@ KRUPP MaK Maschinenbau GmbH Mak Kundendienstinformation - After Sales Service Information - Kundendiensti Nr./No. 001 M551 M552 M601 Overhaul of Pistons Today in modern engines built pistons with chromium-plated ring grooves are used almost exclusively. When the wear limitis reached the original size of the ring grooves in the piston crown can be restored by newchromium-plating. By means of this method you get an almost new spare part with full spare parts guarantee. When remachining the pistons delivered within the scope of the exchange service it has turned out that it is recommendable to send the piston skirts to Krupp Mak for overhaul, too. By a careful check of the skirts, too, after abt. 20 - 30 000 service hours, in connection with a possibly required reconditioning, a long life of the whole piston can be ensured. Ifyou have further questions in this connection, please contact the Krupp Mak representa- tive responsible in your area. Krupp Mek Postfach 90.09 P.O. Box 9009 Telex 292993 maks 2300 Kiet 17 2300 Kiel 17 Teletex 17431 105 Mok Tel, 043) 381-2690 Phone (431) 381-2690 Telefax (-431) 381-3080& KRUPP MaK Maschinenbau GmbH Mak Kundendienstinformation - After Sales Service Information - Kundendienstinformation Nr./No. 002 All types Protective screen Exhaust gas turbocharger For some time already it has proved useful to safeguard the turbine of the turbocharger by a protective screen. Fragments of compensators, valves or thermometer pockets which get into the turbine with the exhaust blast sometimes in spite of most careful maintenance cause expensive damages without turbine protection. Therefore, upon request of customers as special appliance MaK supplies protective screens for the turbines of nearly all engine types adapted to the exhaust gas turbocharger which can be fitted subsequently, too. These protective screens are made of steel with very good high-temperature characteristics and designed in such a way that in case of regular cleaning the flow resistance is negligible. The cleaning together with a wear examination should be carried out approx. every 2500 service hours and depends mainly on the quality of the fuel used. Practical experience has shown that the average attained life of the protective screens Is 15 - 20.000 service hours. For safety reasons we recommend to exchange the protective screens after this period For elaboration of an offer or in case of further questions please contact the competent Krupp Mak respresentative. h 9009 PO. Box 9009 Telex 292093 mo d 2300 Kiel 17 102300 Kiel 17 Teletex 17431 105 Mak fl (04:31) 381-2690 Phone (431) 381-2690 Telefax (431) 3813080& KRUPP MaK Kundendienstinformation « After Sales Service Information + Kundendienstinformation 4/91 M551 M552 M 601 Bedplates of nodular cast iron (GGG) All manufacturers of engines and generating sets are obliged to adapt their products permanently to the conditions of the market and the up-to-date level of technology by continuous development. Only by general application of the knowledge from research and development the high performance standard of MaK engines can be guaranteed in the long run. Within the scope of such a measure, big components have no more been made of cast iron, but of nodular iron for some time now. Apart from an increased stregth this material shows also a clear elongation , i.e. characteristics wich are steel-like and thus allow higher stress. due to specific manufacturing reasons, the surface of the bearing pocket bore i bedplates of nodular iron is sensitive against dry sliding friction under high stress. Between bearing pocket and bearing shell, under cerlain circumstances, seizing might occur when turning out a bearing sheli, In order to avoid such damages on a bearing pocket during removal or mounting the bearing shell is to be relieved from the crankshaft weight. Our repair workshops have suitable tools and the required 'know how’. In case of doubt you can find out, by means of the laterally cast-in drawing number, if your bedplate is made of nodular cast iron. E.g. for 8 M551 1.74.3-12.10.00-. . The fourth figure of the drawing number always stands for the casting material for oe engine types, too. If this figure is a 3, the bedplate is of nodular cast iron ). We recommend, however, to contact the competent MaK representative in any case before removing a bearing.@ KRUPP MaK Kundendienstinformation « After Sales Service Information « Kundendienstinformation Moderne Lagertechnik in MaK Dieselmotoren 5.91 Alle Typen “Das Rillenlager Bei mittelschnellautenden Dieselmotoren bewahrt sich in CGalan-Lavischicht zunehmenden MaGe, besonders im Schwerdibetrieb ein neues Kurbelwellentager, das sich auchim Aufbau wesent- lich von den herkémmiichen Lagern unterscheidet. Wie der Name schon sagt, hat diese Lagarschalenart eine tilentérmige galvanische Laufschicht, womit bemerkens- Werte Vorteile verbunden sind, die auch die Mak veraniaSt hat, diesen Lagertyp immer hautigor in ihren Motoren ein- zusetzen, Im Vergleich zu den bisherigen Dreistoffiagern aut Bleigal- vanikbasis zeichnet sich dieses Lager mit seiner Rillenkon- strultion dadurch aus, da8 os hoher belastoar ist, einage- Tingere VerschleiBrate autweist und bei Schmierdlver- ‘schmutzung weniger stérantalig ist. Ebenso wird durch diese Konstruktion die Sicherheit fr den Lagerzapten ‘erhdht, da die Nickeldammschicht nicht mehr durchge- ‘Aufbau des Rilleniagers auf AL - Basis bhand vorhanden ist Durch diesen