04.2023
Date
TW
Checked by
Customer Representative
06.3 Measurement Report: Rocker Arm
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Side:
Our Order No.:
AU22/1521
D
Nominal dim.:
L
1
0°
28,01
90°
28,03
2
28,01
28,02
Bearing
28,00 mm
Tolerance:
0,00
3
4
5
6
28,01
28,01
28,01
28,01
28,02
28,02
28,03
28,03
28,01
28,03
28,01
28,03
2
27,97
27,97
Shaft
28,00 mm
Tolerance:
-0,04
3
4
5
6
27,97
27,98
27,97
27,97
27,97
27,98
27,97
27,97
27,98
27,98
27,98
27,98
0,03
7
Measurement in:
9
10
0,01mm
8
0,02
7
Measurement in:
9
10
0,01mm
8
R
0°
90°
28,01
28,03
Nominal dim.:
L
1
0°
27,97
90°
27,97
28,02
28,03
28,02
28,03
28,02
28,03
R
0°
90°
27,97
27,97
27,97
27,97
27,97
27,97
27,97
27,97
REMARKS
25.04.2023
Date
TW
Checked by
Customer Representative
01.4 Measurement Report Cylinder Liner Installed
A0°
A90°
B0°
B90°
A0°
A90°
B0°
B90°
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Nominal dim.:
1
2
165,04 165,04
165,05 165,04
165,04 165,04
165,04 165,04
Nominal dim.:
1
2
165,04 165,04
165,04 165,04
165,04 165,03
165,03 165,03
Our Order No.:
AU22/1521
165 mm
3
4
165,04 165,04
165,04 165,03
165,05 165,03
165,05 165,04
Position:
Tolernce: 0,025
5
6
165,04 165,05
165,04 165,04
165,04 165,05
165,03 165,04
1
0,060
7
8
Measurement in: 0,01mm
9
10
165 mm
3
4
165,03 165,04
165,03 165,03
165,03 165,04
165,04 165,04
Position:
Tolernce: 0,025
5
6
165,04 165,03
165,04 165,03
165,04 165,04
165,04 165,05
4
0,060
7
8
Measurement in: 0,01mm
9
10
Crack testing:
Hardness:
REMARKS
18.04.2023
Date
TW
Checked by
Customer Representative
01.5 Measurement Report Cylinder Liner Protrusion
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Our Order No.:
AU22/1521
A-Site
1
2
3
4
Ø
Nominal dim.:
1
8,04
8,04
8,04
8,05
8,04
8,05
8,05
8,04
8,05
8,05
8,04 mm
Tolernce:
3
4
5
8,05
8,05
8,04
8,05
8,04
8,04
8,04
8,04
8,04
8,05
8,05
8,05
8,05
8,05
8,04
8,05
8,04
8,04
8,05
8,05
8,04 mm
Tolernce:
3
4
5
8,05
8,04
8,04
8,06
8,04
8,04
8,04
8,04
8,04
8,05
8,06
8,05
8,05
8,05
8,04
2
0,000
6
8,04
8,04
8,04
8,04
8,04
0,020
7
Measurement in:
9
10
0,01mm
8
0,020
7
Measurement in:
9
10
0,01mm
8
B-Site
1
2
3
4
Ø
Nominal dim.:
1
8,05
8,05
8,05
8,05
8,05
2
0,000
6
8,04
8,04
8,04
8,05
8,04
REMARKS
17.04.23
Date
RS/TT
Checked by
Customer Representative
03.2 Measurement Report: Crankshaft Bearings
0°
60°
300°
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Nominal dim.:
1
2
141,13 141,13
141,16 141,15
141,14 141,15
Our Order No.:
A-Site
141,11 mm
0
Tolerance:
3
4
5
6
141,12 141,12
141,13 141,12
141,15 141,14
141,15 141,15
141,15 141,15
141,16 141,16
0,054
7
141,12
141,15
141,15
AU22/1521
8
Measurement in: 0,01mm
9
10
8
Measurement in: 0,01mm
9
10
B-Site
0°
60°
300°
Nominal dim.:
1
2
141,13 141,13
141,16 141,15
141,14 141,16
0
141,11 mm
Tolerance:
3
4
5
6
141,13 141,13
141,13 141,12
141,16 141,15
141,14 141,14
141,16 141,14
141,16 141,15
0,054
7
141,13
141,14
141,15
REMARKS
20.04.2023
Date
TW
Checked by
Customer Representative
03.3 Measurement Report Connecting Rods
Nr.:
a1
b1
c1
a2
b2
c2
Nr.:
a1
b1
c1
a2
b2
c2
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Our Order No.:
Nominal dim.:
1
2
0
0
112,02 112,00
112,00 112,00
112,00 112,00
112,00 112,00
112,02 112,01
112,01 112,02
112,00 mm
Tolerance:
3
4
5
0
0
0
112,01 112,01
112,01
112,00 112,00
112,02
112,00 112,02
112,00
112,01 112,01
112,01
112,01 112,01
112,00
112,02 112,01
112,01
A-Site
0,00
6
0
112,01
112,00
112,02
112,01
112,01
112,01
Nominal dim.:
1
2
0
0
112,01 112,01
112,00 112,00
112,01 112,02
112,01 112,01
112,01 112,02
112,02 112,01
112,00 mm
Tolerance:
3
4
5
0
0
0
112,00 112,00
112,01
112,02 112,00
