M20C

07.06.
2007
10:16 Uhr
Seite 1
M 20 C Project Guide Generator Set
M-20-C-GenSet.qxd:Layout 1
Caterpillar Marine Power Systems

Headquarters
Europe, Africa, Middle East
Americas
Asia Pacific
Caterpillar Marine
Power Systems
Neumhlen 9
22763 Hamburg/Germany
Caterpillar Marine
Power Systems
Neumhlen 9
MaK Americas Inc.
Phone: +49 40 2380-3000

Telefax: +49 40 2380-3535
Phone: +49 40 2380-3000

Telefax: +49 40 2380-3535
Caterpillar Marine Trading

(Shanghai) Co., Ltd.
25/F, Caterpillar Marine Center
1319, Yanan West Road
200050 Shanghai/P. R.China
Phone: +86 21 6226 2200
Telefax: +86 21 6226 4500
For more information please visit our website:

www.cat-marine.com or www.mak-global.com
3450 Executive Way

Miramar Park of Commerce
Miramar, FL. 33025/USA
Phone: +1 954 447 71 00
Telefax: +1 954 447 71 15
Subject to change without notice.

Leaflet No. 219 06.07 e L+S VM3
Caterpillar Marine Asia

Pacific Pte Ltd
14 Tractor Road
Singapore 627973/
Singapore
Phone: +65 68287-600
Telefax: +65 68287-624
2007 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos,
Caterpillar Yellow and the POWER EDGE trade dress, as well as corporate identity
used herein, are trademarks of Caterpillar and may not be used without permission
M 20 C
Project Guide Generator Set
m
Introduction
Information for the user of this project guide

The project information contained in the following is not binding, since technical data of products may
especially change due to product development and customer requests. Caterpillar Motoren reserves
the right to modify and amend data at any time. Any liability for accuracy of information provided
herein is excluded.
Binding determination of data is made by means of the Technical Specification and such other agreements as may be entered into in connection with the order. We will supply further binding data, drawings, diagrams, electrical drawings, etc. in connection with a corresponding order.
This edition supersedes the previous edition of this project guide.
All rights reserved. Reproduction or copying only with our prior written consent.
Caterpillar Motoren GmbH & Co. KG

P. O. Box, D-24157 Kiel
Germany
Phone
+49 431 3995-01
Telefax
+49 431 3995-2193
Issue
April 2007
m
Contents
Page
1.
Engine description
1-2
2.
General data and outputs
3-4
3.
Restrictions for low load operation
4.
Load application and recovery behaviour
6-7
5.
Technical data
8-9
6.
Genset dimensions and weights
7.
Required dimensions of generator
8.
Space requirement for dismantling of charge air cooler and
9.
10 - 13
14
turbocharger cartridge
15
System connections
16
10.
Fuel oil system
17 - 30
11.
Lubricating oil system
31 - 36
12.
Cooling water system
37 - 44
13.
Flow velocities in pipes
45
14.
Starting air system
46
15.
Combustion air system
47
16.
Exhaust system
17.
Air borne sound power level
18.
Foundation
55 - 58
19.
Control and monitoring system
59 - 67
20.
Diesel engine management system DIMOS
68
21.
Standard acceptance test run
69
22.
EIAPP certificate
70
23.
Painting/Preservation
24.
Lifting of gensets
73
25.
Engine parts
74
48 - 53
54
71 - 72
Contents
1. Engine description
The M 20 C is a four stroke diesel engine, non-reversible, turbocharged and intercooled with direct fuel
injection.
In-line engine M 20 C
Cylinder configuration:
Bore:
Stroke:
Stroke/Bore-Ratio:
Swept volume:
Output/cyl.:
BMEP:
Revolutions:
Mean piston speed:
Turbocharging:
Direction of rotation:
Free end
6, 8, 9 in-line
200 mm
300 mm
1.5
9.4 l/Cyl.
170/190 kW
24.1/24.2 bar
900/1000 rpm
9/10 m/s
constant pressure system
counter-clockwise,
viewed from driving end
Cyl. number
Driving end
Control side
Exhaust side
1
Contents
1. Engine description
Engine design
- Designed for heavy fuel operation up to 700 cst./50 C, fuel grade acc. to CIMAC H55 K55, ISO 8217,
1996 (E), ISO-F-RMH55 RMK55.
- 1-piece dry engine block made of nodular cast iron. It incorporates the crankshaft bearing, camshaft bearing, charge air receiver, vibration damper housing and gear drive housing.
- Underslung crankshaft with corrosion resistant main and big end bearing shells.
- Natural hardened liners, centrifugally casted, with calibration insert.
- Composite type pistons with steel crown and aluminium alloy skirt.
- Piston ring set consisting of 2 chromium plated compression rings, first ring with chrom-ceramic
layer and 1 chromium plated oil scraper ring. Two ring grooves are hardened and located in the
steel crown.
- 2-piece connecting rod, fully machined, obliquely split with serrated joint.
- Cylinder head made of nodular cast iron with 2 inlet and 2 exhaust valves with valve rotators.
Direct cooled exhaust valve seats.
- Camshaft made of sections per cylinder allowing a removal of the pieces sideways.
- Turbocharger with inboard plain bearings lubricated by engine lubricating system
- No water cooling for turbocharger.
- 2-circuit fresh water cooling system with single charge air cooler.
- Nozzle cooling for heavy fuel operation only with engine lubricating oil.
Contents
2. General data and outputs
900 rpm / 60 Hz
1000 rpm / 50 Hz
Engine
kWm
Generator
kWe
Engine
kWm
Generator
kWe
6 M 20 C
1020
969
1140
1083
8 M 20 C
1360
1292
1520
1444
9 M 20 C
1530
1453
1710
1624
Remark:
The generator outputs are based on 95 % efficiency and a power factor of 0.8.
Output definition
The maximum continuous rating stated by Caterpillar Motoren refers to the following reference conditions according to "IACS" (International Association of Classification Societies) for main and auxiliary
engines:
Reference conditions according to IACS (tropical conditions):
air pressure
100 kPa (1 bar)
air temperature
318 K (45 C)
relative humidity
60 %
seawater temperature
305 K (32 C)
The permissible overload is 10 % for one hour every twelve hours. The maximum fuel rack position is
limited to 110 % continuous rating.
Fuel consumption
The fuel consumption data refer to the following reference conditions:
intake temperature
298 K (25 C)
charge air temperature
318 K (45 C)
charge air coolant inlet temperature
298 K (25 C)
net heating value of the Diesel oil
42700 kJ/kg
tolerance
5%
Specification of the fuel consumption data without fitted-on pumps; for each pump fitted on an additional consumption of 1 % has to be calculated.
Increased consumption under tropical conditions
3 g/kWh
3
Contents
2. General data and outputs
Lubricating oil consumption