Aufbau haben sich die Beurtellungskriterian bei Motorenlagern dieses Typs grundsitzich geuindert. Entschel- 25 % vom Umfang, #9 hat das Lager seine Verschleligrenze erreicht. Ebenso triff dieses 2u, wenn mehr als 60 % der Lagerschalenbrelte und > 30 % vom Umfang verschlissen sind. (An- gaben aus Beurteilungskriterien des Lagerschalanherstellers)& KRUPP MaK Kundendienstinformation + After Sales Service Information + Kundendienstinformation 6/91 Alle Typen Umlaufkihlwasser - Aufbereitung Um die Betriebssicherheit moderner Hochleistungsmotoren zu erhalten, ist es _unerlaBlich alle Vorschriften und Richtlinien der Wartungs- und Bedienungsanleitung sorgfaltig zu beachten. Dies gilt auch fur die Aufbereitung des Motor-Kuhlwassers. Fehlender Korrosionsschutz oder eine nicht ausreichende Dosierung des Kihlwasser-Zusatzes fihren sehr schnell zu erheblichen, kostspieligen Korrosionsschaden unter anderem an Zylinderdeckein und Zylinderblécken. Gefaihrdet sind alle mit dem Kihiwasser in Kontakt kommenden Bauteile, auch solche aus hochwertigem GuBmaterial, wie zum Beispiel Kugelgraphitgu8 (GGG). Wir méchten deshalb alle Betreiber von Motoren der Krupp MaK nochmals auf die sorgfailtige Pflege des Umlaufkihiwassers nach Arbeitsblatt 2.2.1 der Motor- Bedienungsanleitung hinweisen.@ KRUPP MaK Kundendienstinformation « After Sales Service Information « Kundendienstinformation 7/91 M551 M552 The exaust valve housing as exchange part. M601 Due to the high mecanical and thermal stress and dependent on the kind of fuel used, exhaust valve housings have different service lifes. For this reason, it proved to be economic to have these component parts reconditioned by the engine manufacturers in exchange method when they reach the wear limit values for the armoring. Due to their particular knowlegde of all load conditions of the exhaust valve housings in the engine, Krupp Mak developed a special reconditioning method which makes the overhauled parts as new and offers to the customer the ab- solute reliability of an ORIGINAL MaK SPARE PART. Due to the missing knowledge of stress to component parts in the engine ope- ration, important working sequences are not beeing carried out with the necessary care. Among others NON-ORIGINAL MaK SPARE PARTS had considerable deficien- cies concerning the execution of welds. As for example shown on the accompanying sectional view, improper weldings inthe area of the cooling port for the valve seat lead to cracks inthe weld with dangerous cooling water leakages caused by crevice corrosion. Among others possible consequential damages might bumt valves and water shock wich would not only bring about expensive repairs but also unnecessary loss of time for the ship. Do not leave reconditioning of your exhaust valve housing to chance. ORIGINAL Mak EXCHANGE PARTS offer SECURITY IN ANY CASE.& KRUPP MaK Kundendienstinformation + After Sales Service Information + Kundendienstinformation 92/3 All types Maintenance of the lub. oil protective strainer On all Mak engines directly before Inlet of the lubricating oil into the engine a Protective strainer is fitted. Its main purpose is to keep dirt particles from the engine- which may be in the pipe system behind the filter circuit as a consequence of shipyard works or repairs. This protective strainer has a 200 um filter gauze insert and must be checked resp. cleaned, therefore, at certain intervals. In the Operating and Maintenance Instructions the maintenance of this protective strainer is described in Job Card 08.04.03 On the occasion of visits of Mak personnel on board it was noticed that checking of this protective strainer is frequently neglected, possibly due to ignorance. Considerable consequential damages caused by defective or dirty filter inserts may result. Therefore, we wish to draw your attention once moreto the importance of observing the maintenance recommendation acc. to the Operating and Maintenance Instructions of the engine.@® KRUPP MaK Kundendienstinformation + After Sales Service Information + Kundendienstinformation 92/4 All types Chroming of Crankshaft Pins and Journals In connection with repairs in the field of crankshafts and their bearing surfaces; we receive increasingly the question as to whether lightly damaged crankshaft pins and joumals can be salvaged by the process of hard-chroming the surface to obtain the original dimensions once more. However the opinion of the Classification Societies in this respects that the restoration of the crankshaft pins and joumals by a process of hard-chroming to the original dimensions does not produce the same quality of finish. According to their knowledge today there have been repeated damages throughout the world-wide fleet where hard chrome treated pins and journals have developed flaws, resulting in consequential damages in many cases, of serious nature. We as Krupp Mak the engine manufacturer, must emphasise to our customers, not ultimately because of the high costs of such damages, that such a repair procedure cannot be recommended. Because of the associated risks for the ship's safety have yet to be assessed up to now, the Classification Societies have decided that the repair procedure on crankshaft pins and journals by hard chroming is not authorized.