112,00
112,02 112,01
112,00
112,00 112,00
112,01
112,01 112,01
112,01
112,00 112,01
112,02
B-Site
0,00
6
0
112,01
112,00
112,02
112,01
112,02
112,00
AU22/1521
0,022
7
0
8
0
Measurement in: 0,01mm
9
10
0
0
0,022
7
0
8
0
Measurement in: 0,01mm
9
10
0
0
REMARKS
20.04.2023
Date
TW
Checked by
Customer Representative
03.3 Measurement Report Connecting Rods Bearing
Nr.:
a1
b1
c1
a2
b2
c2
Nr.:
a1
b1
c1
a2
b2
c2
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Our Order No.:
Nominal dim.:
1
2
520
593
105,08 105,08
105,09 105,09
105,09 105,09
105,09 105,09
105,09 105,09
105,10 105,09
105,07
3
537
105,08
105,10
105,08
105,09
105,08
105,10
mm
4
588
105,09
105,10
105,09
105,09
105,10
105,10
A-Site
Tolerance:
0,00
5
6
535
490
105,075 105,09
105,095 105,09
105,085 105,09
105,085 105,09
105,085 105,10
105,095 105,09
Nominal dim.:
1
2
511
518
105,08 105,09
105,07 105,10
105,08 105,08
105,09 105,09
105,07 105,09
105,09 105,10
105,07
3
601
105,08
105,07
105,09
105,08
105,08
105,08
mm
4
572
105,07
105,07
105,08
105,08
105,07
105,08
Tolerance:
5
702
105,075
105,095
105,085
105,075
105,085
105,095
B-Site
0,00
6
595
105,08
105,10
105,09
105,08
105,09
105,10
AU22/1521
0,046
7
8
Measurement in: 0,01mm
9
10
0,046
7
8
Measurement in: 0,01mm
9
10
REMARKS
11.04.2023
Date
TW
Checked by
Customer Representative
03.6 Measurement Report: Piston Crown
A0°
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Nominal dim.:
1
2
164,60 164,59
Our Order No.:
Position 1
164,59 mm
Tolerance: -0,02
3
4
5
6
164,58 164,60 164,60 164,60
AU22/1521
8
Measurement in: 0,01mm
9
10
0,02
7
8
Measurement in: 0,01mm
9
10
0,02
7
8
Measurement in: 0,01mm
9
10
0,03
7
A90°
B0°
164,60
164,59
164,59
164,59
164,59
164,59
B90°
A0°
Nominal dim.:
1
2
164,74 164,73
Position 2
Tolerance: -0,02
164,72 mm
3
4
5
6
164,71 164,73 164,74 164,73
A90°
B0°
164,74
164,74
164,74
164,74
164,74
164,72
B90°
A0°
Nominal dim.:
1
2
164,81 164,81
Position 3
164,81 mm
Tolerance: -0,02
3
4
5
6
164,81 164,81 164,81 164,81
A90°
B0°
164,81
164,81
164,81
164,81
164,81
164,81
B90°
REMARKS
12.04.2023
Date
TW
Checked by
Customer Representative
03.7 Measurement Report: Piston
Customer:
Modern Power
Engine Type:
12V396TE94
Engine No.:
5583792
AU22/1521
Our Order No.:
Position 1
Nominal dim.:
A0°
164,782 mm
Tolerance:
-0,010
+0,010
7
1
2
3
4
5
6
164,782
164,782
164,772
164,772
164,772
164,772
164,772
164,772
164,772
164,772
164,772
164,782
Measurement in:
8
9
0,01mm
10
A90°
B0°
B90°
Position 2
Nominal dim.:
A0°
164,835 mm
Tolerance:
-0,011
+0,011
7
1
2
3
4
5
6
164,835
164,835
164,825
164,825
164,825
164,825
164,825
164,825
164,825
164,825
164,825
164,825
Measurement in:
8
9
0,01mm
10
A90°
B0°
B90°
REMARKS
12.04.2023
Date
TW
Checked by
Customer
Representative
03.9 Measurement Report Piston Protrusion
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Our Order No.:
8,00 mm
Tolerance:
3
4
5
8,260
8,250
8,250
A-Site
0,160
6
8,250
0,520
7
H
Nominal dim.:
1
2
8,260
8,260
8,00 mm
Tolerance:
3
4
5
8,210
8,250
8,200
B-Site
0,160
6
8,230
0,520
7
H
Nominal dim.:
1
2
8,280
8,230
AU22/1521
8
Measurement in: 0,01mm
9
10
8
Measurement in: 0,01mm
9
10
REMARKS
19.04.2023
Date
TW
Checked by
Customer Representative
05.1 Measurement Report Cylinder Head
H
O
H
O
Customer:
Modern Power
Engine Type:
Engine No.:
12V396TE94
5583792
Our Order No.:
Nominal dim.:
1
2
142,25
142,3
Nominal dim.:
1
2
28
28
A-Site
142,00 mm
Tolerance:
0,00
3
4
5
6
142,57 142,25
142,22 142,43
27,90 mm
Tolerance:
0,00
3
4
5
6
28,02
27,94
28
28,06
Nominal dim.:
1
2
142,23 142,34
Nominal dim.:
1
2
28
28
B-Site
0,00
6
142,45
0,00
6
28
142,00 mm