Actual data can be taken from the technical data.
Nitrogen oxide emissions (NOx-values)

NOx-limit values according to MARPOL 73/78 Annex VI:
11.5/11.3 g/kWh at 900/1000 rpm
Generator according to cycle D2:
10.5/10.0 g/kWh at 900/1000 rpm
General installation aspect:

Inclination angles at which gensets and essential aux. machinery is to operate satisfactorily:
Heel to each side:
Rolling to each side:
Trim by head and stern:
Pitching:
15
+ 22,5
5
+ 7,5
Contents
3. Restrictions for low load operation
The engine can be started, stopped and run on heavy fuel oil under all operating conditions.
The HFO system of the engine remains in operation and keeps the HFO at injection viscosity. The temperature of the engine injection system is maintained by circulating hot HFO and heat losses are compensated.
The lube oil treatment system (lube oil separator) remains in operation, the lube oil is separated continuously.
The operating temperature of the engine cooling water is maintained by the cooling water preheater.
Below 25 % output heavy fuel operation is neither efficient nor economical.
A change-over to diesel oil is recommended to avoid disadvantages as e.g. increased wear and tear,
contamination of the air and exhaust gas systems and increased contamination of lube oil.
Cleaning run of engine

3h
1h
30 min
15 min
PE %
100
Cleaning run after partial load operation
70
Load increase period
approx. 15 min.
50
40
30
20
15
HFO-operation
10
8
Restricted HFO-operation
6
1h
5 6
8 10
15 20 24 h
Emergency start in the event of black out

Emergency start with gravity feed fuel from the diesel oil day tank is possible.
The bottom edge of the diesel oil day tank has to be arranged approx. 4 m above injection pump level.
5
Contents
4. Load application and recovery behaviour
The permissible load increase according to ISO 8528-5 and IACS must be carried out in several steps,
depending on the mean effective pressure. The ships network must be designed so that this permissible load increase is kept. The shipyard is to provide the approval of the responsible classification
society in time before classification acceptance of the engine.
Reference values for load steps, depending on bmep at continuous rating
4. load step
Load increase referred to continuous rating
100
90
[%]
80
3. load step
70
60
Limiting curve for

3rd load step
2. load step
50
Limiting curve for

2nd load step
40
1. load step
30
Limiting curve for

1st load step
20
10
10
12
14
16
18
20
22
24
26
28
BMEP at cont. rating of diesel engine

[bar]
Example:
6 M 20 C, 1140 kW, 1000 rpm, bmep = 24.2 bar
1. max. load from

2. max. load from
3. max. load from
4. max. load from
0%
33 %
54 %
75 %
to
to
to
to
33 % MCR
55 % MCR
75 % MCR
100 % MCR
Contents
4. Load application and recovery behaviour
Recovery behaviour after load increase based on reference values for load steps as well as unloading.
Standard settings:
- Droop 4 %
- Fuel rack 110 %
- Speed setting range + 5 %
Standard speed governor, make RE, type 1102, equipped with:
- Speed setting motor (24 V DC/100 % continuous duty) for a setting speed of 4 - 8 sec/Hz
- Start fuel limiter
- Shut-down solenoid (24 V DC/100 % continuous duty) for remote stop (not for automatic engine
stop)
- Infinitely adjustable from the outside at the governor, 0 - 10 % droop
Option for DE-drive only: RE, Viking 25 electronic governor
Contents
5. Technical data
(preliminary)
Cylinder
Performance data
Maximum continous rating acc.
ISO 3046/1
Speed
Minimum speed
Brake mean effektive pressure
Charge air pressure
Compression pressure
Firing pressure
Combustion air demand (ta = 20 C)
Delivery/injection timing
Exhaust gas temperature after
cylinder/turbine
Specific fuel oil consumption
Propeller/const. speed 1)
100 %
85 %
75 %
50 %
Lubricating oil consumption 2)
Turbocharger type
kW
1020
1140
1360
1520
1530
1710
rpm
rpm
bar
bar
bar
bar
m3/h
b. TDC
900
280
24.06
3.1
1000
300
24.2
3.25
900
280
24.06
2.9
1000
300
24.2
3.25
900
280
24.06
3.1
1000
300
24.2
3.3
145
180
5800
7/-
145
180
6650
9/-
7845
7/-
145
180
9260
9/-
8620
7/-
10150
9/-
380/343 375/350 360/335 380/320 380/351 400/340
g/kWh
g/kWh
g/kWh
g/kWh
g/kWh
186
190
186
190
186
190
189
186
189
186
189
186
188/189
189
188/189
189
188/189
189
195/199 191/195 195/199 191/195 195/199 191/195
0.6
0.6
0.6
KBB HPR 4000
KBB HPR 5000
KBB HPR 5000
Fuel
Engine driven feed pump
(for gas oil/MDO only)
Stand-by feed pump
Mesh size MDO fine filter
Mesh size HFO selfcleaning filter
Mesh size HFO fine filter
Nozzle cooling by lubricating oil
system for heavy fuel only
m3/h/bar
1.2/5
1.2/5
1.2/5
m3/h/bar
mm
mm
mm
0.80/5
0.025
0.010
0.034
1.0/5
0.025
0.010
0.034
1.2/5
0.025
0.010
0.034
m3/h/bar
m3/h/bar
bar
m3/h/bar
m3/h/bar
m3/h/bar
m3
C
mm
mm
52.5/10 58.8/10
30/10
4-5
43/3
40/3
5/5/8/3
1.7/0.5
55-65
65
0.03
52.5/10 58,8/10
35/10
4-5
48.3/3
45/3
8/5/10/3
2.3/0.6
55-65
65
0.03
52.5/10 58.8/10
40/10
4-5
61/3
48/3
8/5/10/3
2.6/0.8
55-65
65
0.03
Lubricating Oil
Engine driven pump
Stand-by pump
Working pressure on engine inlet
Engine driven suction pump
Stand-by suction pump
Prelubrication pump (press./suction)
Sump tank content (dry/wet)
Temperature at engine inlet
Selfcleaning filter DN
Mesh size selfcleaning filter
Contents
5. Technical data
(preliminary)
Cylinder
m
bar
m3
C
0.12
2.5/6.0
0.1
60 - 65
0.16
2.5/6.0
0.1
60 - 65
0.18
2.5/6.0
0.1
60 - 65
m /h/bar
m3/h/bar
mm
3
m /h/bar
25/4.0
30/4.0
30/4.0
50
40/45 / 4.0
30/4.0
35/4.0
40/4.0
65
40/45 / 4.0
35/4.0
40/4.0
45/4.0
65
40/45 / 4.0
42
42
42
kJ/kWh
kJ/kWh
kW
kW
kW
kW
550
500
550
500
550
500
Fresh water cooling