& KRUPP MaK Kundendienstinformation - After Sales Service Information - Kundendienstinformation 93/1 all Type Vibration dampers, for all engine types Most of the MaK engines are equipped with a vibration damper which protects the crankshaft against dangerous torsional vibrations. Torsional vibrations are influenced by the operating principle of the combustion engine, by the firing sequence, and last but not least by the degree of mass. balancing. In many cases they are inevitable. The vibration damper has the effect that resonant torsional vibrations will not develop in critical speeds. Consequently it is a vital component for the Diesel engine. A good vibration damper works without being noticed and completely without problems for a rather long period. The scope of maintenance work required is comparatively small, and the maintenance intervals are long. For the above reasons it is quite possible that a vibration damper is not noticed before its function is reduced. Of course, this involves considerable risks for the crankshaft. Therefore, we wish to draw your attention once more to the absolute necessity of observing the scheduled maintenance intervals stated in the operating manual of the engine. ‘As sometimes thorough maintenance works are not possible on board, Krupp MaK has organized an overhaul and exchange service for all standard vibration damper types some time ago.@ KRUPP MaK Kundendienstinformation - After Sales Service Information + Kundendienstinformation 93/4 M601 M453 Pump element for fuel injection pump On high-powered Diesel engines perfect atomization of the injected fuel leads to an optimum combustion and consequently to a reduction of the fuel consumption. However, for exact atomization short injection periods and high injection pressures are basic requirements. The resulting enormous load on the whole injection system involves high quality requirements with regard to manufacture and used material. On the pump elements used now traces of cavitation in the upper part of the plunger are caused by this mode of operation which are harmless up to a point and do not influence the function of the pump element. Frequently such elements are replaced prematurely due to overcaution, although they would still have worked properly for some thousand service hours. Elements with traces of cavitation, as shown in the picture, are still fully operable and can be used further without hesitation. Only if the edge itselt is attacked, the injection behaviour is affected. If exchange is absolutely necessary, if possible, all elements should be replaced at the same time. At present, in close cooperation with the component suppliers, Krupp Mak is developing a pump element excluding the appearance of these traces of cavitation, too, As soon as such an element is available you will be informed by your competent Mak representative.& KRUPP MaK Kundendienstinformation + After Sales Service Information + Kundendienstinformation 93/5 All types Check of injection nozzles The fuel consumption of a diesel engine depends more or less on an exact atomization of the injected fuel. The nozzle elements being used nowadays, have been especially improved for the short injection times at high injection pressures. Unfortunately this dynamic process cannot be realized any more during an inspection of the nozzles. That is to say, an inspection proving the perfect nozzle condition by means of usual testers is only possible to a certain degree. The normally existing nozzle testers can, therefore, only be used for adjustment of the opening pressure, for checking of the nozzle bores i.e. their non-plugged condition and, to a certain extent, for leakage tests of the nozzle needles. For a secure judgment of the nozzle condition only the behaviour of the exhaust gas temperature is decisive. Nozzle inspections should, therefore, only be effected if the exhaust gas temperature obviously deviates from the mean value of all cylinders in the specific load range. Inspections by pressure-testing, dependent on time intervals, will not bring about any essential knowledge because also the distinctive nozzle buzzing of earlier times is no longer existing. Due to the long-term wear it is, however, recommendable to exchange the nozzle elements after 6000 running hours at the latest. Up-dated job cards of the Operating and Maintenance Instructions can be obtained by request from your local MaK Service Station.@® KRUPP MaK Kundendienstinformation + After Sales Service Information - Kundendienstinformation 93/6 All types Check of the fuel rack zero-position on stop We learned by experience that for adjustment of engine operating values after overhauls of injection pumpsor for correction of exhaust gas temperatures, the injection pump fuel rack is changed frequently. This measure is only admissible in exceptional situations and then only within a limit of +#/- 1. After each overhaul as well as at regular intervals the fuel rack zero-position on stop of alll injection pumps is to be checked by all means. In any case it must be ensured that the injection pump stop position coincides with the zero discharge. In this connection attention must be paid to the fact that not always the zero fuel rack position is identical with the zero discharge. Please draw the exact data from the acceptance brake certificate (test bed certificate) where you will find a description under "position of the fuel rack when the control lever is in stop position’. In case of nonobservance it might happen that the unloaded engine runs in overspeed in spite of the stop position of the pumps. For the same reason attention must be paid thatthe fuel racks of all injection pumps are easily moving and the overspeed protection is o.k.