Tolerance:
3
4
5
142,82 142,61
142,8
27,90 mm
Tolerance:
3
4
5
28
27,99
28
AU22/1521
1,00
7
8
Measurement in: 0,01mm
9
10
0,20
7
8
Measurement in: 0,01mm
9
10
1,00
7
8
Measurement in: 0,01mm
9
10
0,20
7
8
Measurement in: 0,01mm
9
10
REMARKS
25.04.23
Date
TW
Checked by
Customer Representative
Test Run Report
7. Test Run Report
44
Service Report – Gear Box
Customer
Modern Power Marine Services Co
Service Engineer
RME Service Team.
Date of Service
Jan – March 2023
Location
RME Workshop
Vessel Name
AL KHARJ
Gearbox Type
WVS 730
Gearbox S/N
K65114- K65115
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 1 of 14
1.
Subject:
Major overhauling of two off REINTJES gearboxes of model WVS 730 installed in onboard Al Kharj
2.
Scope of work:(a)
To receive the gearboxes at the RME workshop.
(b)
To dismantle external accessories.
(c)
Remove the top covers.
(d)
To move input/Intermediate shaft out of gearboxes.
(e)
To dismantle the output shafts inside the housing.
(f)
To strip down the shafts for individual components cleaning and inspection.
(g)
Submit condition report if required.
(h)
To recommend additional parts required if found damaged during the inspection.
(i)
To replace all bearings, clutch discs, and shaft seals.
(j)
To replace all other standard parts required for major overhauling.
(k)
To maintain oil pumps, control valves, heat exchangers, and oil filters.
(l)
To box up both gearboxes and adjust clearances to specified values in the operation
manual.
3.
(m)
To test the gearbox on the test bench at idle rpm without load.
(n)
Painting of the gearboxes.
(o)
To attend the sea trials after the overhauling.
(p)
To submit a full-service report.
Service Activity:- The following service activities are attneded by the service enginners on
the gearbox
(a)
Dismantling: Removal of all external accessories from the gearboxes.
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 2 of 14
Gearbox at REINTJES Workshop
 Disconnecting the input coupling hub, input seal unit, and side covers.
Dismantling of coupling hub and side covers
 Loosening and moving the top covers out from the units.
 Lifting the top covers out from the units.
 Moving the input and intermediate shafts out from the units.
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 3 of 14
`
`
Intermediate shaft
Input shaft
 Dismantling of the Input and intermediate shafts:-
Old Carrier & Lower gearbox housing
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 4 of 14
Old clutch clearances
Old clutch plates
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 5 of 14
Old Carrier
Input shaft dismantling
Pinion shaft dismantling
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 6 of 14
Dismantled input shaft piston unit & Pinion shafts
 Dismantling the thrust cover and thrust bearings of the output shaft.
Dismantling of thrust cover
Output shaft with wheel
 With the help of high-pressure special tools take out the output shaft wheel from
the output shaft & gearbox and move it out from the housing.
 Dismantling the input and intermediate shafts completely.
 Heat exchanger cleaning, pressure testing and anodes & seal replacement.
 Cleaning & visual inspection of all components for any damages or cracks.
(b)
Assembling: REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 7 of 14
Output Shafts: Installation of the output seal along with P20 bearing onto the shaft.
 Installation of the output shaft wheel with help of high-pressure special tools on
the output shaft inside the gearbox housing.
 Installation of the thrust bearing onto the output shaft.