3
Engine content
Pressure at engine inlet min/max
Header tank capacity
Temperature at engine outlet
2-circuit system
Engine driven pump HT
Stand-by pump HT
HT-Controller DN
Engine driven pump NT
Temperature at charge air cooler
inlet
Heat Dissipation
Specific jacket water heat
Specific lub. oil heat
Lub. oil cooler
Jacket water
3)
Charge air cooler
Heat radiation engine
156
142
414
174
158
441
208
189
471
232
211
563
234
213
562
261
238
588
52
69
78
mm
mm
mm
400
400
400
500
500
500
500
500
500
bar
0.03
0.03
0.03
Exhaust gas
Silencer/spark arrester DN 25 dBA
DN 35 dBA
Pipe diameter DN after turbine
Maximum exhaust gas pressure
drop
5)
Temperature at 25 C air intake
45 C air intake
5)
Mass at
25 C air intake
45 C air intake
C
C
kg/h
kg/h
340
362
7380
7085
340
362
8230
7715
334
354
9677
9290
314
333
11485
11025
351
372
10703
10275
337
357
12505
11800
Starting air
Starting air pressure max.
Minimum starting air pressure
Air consumption per start 4)
bar
bar
Nm3
30
10
0.5
30
10
0.5
30
10
0.5
1)
Reference conditions: LCV = 42700 kJ/kg, ambient temperature 25 C charge air temperature 45 C,
tolerance 5 %, + 1 % for each engine driven pump
2)
Standard value, tolerance + 0.3 g/kWh, related to full load
3)
Charge air heat based on 45 C ambient temperature
4)
Preheated engine
5)
Tolerance 10 %, relative air humidity 60 %
Contents
6. Genset dimensions and weights
Engine
type
1)
Dry weight
Dimensions [mm]
Engine
Genset
[t]
[t]
6 M 20 C
6073
4900
2165
1054
1680
1170
627
783
1322
4405
11
20
8 M 20 C
6798
5548
2335
1054
1816
1170
710
783
1422
5053
14
27
9 M 20 C
7128
5875
2335
1054
1816
1170
710
783
1422
5380
15
30
Dependent on generator maker/type
Removal of:
in transverse direction
in longitudinal direction
X1
X2
=
=
2976 mm
3296 mm
Cylinder Liner in transverse direction

in longitudinal direction
Y1
Y2
=
=
2981 mm
3156 mm
Genset centre distance of 2 gensets
Minimum
2010 mm
Recommended 2120 mm
Piston
10
1)
Contents
Scale 1 : 50
6. Genset dimensions 6 M 20 C
11
Contents
Scale 1 : 50
12
Contents
Scale 1 : 50
13
Contents
7. Required dimensions of generator
Generators structural requirements for MaK diesel gensets M 20 C

Assembly control dimension "XX" and end float marked on the bearing
* Bore distances without tolerances + 0.8 mm,

the location of the holes has to be agreed
- Mounting flap for anti-condensation heater is required above the mounts

- With air cooling the air outlet is required above the mounts
- Plain bearings must be removable without coupling removal
Type
Design
D max.
B 20
1210
1350
1200
6 M 20 C
8 M 20 C
9 M 20 C
14
X
200
250
285
150
22
Contents
8. Space requirement for dismantling of charge air cooler and

turbocharger cartridge
Charge air cooler cleaning

Cleaning is carried out with charge air cooler dismantled. A container to receive the cooler and cleaning liquid is to be supplied by the yard. Intensive cleaning is achieved by using ultra sonic vibrators.
Turbocharger Removal/Maintenance
Caterpillar Motoren recommends to provide a lifting device above the bearing housing of the turbocharger (see "B").
Weights of Turbocharger [kg]
Turbo- Silencer Compressor Turbine
charger,
housing
housing
compl.
Dimensions [mm]
Cartridge
Rotor
6 M 20 C
236
25
46
51
54
13
515
268
892
1330
830
8/9 M 20 C
354
55
87
87
88
20
670
276
1025
1400
910
15
Contents
9. System connections
C15
C21
C22
C23
C25
C28
C37
C39
C60
C61
16
Charge Air Cooler LT, Outlet

