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
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
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