 Adjustment of the thrust clearance to the required range and fixing the thrust
cover.
Below mentioned major Items are replaced on the output shaft of both gearboxes.
Pos No
Description
Remark
P20/P21/P22
Anti-Friction Bearing
Replaced
E219
Shaft Sealing Ring
Replaced
E 203
Spring
Replaced
P2
Bush
Replaced
E374/E372
Bearing Housing
Replaced
Input Shafts: Fixing all the 03 bearings on to the pinion shaft of both units.
 Fixing the clutch housing on to the pinion shafts along with its bearings on all shafts
of both units.
 Installation of the new carrier on the ahead clutch of the gearboxes.
 Installation of the new clutch plates on the gearboxes and adjustment of the
clearance to required range.
 Overhauling of the piston units with new bolts, springs and piston rings.
 Fixing the new bearings along with bearing housings on to the input shafts of both
units.
 Replacement of the input shaft seal units with new bush and seal.
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 8 of 14
 Pushing the coupling hubs with high-pressure special tools to required depth.
Below mentioned major items are replaced on the input shaft of the gearbox
Pos No
Description
Remark
E1011/E340/W12
Bush
Replaced
E1012
Clamping Sleeve
Replaced
E1017
Bearing Housing
Replaced
E11
Sahft Sealing Ring
Replaced
E122/E123/E124/
E125/E15
E331/G316/K2/
R105/R43/W103
K120
Antifriction Bearing
Replaced
Retaining Ring
Replaced
Oring
Replaced
K13/W166
Hexagon screw
Replaced
K18/K7
Rectangular ring
Replaced
K22/K23
Clutch Plates
Replaced
K30
Carrier
Replaced on Ahead Direction
K41/K60
Allen Screw
Replaced
K5/K6
Bolt/Springs
Replaced
K8
Locking wire and Accessories
Replaced
W179
Non Return Valve
Replaced
Intermediate Shafts: Fixing all the 03 bearings on to the pinion shaft of both units.
 Fixing the clutch housing on to the pinion shafts along with its bearings on all shafts
of both units.
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 9 of 14
 Installation of the new carrier on the ahead clutch of the gearboxes.
 Installation of the new clutch plates on the gearboxes and adjustment of the
clearance to required range.
 Overhauling of the piston units with new bolts, springs and piston rings.
 Fixing the new bearings along with bearing housings on to the input shafts of both
units.
Below mentioned major parts have beenreplaced on intermediate shaft of both
gearboxes
Pos No
Description
Remark
E1013/E1028/W12
Bush
Replaced
E1014
Clamping Sleeve
Replaced
E1027
Bearing Housing
Replaced
E11
Sahft Sealing Ring
Replaced
E122/E123/E124/
E125/E13
G281/K2/
R105/R44
K128
Antifriction Bearing
Replaced
Retaining Ring
Replaced
Oring
Replaced
K13/W166
Hexagon screw
Replaced
K18/K7
Rectangular ring
Replaced
K22/K23
Clutch Plates
Replaced
K30
Carrier
Replaced on Ahead Direction
K119/K60
Allen Screw
Replaced
K5/K6
Bolt/Springs
Replaced
K8
Locking wire and Accessories
Replaced
W179
Non Return Valve
Replaced
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 10 of 14
Photos during the assembling of the gearboxes:-
Output wheel installation
Input & intermediate shafts
Output shaft
Clutch housing with carrier
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 11 of 14
New Clutch Plates
New Piston Springs
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 12 of 14
New Oil Distributor & Input Shaft Seal
Gearboxes after Painting
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 13 of 14
4.
Conclusion:(a)
Major overhauling of both gearboxes has been carried out as per standard REINTJES
overhauling procedure and all required parts have been replaced.
(b)
Test bench trials of both gearboxes has been done on the test bench and all parameters
found to be satisfactory.
5.
Recommendation:(a)
Use only REINTJES recommended lubricants.
(b)
Follow the REINTJES maintenance plan procedures.
(c)
Maintain idle RPM for safe and smooth clutch engagements.
THE END OF THE REPORT
REINTJES MIDDLE EAST LLC
REINTJES Middle East L.L.C., A subsidiary of REINTJES GmbH, Germany
UAE Office: WS119A, Dubai Maritime City, P.O. Box 31449, Dubai – U.A.E., Tel.: +971 4 3604814, Fax: +971 4 3604815
India Office: 501, Meridian Business Centre, Plot No.27, Sector-30A, Vashi, Navi Mumbai, Maharashtra, India,Tel: +91 22 2781 0317,
Fax: +91 22 2781 0318E-mail: reintjes@reintjesmiddleeast.com
Website: www.reintjesmiddleeast.com
Page 14 of 14