Freshwater Pump HT, Inlet
Freshwater Pump LT, Inlet
Freshwater Stand-By Pump HT, Inlet
Freshwater, Outlet
Freshwater Pump LT, Outlet
Vent.
Drain Cooling Water
Separator Connection, Suction Side
Separator Connection, Delivery Side
DN 50
DN 65
DN 65
DN 50
DN 50
DN 50
DN 10
DN 25
DN 32
DN 32
C62a
C73
C75
C78
C81b
C86
C91
C91a
Drain Pre-Lube Pump

Fitted Fuel Pump, Inlet
Fuel Stand-By Pump, Connection
Fuel, Outlet
Fuel Duplex Filter, Dripoil
Starting Air
Crankcase Ventilation
Exhaust Gas Outlet
6 M 20 C
8/9 M 20 C
DN 32
DN 20
DN 20
DN 20
DN 10
DN 40
DN 50
DN 400
DN 500
Contents
10. Fuel oil system

MGO/MDO operation
Two fuel product groups are permitted for MaK engines:
Pure distillates:
Gas oil, marine gas oils, diesel fuel
Distillate/mixed fuels:
Marine gas oil (MGO), marine diesel oil (MDO). The difference between distillate/mixed fuels and pure distillates are
higher density, sulphur content and viscosity.
MGO
MDO
Designation
Max. viscosity
[cSt/40 C]
Designation
Max. viscosity
[cSt/40 C]
ISO 8217: 2005
ISO-F-DMA
1.5 - 6.0
ISO-F-DMB
ISO-F-DMC
11
14
ASTM D 975-78
No. 1 D
No. 2 D
2.4
4.1
No. 2 D
No. 4 D
4.1
24.0
EN 590
EN 590
Max. injection viscosity 12 cSt (2 E)
Day tank DT 1:
To be layed out for heat dissipation from injection pumps,

approx. 1 kW/cylinder
Strainer (separate) DF 2:
Mesh size 0.32 mm, dimensions see HFO-system
Preheater (separate) DH 1:
Heating capacity
Q [kW] =
Peng. [kW]
166
Not required with:

- MGO < 7 cSt/40 C
- Heated day tank
17
Contents
10. Fuel oil system

MGO/MDO operation
Feed pump (fitted) DP 1:
Capacity see technical data
Transfer pump (fitted) DP 3:
Capacity equal to feed pump

Option for MGO operation only
Pressure regulating valve (separate) DR 2
Fine filter (fitted) DF 1:
Duplex filter, mesh size see technical data.
Separator DS 1:
Recommended for MGO

Required for MDO
Capacity
V [l/h] = 0.22 Peng. [kW]
18
Contents
10. Fuel oil system

MGO/MDO operation
General notes:
For location, dimensions and design
(e. g. flexible connection) of the connecting points see engine installation drawing.
DH1 not required with:
- Gas oil < 7 cSt/40
- heated diesel oil day tank DT1
Accessories and fittings:

DF1
Fine filter (duplex filter)
DF2
Primary filter (duplex filter)
DF3
Coarse filter
DH1 Preheater
DH2 Electrical preheater (separator)
DP1
Feed pump
DP3
Transfer pump (to day tank)
DP5
Transfer pump (separator)
DR2
Pressure regulating valve
DS1
Separator
DT1
Day tank, min. 1 m above crankshaft level
DT4
Storage tank
KP1
KT1
FQ1
LI
LSH
LSL
PDI
PDSH
PI
PSL
TI
TT
Fuel injection pump

Notes:
Drip fuel tank
p Free outlet required
Flow quantity indicator
s Please refer to the measuring
Level indicator
point list regarding design of the
Level switch high
monitoring devices
Level switch low
z For systems without stand-by
Diff. pressure indicator
pump connect C75 for filling-up
Diff. pressure switch high
of the engine system!
Pressure indicator
Pressure switch low
Temperature indicator
Temperature transmitter (PT 100)
Connecting points:
C73
Fuel inlet
C75
Connection, stand-by pump
C78
Fuel outlet
C80
C81
C81b
Drip fuel
Drip fuel
Drip fuel (filter pan)
19
20
1)
mg/kg
Calcium
Fuel shall be free of used lubricating oil (ulo)
Kinematic viscosity at 100 C mm2/s (cSt)

Kinematic viscosity at 50 C mm2/s (cSt)
Kinematic viscosity at 100 F Redw. I sec.
An indication of the approximate equivalents in

kinematic viscosity at 50 C and Redw. I sec.
100 F is given below:
mg/kg
mg/kg
mg/kg
Aluminium + Silicon
Phosphor
mg/kg
Vanadium
Zinc
% (V/V
% (m/m)
% (m/m)
Total sedim, after ageing
Sulphur
% (m/m)
Ash
Water
% (m/m)
Carbon Residue
(Conradson)
Pour point (winter)

(summer)
cSt 1)
Flash point
Kin. viscosity at 100 C
7
30
200
max
max
max
max
max
max
max
max
max
max
max
min
min
max
max
kg/m3
Density at 15 C
10
40
300
6 5)
950 2)
0
6
15
80
600
150
CIMAC
B 10
30
15
15
80
3.5
0.5
35
380
3000
300
14
24
RMB30
CIMAC
C 10
975 3)
25
180
1500
0.10
0.10
60
10
RMB30
12 6)
RMA30
Limit
Dim.
Related to ISO8217 (2005):F-
Characteristic
CIMAC
A 10
Designation:
45
500
5000
30
15
15
80
350
4.0
0.5
0.10
0.10
14
30
60
15
980 4)
RMD80
CIMAC
D 15
55
700
7000
200
0.10
15
15 5)
30
15
15
80
4.5
0.5
CIMAC
F 25
500
0.15
20
RMF180
0.10
30
60
25
991
RME180
CIMAC
E 25
7)
6)
5)
4)
3)
2)
30
15
15
80
4.5
0.5
0.10
30
60
35
600
30
15
15
80
600
4.5
0.5
0.10
0.15 7)
0.15 7)
30
60
45
1010
RMK500
CIMAC
K 45
22
991
RMH500
CIMAC
H 45
22
1010
RMK380
CIMAC
K 35
ISO: 975
ISO: 981
ISO: 985
ISO: not limited
ISO: Carbon Residue 10
ISO: 0.20
300
0.15
18
CIMAC
H 35
RMH380
991
RMG380
CIMAC
G 35
Requirements for residual fuels for diesel engines (as bunkered)
991
22
30
60
55
30
15
15
80
600
4.5
0.5
0.10
1010
RMK700
CIMAC
K 55
0.15 7)
RMH700
CIMAC
H 55
m
Contents
10. Fuel oil system