@® KRUPP MaK Kundendienstinformation - After Sales Service Information - Kundendienstinformation 93/7 M601 Fuel injection pump Mak var. -48 PGO - GOo8 Mak var. -58 PGO - G008 B To avoid cavitation, frequently observed at the plungers and mentioned in our After Sales Service Information 93/4, a new pump element was developed with spec. U 821. By means of a modification in the area of the control edge, the delivery characteristics of this element have been improved in a way that the tendency to cavitation has been eliminated. This pump element is available immediately, in exchange of the element U 808 C. However, attention must be paid that the application of the element U 821 involves a reduced fuel rack position of the injection pump by 5 points at equal performance. Therefore, it can only be installed if all injection pumps of an engine are equipped with it at the same time. Consequently the max. fuel rack position has to be altered (reduced) adequately. In case of any further questions please do not hesitate to contact your MaK Service Station or the MaK After Sales Service in Kiel.Mak Service Information 97/4 General Do not close the stop valve for the starting air during operation. The air system of the engine does not only supply the starting system but also the emergency stop ‘system of the engine and, if existing, the oil mist detector. From time to time we have observed that after the engine starting process the stop valve for the starting air was closed. Ifthe stop valve is closed not only the starting air but also the air supply to the emergency stop oylindars at the injection pumps and to the oil mist detector is shut off. That means the function of two essential safety systems is not given The operational reliability ofthe engine, however, imperatively requires thatthe starting air supply is always opened during operation. In no case the stop valve for the starting air must be closed during operation. For any additional information please contact the Mak After-Sales Service. Posty? 0. Box Telefoane (431) 2995-600 MaK Motoren GmbH 0-24157 Kel af O13 295-696 —————— stoner Stee 2 Teles. 782958 ak ‘catia Company 158 Kh fen terseniwak deMak Service Information 98/3 All Enginelines as far as concerned Oil Mist Detector (Visatron 115/87) Within the scope of our product follow-up we do not only judge the operating behaviour of the vari- ous engine lines in general, but also the behaviour of single components. The oil mist detector of the company Schaller, type Visatron VN 115/87, used by us exclusively in recent years, has reached a very high level of reliability. There are practically no false alarms any- more if maintenance is carried out properly. For this reason, it must be implied that in case of an alarm, there is really an engine failure and it is absolutely necessary to ascertain the reason of this, trouble before the engine is started again. In case of an alarm most of the classification societies only demand a reduction of engine output. Occasionally the crew waited too long before the engine was stopped to investigate the reason for the alarm. The result was, in some cases, severe damage that could have been avoided. Therefore MaK urgently recommends to all customers to connect the oil mist alarm of the oil ist detector in the safety system to the automatic engine stop. A binding stipulation of the lassification societies that the alarm must be connected to automatic engine reduction does not exist. The engine manufacturer may give another recommendation. This work can be carried out by the crew without problems. The relevant terminals can be found in the circuit diagram supplied with the engine. Should there be problems, the service organisation of Mak will be able to assist. We consider it recommendable to upgrade older devices, which are possibly susceptible to failures, to the present series, as far as it is technically possible. The technical possibilities in every par ticular case would have to be checked. MaK would be pleased to assist and submit an offer if you are interested. Poatac, 5 D2a57 Ke © False 3 pana MaK Motoren Gmbh & co. KG ACaterpillar CompanyMak Service Information 99/01 M601 Camshaft additional masses 1100 KW engines The camshaft of the 1100 KW engines is provided with additional masses at the cylinders 5, 6, 7 and 8 which are mounted between the fuel and exhaust cams. Should it be necessary to change a fuel cam of the above-mentioned cylinders the respective addi- tional mass must be removed because the space for a repair cam is not sufficient. This proceeds as follows: 1, Incase only one fuel cam is changed, the removed mass is to be mounted at cylinder 4. Drilling of a new pin hole is not necessary. 2. Incase two fuel cams must be changed, all additional masses are to be removed and a vi- bration damper assembly for the camshaft must be mounted according to drawing No. 1.80.7-62.29.00-01 Attention: The now open pin holes must not be sharp-edged. They must be rounded carefully. Postal 0. Box Toltor/Phene: 49-41 -2995-000 mbH & Co, D2mi87 Ke h 072895 85 Jak Miokoren Gali 5co:k Faldastinr Soe 2 Tele 722 283 make A Caterpillar Company Dam8a Ke piste mul terseeemakdeMak Service Information 99/2 All engines as far as concerned Oil Mist Detector Modification of the Alarm Setting »Ship’s Name” Engine Type Engine No. 1. O Yes, we did change the alarm to engine stop. 2 O Yes, we want to modify the alarm setting, but we need some further information from Mak. 3. 