Heavy fuel operation
Contents
10. Fuel oil system
Viscosity/temperature diagram
21
Contents
10. Fuel oil system

Minimum requirements for storage, treatment and supply systems

Bunker tanks:
In order to avoid severe operational problems due to incompatibility, each bunkering must be made in a separate storage tank.
Settling tanks:
In order to ensure a sufficient settling effect, the following

settling tank designs are permissible:
- 2 settling tanks, each with a capacity sufficient for
24 hours full load operation of all consumers
- 1 settling tank with a capacity sufficient for 36 hours full
load operation of all consumers and automatic filling
- Settling tank temperature 70 - 80 C
Two day tanks are required. The day tank capacity must
cover at least 4 hours/max. 24 hours full load operation of all
consumers. An overflow system into the settling tanks and
sufficient insulation are required.
Day tank:
Guide values for temperatures
Separators:
Fuel viscosity
cSt/50 C
Tank temperature
[C]
30 - 80
70 - 80
80 - 180
80 - 90
180 - 700
max. 98
Caterpillar Motoren recommends to install two self-cleaning separators. Design parameters as per supplier recommendation. Separation temperature 98 C! Maker and type
are to be advised to Caterpillar Motoren.
Capacity
V [l/h] = 0.22 Peng. [kW]
22
Contents
10. Fuel oil system

Supply system (Separate components): A closed pressurized system between daytank and engine
is required as well as the installation of an automatic backflushing filter with a mesh size of 10 m (absolute).
Strainer HF 2:
Pressure pumps HP 1/HP 2:
Mesh size 0.32 mm
Output
[kW]
DN
H1
< 5000
32
249
< 10000
40
< 20000
> 20000
H2
220
206
180
330
300
250
210
65
523
480
260
355
80
690
700
370
430
mm
Screw type pump with mechanical seal.

Installation vertical or horizontal. Delivery head 5 bar.
Capacity
.
V [m3/h] = 0.4 .
Peng. [kW]
1000
23
Contents
10. Fuel oil system

Pressure regulating valve HR 1:
Controls the pressure at the engine inlet, approx. 4 bar.
Engine outputs
<
= 8000 kW
<
= 3000 kW
> 8000 kW
Mesh size 10 m sphere passing mesh, make Boll & Kirch*,

without by-pass filter.
Self cleaning filter HF 4:
* In case of Caterpillar Motoren supply.

<
= 8000 kW, Type 6.60, DN 50

Dismantling of sieve
300 mm
24
> 8000 kW, Type 6.61, DN 100

Dismantling of sieve
300 mm
Contents
10. Fuel oil system

Mixing tank (without insulation) HT 2:

Vent
Inlet
from
pressure
pump
Outlet
to engine
Circulating pumps HP 3/HP 4:
From
engine
Engine output
Volume
Dimensions [mm]
Weight
[kW]
[l]
[kg]
< 4000
50
950
323
750
70
< 10000
100
1700
323
1500
120
> 10000
200
1700
406
1500
175
Design see pressure pumps.
Capacity
.
V [m3/h] = 0.7 .
Peng. [kW]
1000
Design head: 5 bar
Final preheater HH 1/HH 2:
Heating media:
- Electric current (max. surface power density 1.1 W/cm2)
- Steam
- Thermal oil
Temperature at engine inlet max 150 C.
Viscosimeter HR 2:
Controls the injection viscosity to 10 - 12 cSt.

Higher injection viscosity possible up to 16 cSt in combination with main engines.
To be confirmed by Caterpillar Motoren.
Fine filter (fitted) HF 1:
- Mesh size 34 m
- Without heating
- Differential pressure indication and alarm contact fitted
25
Contents
10. Fuel oil system

Mixing receiver HT 4:
Permits the individual change-over to MGO/MDO. Reduces

the temperature variation during change over.
Capacity:
approx. 30 l
Dimensions:
approx. 320 mm
height approx. 665 mm
without insulation
Diesel oil intermediate tank DT 2:
Required for the individual change-over to MGO/MDO.

Capacity:
approx. 50 l
Dimensions:
see mixing receiver
Diesel oil feed pump DP 1:
Capacity and delivery head

see heavy fuel oil circulating pump HP 3/HP 4
Fuel Cooler DH 3:
Required for heat dissipation with MGO/MDO operation.
26
Contents
10. Fuel oil system

C76
C78
- Peak pressure
max. 16 bar
Tanks and separators integrated in

the main engine system
General notes:
For location, dimensions and design (e. g. flexible connection) of the connecting
points see engine installation drawing. Valve fittings with loose cone are not accepted in the admission and return lines.
DH3
MGO/MDO cooler
DP1
Diesel oil feed pump
DR2
DT1
Diesel oil day tank
DT2
Diesel oil intermediate tank
HF1
HF2
Primary filter
HF4
Self cleaning filter
HH1
Heavy fuel final preheater
HH2
Stand-by final preheater
HH4
Heating coil
HP1/HP2 Pressure pump
HP3/HP4 Circulating Pump
HR1
HR2
Viscometer
HT1
Heavy fuel day tank
HT2
HT4
KP1
FQ1
LI
LSH
LSL
PDI
PDSH
PDSL
PI
PSL
TI
VI
VSH
VSL
Mixing tank
Mixing receiver
Injection pump
Level indicator
Level switch high
Level switch low
Diff. pressure switch low
Pressure indicator
Pressure switch low
Viscosity indicator
Viscosity Control switch high
Viscosity Control switch low
Notes:
ff Flow verlocity in circuit system
< 0.5 m/s
m Lead vent pipe beyond day tank
level
monitoring devices
tt Neither insulated nor heated pipe
u From diesel oil separator or diesel
oil transfer pump
All heavy fuel pipes have to be insulated.
---- heated pipe
Connecting points:
C76
Inlet duplex filter
C78
Fuel outlet
C80
Drip fuel
C81
Drip fuel
C81b Drip fuel (filter pan)
27
Contents
10. Fuel oil system

Heavy fuel oil supply- and booster standard module

(Pressurized System), up to IFO 700 for steam and thermaloil heating, up to IFO 180 for electr. heating
Technical specification of the main components:
1. Primary filter
1 pc. Duplex strainer 320 microns
2. Fuel pressure pumps, vertical installation
2 pcs. Screw pumps with mechanical seal
3. Pressure regulating system
1 pc. Pressure regulating valve
4. Self cleaning fine filter
1 pc. Automatic self cleaning fine filter 10 microns absolut (without by-pass filter)
5. Consumption measuring system
1 pc. Flowmeter with local totalizer
6. Mixing tank with accessories
1 pc. Pressure mixing tank
approx. 49 l volume up to 4,000 kW

approx. 99 l volume from 4,001 - 20,000 kW
(with quick-closing valve)
7. Circulating pumps, vertical installation

2 pcs. Screw pumps with mechanical seal
8. Final preheater
2 pcs. Shell and tube heat exchangers
28
each 100 % (saturated 7 bar or thermal oil 180 C)

each 100 % electrical
Contents
10. Fuel oil system

(steam/thermaloil)
(electrical)
9. a) Heating medium control valve

b) Control cabinet
1 pc. control valve with built-on positioning drive 1 pc. control cabinet for electr. preheater
10. Viscosity control system
1 pc. automatic viscosity measure and control system VAF
Module controlled automatically with alarms and starters
Pressure pump starters with stand-by automatic
Circulating pump starters with stand-by automatic
PI-controller for viscosity controlling
Starter for the viscosimeter
Analog output signal 4 - 20 mA for viscosity
Alarms
Pressure pump stand-by start
Low level in the mixing tank
Circulating pump stand-by start
Self cleaning fine filter pollution
Viscosity alarm high/low
The alarms with potential free contacts
Alarm cabinet with alarms to engine control room and connection possibility for remote start/stop and
indicating lamp of fuel pressure and circulating pumps
Performance and materials:
The whole module is tubed and cabled up to the terminal strips in the electric switch boxes which are
installed on the module. All necessary components like valves, pressure switches, thermometers,
gauges etc. are included. The fuel oil pipes are equipped with trace heating (steam, thermaloil or
electrical) where necessary.
The module will be tested hydrostatical and functional in the workshop without heating.
For power in kW up to (50/60 Hz)

Length in mm
Width in mm
Height in mm
Weight (approx.) in kg
Steam
Thermal oil
4000/4800
2200
1200
2000
2300
4000/4800
Steam
Thermal oil
8000/9600
8000/9600
2700
1200
2000
2400
3200
1200
2000
2500
3500
1200
2000
2700
Electric
Electric
Steam
Steam
Thermal oil Thermal oil
12000/14400 20000/24000
3500
1350
2000
3100
3500
1500
2000
3600
29
Contents
10. Fuel oil system

C76
C78
- Peak pressure
max. 16 bar
General notes:
For location, dimensions and design (e. g. flexible connection) of the connecting
points see engine installation drawing.
Tanks and separators integrated in the main engine system.
DH3
Fuel oil cooler from MDO operation
DP1
Diesel oil feed pump
DR2
Fuel pressure regulating valve
DT1
Diesel oil day tank
DT2
Diesel oil intermediate tank
HF1
HF2
Fuel primary filter
HF4
HH1
Final preheater
HH2
Stand-by final preheater
HH4
Heating coil
HP1
Pressure pump
HP2
Stand-by pressure pump
HP3
Circulating pump
HP4
Stand-by circulating pump
HR1
HR2
Viscometer
HT1
Day tank
30
HT2
HT4
HT8
KP1
FQ1
LI
LSH
LSL
PDI
PDSH
PDSL
PI
PSL
TI
VI
VSH
VSL
Mixing tank
Mixing receiver
Compensation damping tank
Fuel injection pump
Level indicator
Level switch high
Level switch low
Diff. pressure switch low
Pressure indicator
Pressure switch low
Viscosity indicator
Viscosity control switch high
Viscosity control switch low
Notes:
dd To diesel oil storage or overflow
tank
ff Flow velocity in circuit system
< 0.5 m/s
m Lead vent pipe beyond service
tank level
monitoring devices
u From diesel oil separator or diesel oil transfer pump
All heavy fuel pipes have to be insulated.
---- heated pipe
Connecting points:
C76
Inlet duplex filter
C78
Fuel outlet
C80
Drip fuel connection
C81
Drip fuel connection
C81b Drip fuel connection (filter
pan)
Contents
11. Lubricating oil system

Lube oil quality
The viscosity class SAE 40 is required.
Wear and tear and thus the service life of the engine depend on the lube oil quality. Therefore high
requirements are made for lubricants:
Constant uniform distribution of the additives at all operating conditions. Perfect cleaning (detergent
effect) and dispersing power, prevention of deposits from the combustion process in the engine. Sufficient alkalinity in order to neutralize acid combustion residues. The TBN (total base number) must be
between 30 and 40 KOH/g at HFO operation. For MDO operation the TBN is 12 - 20 depending on sulphur
content. RE-governor should be fitted with a normal 15 W 40 multipurpose oil.
Manufacturer
AGIP
BP
CALTEX
CASTROL
CEPSA
CHEVRON
TOTAL LUBMARINE
ESSO
MOBIL
SHELL
TEXACO
I
II
1)
Diesel oil/Marine-diesel
oil operation
DIESEL SIGMA S
CLADIUM 120
ENERGOL DS 3-154
VANELLUS C 3
DELO 1000 MARINE
DELO 2000 MARINE
MARINE MLC
MXD 154
TLX PLUS 204
KORAL 1540
DELO 1000 MARINE OIL
DISOLA M 4015
AURELIA 4030
EXXMAR 12 TP
EXXMAR CM+
ESSOLUBE X 301
MOBILGARD 412
MOBILGARD ADL
MOBILGARD M 430
1)
MOBILGARD 1-SHC
GADINIA
GADINIA AL
ARGINA S
ARGINA T
TARO 16 XD
TARO 12 XD
TARO 20 DP
II
X
X
X
X
X
X
X
X
HFO operation
CLADIUM 300 S
CLADIUM 400 S
ENERGOL IC-HFX 304
ENERGOL IC-HFX 404
DELO 3000 MARINE
DELO 3400 MARINE
TLX PLUS 304
TLX PLUS 404
X
X
X
X
X
X
X
X