0 Yes, we intend to have the alarm setting modified by a MaK technician and will place an order with MaK. Yes, we want to get the oil mist detector replaced by the new type if possible. Please letus have a respective quotation. No, we do not want to modify the alarm settings. Reason (s): Mak Motoren smbH & co. KG ‘A Caterpillar CompanyMak Service Information Ball Valves on Boll & Kirch Fuel Duplex Filters 00/06 All Types We have received reports that leakages have occurred to the ball valves of the fuel duplex filters. The reported cases show the following characteristics of damage: a) Leakage at the O-ring of the ball valve stuffing box. b) Moving of the ball valve shatt by its own with the consequence of fuel leakage. Our filter supplier has informed us that neither the straight-way nor the angle type ball valves, fitted at the fuel and lub. oil duplex filters, may be repaired in the event of leakage. Repairs at the ball valve stuffing box would destroy the adhesive locking of the stuffing box nut. This might lead to loosening of the stuffing box nut and to moving of the ball valve shaft. The ball valve assembly must be replaced in the event of a leak. Teton 4-3-9600 Motoren gmt & co Tlf 4-497 3895 288 Mak Mbtoven jorolla.ce: ks A Caterpillar Company mal tersracot9GAT oomBOLLFILTER Protection Systems BOLL & KIRCH Fiterbau GmoHt Boll & Kirch Office North Ahrensburg 02™ May .2000 Service Letter Globe valves fitted to Boll & Kirch Duplex Filters On the occasion of a recent incident we would like to point out that globe valves which are fitted to Boll & Kirch lube oil and fuel oil duplex filters — in angle or in straight design — cannot be repaired in case of a leakage. Efforts to repair the stuffing box or to replace the seal ring cause the destruction of the adhesive safety locking. This may result in an uncontrollable loosening of the stuffing box nut, ! In case of a leakage these ball valves have to be changed completely ! N.Weichhold Boll & Kirch Office NordService Information No.04/01 eee 2001 July Focused on cramer Hands Check of injection nozzles All types The fuel consumption of a diesel engine depends more or less on an exact atomization of the injected fuel. The nozzle elements being used nowadays, have been especially improved for short injection times at high injection pressures. Unfortunately this dynamic process cannot be realized any more during an inspection of the nozzles. That is to say, an inspection proving the perfect nozzle condition by means of usual testers is only possible to a certain degree. The normally existing pressure testers can, therefore, only be used for adjustment of the opening pressure, for checking of the nozzle bores, i.e. their non-clogged condition and, to a certain extent, for leakage tests of the needles. For a secure judgment of the nozzle condition only the behaviour of the exhaust gas temperature of each cylinder is decisive. Nozzle inspections should, therefore, only be effected if the exhaust gas temperature ‘obviously deviates from the mean value of all cylinders in the specific load range. Inspections by pressure-testing, dependent on time intervals, will not provide any valid insights knowledge because also the distinctive nozzle buzzing of earlier times is no longer existing. Due to the long-term wear it is, however, recommendable to exchange the nozzle elements after 6000 running hours (old C-Engines, M 332 to 601) and 8000 running hours (new engine generation, M 20 to M 43) respectively at latest. Corresponding job cards of the Operating and Maintenance Instructions can be obtained by request from your local Service Station. Caterpillar Motoren GmbH & Co, KG, Kel, Germany + Phone: +49(0) 431-395-2245 Fax: +49 (0) 431-095-2010 Ema ju tecservice@CATcom + wwwak-global comSERVICE aoaedon Stet hete Original Mak Injector Nozzle Elements Optimised Lifetime Excellent Quality Excellent Reliability Short Delivery Time Low Total Cost M332¢ M35 M453 C M552 C Moot c M20 M25 M32/M32C M43 ‘© Optimised Lifetime: Mak Premium Injector Nozzle Elements are designed and manufactured fora lifetime of 8,000h (6,000h for M332 C, M 35, M 453 C, M §52.C, M601 C}, if MaK’s Instructions for Heavy Fuel Operation are followed. Only the best ‘materials and pro 68 are used to provide long component lifetime Injection nozzle holes before and after treatment, scale 25:1 ‘+ Excellent Quality: A special aftertreatment ta the injection holes developed by Mak engineers enables the Nazzle Element to provide an optimised spray pattern over the entire lifetime. The Nozale Element is designed to work precisely with all other parts of the combustion chamber. The optimised spray pattern is a major contribution to an optimised burning process in the combustion chamber. A perfect spray pattem protects the liner from carbon deposits and makes a contribution to achieve low fuel consumption. The optimised burning process provides longer life for valves as well as liners, piston rings and piston crowns. This is best possible with Original Mak Injector Nozzle Elements which are optimised for use in our engines. © Excellent Reliability: Every Original Mak Injector Nozzle Element is tested with a process specially designed by Mak engineers. All measurements are recorded to ensure our quality is constantly maintained, Additionally, we use field information for continuous improvement * Short Delivery Time: Original Mak injector Nozzle Elements are usually shipped within 24h after the order has been placed, as are most MaK Original Spare Parts, to best serve our customers. © Low Total Cost: Original Mak injector Nozzle Elements provide extra value for the price the customer pays. The operation costs for the engine is reduced ‘+ For quotations or orders please contact your local MaK Service Organization. Original MaK Injector Nozzle Elements are World-Class High-Tech Products Publish Catepilar Metoren GmbH & Co KG Kil, Gemany LeatetNo. 