AURELIA XL 4030
AURELIA XT 4040
EXXMAR 30 TP
EXXMAR 40 TP
EXXMAR 30 TP PLUS
EXXMAR 40 TP PLUS
MOBILGARD M 430
MOBILGARD M 440
X
X
X
X
X
ARGINA T
ARGINA X
X
X
TARO 30 DP
TARO 40 XL
X
X
II
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Approved in operation
Permitted for controlled use
When these lube oils are used, Caterpillar Motoren must be informed because at the moment there is insufficient experience available
for MaK engines. Otherwise the warranty is invalid.
Synthetic oil with a high viscosity index (SAE 15 W/40). Only permitted if the oil inlet temperatures can be decreased by 5 - 10 C.
31
Contents
Lube oil quantities/- change intervals:
Circulating quantity: 0.8 - 0.9 l/kW output

The change intervals depend on:
- the quantity
- fuel quality
- quality of lube oil treatment (filter, separator)
- engine load
By continuous checks of lube oil samples (decisive are the
limit values as per "MaK Operating Media") an optimum condition can be reached.
Gear type pump
Force pump (fitted) LP 1:
Suction strainer (fitted) LF 4
Selfcleaning filter (fitted) LF 2:
Mesh size 30 m (absolute), type 6.48, make Boll & Kirch.

Without by-pass filter. Without flushing oil treatment..
Cooler (fitted) LH 1:
Tube type
Temperature controller:
Not required
Prelubrication pump (fitted) LP 5:
Delivery head 5 bar

Continuous lubrication is carried out with stopped genset.
Starter to be supplied by the yard.
6 M 20 C
8/9 M 20 C
32
Hz
Capacity [m3/h]
Electr. motor [kW]
50
4.0
1.4
60
5.0
1.8
50
6.6
2.3
60
8.0
3.0
Contents
Circulating tank LT 1:
Located in the base frame, equipped with high/low level

switch and level control stick.
Crankcase ventilation:
The location of the ventilation is on top of the engine block

near to the turbocharger (see system connections C 91).
The vent pipe DN 50 must be equipped with a condensate
trap and drain. It has to be enlarged to DN 65 approx. 1 m
after the connection point and to be arranged separately for
each genset. Crankcase pressure max. 150 Pa.
Treatment at MGO/MDO operation

The service life of the lube oil will be extended by by-pass
treatment.
Centrifuge (Option, fitted) LS 2:
Minimum requirement
Separator LS 1:
Recommended with the following design:

- Separating temperature 85 - 95 C
- Quantity to be cleaned three times/day
- Self cleaning type
Separation capacity
Veff [l/h] = 0.18 Peng [Total kW]
For auxiliary gensets: Strongly recommended
1 separator for max. 3 engines
For diesel-electric drive: Required
1 separator for max. 3 engines with automatically switch
over in intervalls of 1.5 hours. See treatment at heavy fuel
operation.
33
Contents

MGO/MDO operation
General notes:
For location, dimensions and design (e. g. flexible connection) of
the connecting points see engine
installation drawing.
Notes:
e Filling pipe
f Drain
h Please refer to the measuring
point list regarding design of
the monitoring devices
o See "crankcase ventilation
installation instructions"

LF2
LF4
Suction strainer
LH1
Cooler
LH2
Preheater
LP1
Force pump
LP5
Prelubrication pump
LP9
LR2
LS1
Separator
LS2
Centrifuge (option)
LT1
Sump tank
34
LI
LSH
LSL
PDI
PDSH
PI
PSL
PSLL
TI
TSH
TT
Level indicator
Level switch high
Level switch low
Pressure indicator
Pressure switch low
Pressure switch low
Temperature switch high
Temperature transmitter (PT 100)
Connecting points:
C60
Separator connection, suction
side or drain or filling pipe
C61
Separator connection, delivery
side or from by-pass filter
C62a
Oil drain, prelubrication pump
C91
Crankcase ventilation to stack
NC
Normally closed
Contents

Treatment at heavy fuel operation
Separator LS 1:
Required with the following design:

- Separating temperature 95 C
- Quantity to be cleaned five times/day
- Utilization 20 % max.
Capacity
Veff [l/h] = 0.29 . Peng [Total kW]
For auxiliary gensets:
1 separator per genset recommended

1 separator for maximum 3 gensets required
The following is to be observed:
1. The separator is switched over successively and automatically controlled in intervals of 1.5 hours to the respective sump tank of the diesel genset.
2. The change over valves are to be provided with mutual
mechanical or electric interlocks in order to avoid faults
in switching over.
3. All diesel gensets (operation, stand-by, stopped) are to
be included in these change over intervals.
4. If a diesel genset is not available (servicing, maintenance
etc.), it must be taken out of the interval control. For this a
contact of a higher ranking start/stop automatic (integrated in the power management system) must be provided for the interval control.
5. The separator must always be running or restarted after
a failure/black-out.
Change over valves and the automatic switch over control
system have to be supplied by the yard.
For diesel-electric drive:
1 Separator per genset required
35
Contents