11 +e 1200+ L8S +1 vow mek gal coMak SERVICE Focased on Service Information No.06/02 June 2002 Relief Valve Maintenance All Engine Types The operating instructions do not include any maintenance rules for the relief valve. Adjustment and testing only take place once in the factory before test bed run. As due to its design the setting pressure cannot be adjusted subsequently, no test/overhaul of the relief valve will be specified in future. Experience from the field also shows that after overhauls or tests of relief valves their tightness is not ensured any more! Relief valves must always be changed after 30 000 operating hours. Relief valves must also be changed after opening because of excessive cylinder pressure! The Mak Operating Instructions of the Relief Valve have been changed accordingly in chapter “Maintenance and Replace” (A5.05. 01.06.70.00). The revised sheets can be obtained for the respective engine type from all field organizations. Catrpilar Motoren GmaH & Co. K, Kil, Germany + Phone +490} 431-195-2265» Fax +490) 41 395-2010 E-malu_tecservice@CAT com + wwrmak-globalcomService Information No,02/03 May 2003 Questionnaire All Engines Engine Condition in Respect to SOLAS Chapter II-2 lease fill in this form completely, Only then we are advice. '@ position to offer you extensive and detailed Date_[Engine-Wo. [Engine type| “Ships name" Company SOLAS iI-2 Part A Chapter 115.29 High pressure pipes with inflammable liquids > 20bar Interpretation: This regulation requires al external igh pressure fel dalvery lines between the high prassure Taal sumps ond fel injectors tobe protected with a jacketed piping system capable of eontaning fuel tensa high pressure hne failure. jacketed pipe incorporates an outer ioe into which the high pressure fuel pipe is placed forming @ srmanent assombiy The jacketed piping systems to include @ means for callocton of leakages and arrangements are to la provided for an atorm tobe given ona uel ine faure. \7he System sold by Caterpillar Motoren complies withthe SOLAS regulations in all aspects. = yes [no [Double wall pipes existing? [Do the double wall have connections forleak oi? ondition ofthe pipes. Action necessary? iste injection pump space shielded? |sthe Cover ofthe injection pump space ina sufcient condition? fer requested? isa leak oll line existing? isthe condition ofthe leak oii fer requested? order, action necessary? is a leak oil monitoring existing? isthe condition ofthe leak oil monitoring in order, action necessary? fer requested” isa leak oll alarm existing? isthe condition of the leak ol alarm in a workable condition? (Cables, connection tothe alarm plant)? fer requested? Is a survey by a CAT technician requested?Service Information No.02/03 May 2008, Questionnaire All Engines Engine Condition in Respect to SOLAS Chapter II-2 [SOLAS 11-2 Part A Chapter 5.2.11 Low pressure pipes with inflammable liquids 25 - 20 bar ‘Interpretation: This regulation requires oi fut, lubricating ol and other flammable oi piping tobe screened or | thers suitably protected to avoid as far as practicable ol spray. Spray shields are intended fr use areund flanged its, aged bonnets and any ther flanged eannections in al pressure systems which are located above the floor plat 1d whic have no insulation in way ofthe joints. The purpose of spray shields sto prevent the inpingemaent of leaked or syed faminable uid onto a hot surface or other source ef ignition. [tbe Henge protections supplied by Caterpilar Motoren meet the SOLAS requirements yes [no Is the iow pressure pipe stilin the original state? |sthe condition ofthe low pressure system in order? |s.an offer for screening ofthe pipe connections requested? [sa survey by a CAT technician requested? (OLAS i-2 Part A Chaptor 152.11 [Hot surfaces Interpretation: This regulation requires that ll surfaces with tamperatures above 220 Celss M30"), which may ba [impinged asa result of @fuo lubricating oi and other flammable ol syst failure bo property insulated. sulaion of hot surfaces is preliminary to reduce the risk of fre by reduce the temperatures of surfaces below the auto- faniton temperature of ual olf or other fama ols fanutecture’s structions should bo follaved it avaiable. Permanent insulation shouldbe used tothe greatest extent Jpossibie. insulation should be provided with reedly removable sections to alow access for normal maintenance. Where fie insulation used iso absorbent or may permit the penetration of il the insulation shouldbe oncased in steel sheathing oF equivalent material This epolies not only to the exhaust piping, but aso to other heat surfaces like those ofthe safety/ndicator cocks or pre~ waters with temperatures above the permissible liz \7he exheust cladding supplied by Caterpilar Motoren is classified by 4 clessiication societies it mounted by our sonnel. The shiold of the safety and indicator velves complies also withthe SOLAS regulations. - - es [no [Are the exhaust pipes / exhaust cladding stil in the original state? re the safety / indicator valves insulated? is the condition ofthe exhaust cladding in good order? s the visit ofa technician to determine necessary actions requested?Service Information No.02/03 May 2008 Questionnaire All Engines Engine Condition in Respect to SOLAS Chapter II-2Service Information No.07/03 Date 23.07.2008 Handling of SOLAS Activities Non Current Engines ‘On July 01, 2003, the 1994 Amendments to SOLAS II-2 came into force and are now mandatory for older ships as well as new ships. In the second quarter of 2003, Caterpillar Motoren, our Dealers, and our Service Stations have seen a growing number of inquiries from our customers. Handling and resolving of these inquiries has shown us that much communication is necessary to find a solution that fits the engine and meets the required standard. difficult to have a standard solution for all engines, or even for one series of engine, regardless of their age, original design status or current condition. We are also mindful that the costs related to the necessary modifications must be acceptable to our customers. With these goals as our target, we have created parts kits that are flexible enough to meet the requirements of every engine. If the components of these kits are mounted by authorized service personnel you can be sure that the respective SOLAS requirements are covered. To avoid serious problems, like vessel detention, Caterpillar Motoren recommends that owners with engines that are not complying with the SOLAS regulations should upgrade them to full compliance. Your dealer / agent is your primary contact to discuss this issue in detail For more information please see the attached Parts News.Checklist for info about operating conditiones for marineengines Ship / Station: ‘Main Engine: Brand of uel: Ship.comp. /Customer: Aggregate: Brand of oil ‘Engine-No: Pat ito operation: Enginetype: Last overhaul: Output: Fanning hours: Seeet Fesing rte ok fot [i ox foot [oe (rankessodoors Conta jctee Esteongnoie Comsbatdoors fw tr TT omacin etna sora ger teasing + Change over cock = Connection ro = oncamehoite itis indicator = Comet. conponsetr on oxhauateride [x cotngnarepunas TET oagear coe al (ikea sa Seating waterside = Compingside Sealy Hangoconscton = esse copings —, (pindertond covers oot watipe otto cw dt / sonia hg i ii for tro = Pushed guidance Turbocharger othe = Airpessnge = Turbocharger gato Wein ong se = Ips sing ~Coolatercllectn tcompenstor Cooler drain = reve hosing Waterss ditib.buslyLheed senna stam q Fue dsribuion ~ Bistribationpipe =f ret Foley [ontonal st ak feck [no [sspany sop ston ing vie Panwa aindor ‘Sitarngenr| som syon - sewiteW Satine terse Sip ane es = rerperdiga! ei EEE ain soin abe = Stpsgnls = hagelating shojo ister = Stecking Aagalaing shat es Teta engine peation ~ Gonvalhanle -Sapearet Spatogion [cnet vinul check ot Tack] ie [= at [ok | ro at [aot | [st ais coe nia Teste 7a ae : = Font wallte indetorpael funog sare Back wal pate Exhestssthoro, umag ssc tlt = Holder Consoles = thr themes fuming el = Serews Pressswtet/raanie ung suse aes ~ Sensors / Cables usec ring via [oer Sige = Fixings / Consoles Edo [tert cover czas iter i \inape goverorfeguting shat exe caging ting sen secred Hubber slononts Shit ck device spacer[Fut pressure int. fousonretin Combustion Luton fir tar fier of te one of tesyten : Inston oft ge on thn engine wath eis fo. of urploes engietns Yan Ie. ofunplaec paes Year tos: with he resut".0" the Kindo fault has to be documented ne, [an tt an tlic writen checks or important and have tobe tothe key of fous see below. |docuneniae immediatly, Inthe columa inp” documento the impact level ace. toth key, Jatrorat riten ts ros important nan te 5. ie example Below) leer a. emai othe column n.ok and improvement econmendsian pate ea /Date Kind of fault: ‘Shorteod Designation; Shortcode: Designation: Impact level: 2 broken Ww detached ‘Lrepair immed, because of eng, damage 3 inserted i electical defect 4 jammec B volume to smal repair as soon as possible 5 locked “ distored 6 cratked 6 seized 3. repair during next overhaul 7 blown through 6 damaged 8 \weared v temperature cifferences 3 leaking 8 out of oer 0 deformed 8 not existent Example: [Testing for leaks ‘ok ooklimp] ok. =okay (Cronkcasedoors x not okay Camshatidoors. a[2 ImnpactievelCATERPILLAR’ Caterpillar Marine Division Technical Product Support Falekensteinar Sv 2, 24158 Kil Service Organisation for P. 0. Box, 24157 Kiel MaK Marine Engines Verteiler: Your Reference Our Reference Phone 24187 Kiel vT6 Direct dialling 15.08.2003 Papendieck +49 (0) 431 3995-2825 Fax 3995-4825 or 3995- E-mail [email protected] ‘SOLAS Requirements on Fire Protection Third Information Gentlemen, This is the third letter on the SOLAS subject. With this letter we would like to inform you about the further pro- ceeding. Basis are our activities since our last information. We think that this is a chance of additional parts and service sales for us and also for you, our dealers / agents. We, therefore, want to make an active use of this opportunity via the following communications and actions: 4. Availability of Part Kits As already mentioned we will start this action with the insine engines of the series M453, ‘The part kits "A" and "B" is expected to be available in week 36. ‘The exhaust claddings (part kit "C’). (© Has to be ordered specifically to engine. © Delivery time will be 4 weeks. ‘©The modification of the cladding can be done only during stay in a dockyard, © The dockyard dates have to be verified by the dealers, ‘= The pump room cladding (part kit ‘D’) is expected to be available in week 36, Compared with the previous design this cladding will be an improved version with handy sections. Caterpitar Watine Dision Caterpilar Mtoren GmbH &Co. KG Sonera Parmer: ADivsion ot Falckenstsine Saba 2, 24159 Kel Catrpilar Motoren Verwaungs-Gmbi CaterpiarMctocan Gt & Co.KG 0, Bom, 2487 Ke oyistered Seat Kil Neumihions, 276 Hamaurg Registered Soot Ki Royse of Companies: Local Coureof Kil HR 21 Pane: +48 (0) 40 22802000 Registro Compania Management Boar Jon Grantiman, Chirman Teefx: 90) 40230-2505 oes Cour of Kal RA 3705 Oswald Scat, aut Wrobiewsts Regist of Companies: Local Covet ot Hamburg HRA 9522 ‘Managing Dacor: Raberte Dons sas2mes00Caterpillar Marine Division The part kts for the other old engine series will be available as follows: Mast / M452 / M551 / M552 / M282 / M 323 / M601 / M35 Part kits .A* available ex shelf Part kits “B* , °C", *D* availability will be announced within short For our new engine series from the M20 up to the M43 we will give you separate communications. 2. Customer Information Caterpillar intends to inform the shipping companies owning M453 engines directly by means of a letter about SOLAS in week 34. This letter will indicate that the dealer or agent responsible for their area will contact them, Please send us, preferably the e-mail addresses of the contact persons in the shipping companies. 3. Customer Calls ‘After having al! information at hand, please immediately contact the superintendents of the shipping compa- nies located in your area of responsibly, beginning withthe M453 operators. This personal contact is an indispensable prerequisite to attaining the objectives expected from this action. In the attached communica- tions please find the following information: + Line of reasoning (Service information + Overview of SOLAS Parts) for your talks with the customers. {paper copies by mail) ‘List containing the M453 engines in your contract area. (by fax in case only Internet address is available to us) ‘Bulletin with the most important information on SOLAS. (paper copies by mail) ‘Price list for the M453 part kits. (by fax in case only Internet address is available to us) ‘*Questionnaire to ascertain the current SOLAS equipment ofthe engines. * Check lst to ascertain the current condition of the engines. 4. Pricing . From the price list you will soe thatthe operators wil be given discounts and the dealers given bonuses by CAT for the part kits, Likewise a discount of 10 % of the labor costs is expected from our dealers / agents vis- a-vis the operators. This discount wil not be refunded by CAT. From our point of view sharing can reasonably be expected from you, since this action will lead to additional sales and further service orders. 5. Questionnaire Please review the questionnaire with your customer. It will help to ascertain the current equipment on the engines. For this purpose please offer the shipping agents visits on board by your skilled service personnel. If this visit results in an order for a CAT parts kit these visits on board should be at no cost to the shipping com- panies and will be refunded by CAT with € 500 max. for one visit ifthe necessary parts volume will be ordered with you. 6. Check List, Please review the check list with your customer. It shall serve as documentation of the current condition of the engines to enable the creation of additional offers for parts deliveries or service activities. sasnoensCaterpillar Marine Division 7. Contact Person in your Organization In case of further inquiries please let us have the name of the SOLAS contact person in your organization, 8. Contact Person in Kiel Your contact persons in Kiel are: Marketing Bodo Albrecht Tel: +49 (0}40 2980 3103 E-Mail: [email protected] Engineering & Regulations: Karl-Heinz Papendieck Tel: +49 (0)40 3995 2825 E-Mail: [email protected] Part kits: Klaus Humboldt Tol: +49 (0}40 3995 2822 E-Mail: [email protected] 9. Assembly ‘Authorized service personnel of the CAT service organization shall exclusively carry out the assembly. ‘The time required for a 6 cylinder M 453 engine is as follows: Part kit A ‘3 hours (2 persons) Part kit (B 4-8 hours (2 persons) without pump cladding Part kit ;C*: 20 hours (2.persons) during shipyard period Part kit “D" 3-6 hours (2 persons) eventually during shipyard period ‘These hours may vary due to local conditions. 10. Assembly Drawings For assembly of the part kits you will receive assembly drawings. Please ensure that unauthorized persons do not copy these drawings. 11. Certificate CAT will issue a copy of a type approval certificate by the responsible classification society which confirms that the required parts kit mounted by our Service Organization meets the necessary SOLAS requirements. 412. Warranty After mounting the part kits by authorized service personnel Caterpillar grants @ warranty of 12 months, max. 15 month after delivery, on these parts provided again that the part kits were completely mounted, Let us jointly utlize this possibilty to intensify our business relations with our customers and increase our sales. . ‘Should you have any further questions please contact one of the persons mentioned before. With best regards Caterpillar Motoren GmbH & Co. KG .V Heinsohn LV. Papendieck soca