General notes:
the connecting points see engine
installation drawing.
Notes:
e Filling pipe
f Drain
h Please refer to the measuring
point list regarding design of
o See "crankcase ventilation installation instructions"

LF2
LF4
Suction strainer
LH1
Cooler
LH2
Preheater
LP1
Force pump
LP5
Prelubrication pump
LP9
LR1
Temperature control valve
LR2
LS1
Separator
LT1
Sump tank
36
LI
LSH
LSL
PDI
PDSH
PI
PSL
PSLL
TI
TSH
Level indicator
Level switch high
Level switch low
Pressure indicator
Pressure switch low
Pressure switch low
Temperature switch high
Connecting points:
C60
Separator connection, suction
side or drain or filling pipe
C61
Separator connection, delivery
side or from by-pass filter
C62a
Oil drain, prelubrication pump
C91
Crankcase ventilation to stack
NC
Normally closed
Contents
12. Cooling water system
The heat generated by the engine (cylinder, turbocharger, charge air and lube oil) is to be eliminated by
means of treated freshwater acc. to the MaK coolant regulations.
The inlet temperature in the LT-circuit is max. 38 C.
Two-circuit cooling
Standard cooling system:
Charge air temperature control not required. Watercooled generators are not equipped with pipes.
HT-fresh water pump (fitted) FP 1:
Capacity: acc. to heat balance
LT-fresh water pump (fitted) FP 2:
Capacity: acc. to heat balance
HT-temperature controller (separate) FR 1:
P-controller with manual emergency adjustment

(basis).
Dimensions [mm]
Weight
DN
[kg]
6 M 20 C
HT
50
165
150
225
177
24
8/9 M 20 C
HT
65
185
165
254
158
26
3 x 6/8/9 M 20 C LT
125
250
241
489
200
67
37
Contents
LT-temperature controller (separate) FR 2:
P-controller with manual emergency adjustment.

Not required with the combination of the main engine LT-system.
Preheater with pump (fitted on base frame)

FH 5/FP 7:
Freshwater cooler (separate) FH 1:
Consisting of circulating pump (3.5 m3/h), electric

heater (7 kW) and switch cabinet (separate: W x H x
D = 450 x 300 x 200 mm). Voltage 380 - 460, frequency
50/60 Hz.
Plate type, size depending on the total heat to be

dissipated.
For auxiliary genset normally integrated in the main
engine cooling system.
Header tank:
For auxiliary genset normally integrated in the main

engine system.
- Arrangement: min. 4 m above crankshaft centre
line.
- Size acc. to technical engine data, in case of several engines + 25 % volume per engine.
- All continuous vents from engine are to be connected.
38
Contents
Drain tank with filling pump:
Is recommended to collect the treated water when carrying

out maintenance work (to be installed by the yard).
Electric motor driven pumps:
Option for fresh and seawater , vertical design.

Rough calculation of power demand for the electric balance.
P=
P P. M V H -
Power [kW]
Power of electr. motor [kW]
Flow rate [m3/h]
Delivery head [m]
Density [kg/dm3]
Pump efficiency
0,70 for centrifugal pumps
.
HV
367
[kW]
PM = 1.5 P
PM = 1.25 P
PM = 1.2 P
PM = 1.15 P
PM = 1.1 P
< 1.5
1.5 - 4
4 - 7.5
> 7.5 - 40
> 40
kW
kW
kW
kW
kW
39
m
Heat balance 6 M 20 C
40
Contents
Contents
Heat balance 8 M 20 C
41
m
Heat balance 9 M 20
42
Contents
Contents

Integrated in the main engine LT-cooling water system
General notes:
For location, dimensions and design (e. g. flexible connection) of the connecting points see
engine installation drawing.
Notes:
h
Please refer to the
measuring point list regarding design of the
monitoring devices
Distance min. 1 m
NC
Normally closed
Connecting points:
C15 Charge air cooler, outlet
C21 Freshwater pump HT,
inlet
C22 Freshwater pump LT,
inlet
C25 Cooling water, engine
outlet
C37 Ventilation connection
C39 Drain
CH1 Charge air cooler
FH5 Freshwater preheater
FP1 Freshwater pump (fitted
on engine) HT
FP2 Freshwater pump (fitted
on engine) LT
FP7 Preheating pump
FR1 Temperature
control
valve HT
LH1 Luboil cooler
PI
Pressure indicator
PSL Pressure switch low
TI
TSH Temperature switch high
TSHH Temperature switch high
to central cooling
system LT
from central cooling
system LT
43
Contents

For gensets not integrated in the main engine LT cooling water system

FH1 Freshwater cooler
FR2 Temperature control valve LT
SF1 Duplex seawater filter
SP1 Seawater pump
SP2 Seawater stand-by pump
ST1 Sea chest
PI
Pressure indicator
TI
Notes:
o Mesh size 2 - 5 mm
z Short circuit pipe for adjusting a
minimum seawater inlet temperature of 10 - 20 C
Connection see drawing page 43

to gensets
from gensets
44
Contents
Volume flow [m3/h]
13. Flow velocities in pipes
Example:
di = 100 mm, V = 60 m3/h

Velocity in the pipe 2.1 m/s
Velocity in the pipe [m/s]
45
Contents
14. Starting air system
Required pressure 30 bar

Air starter (fitted) AM 1:
With pressure reducer 30/10 bar.
Min. starting air pressure and air consumption see technical data.
General notes:
the connecting points see engine installation drawing.
Clean and dry starting air is required.
Notes:
a
Control air
d
Water drain (to be mounted at the lowest point)
e
To other gensets
h
Please refer to the measuring point list regarding design of
j
Automatic drain (recommended)
Connecting points:
C86 Connection, starting air
46

AC1
Compressor
AC2
Stand-by compressor
AM1
Air starter
AR1
Starting valve
AR4
Pressure reducing valve
AR5
Oil and water separator
AT1
Starting air receiver
AT2
Starting air receiver
PI
Pressure indicator
PSL
Pressure switch low, only for main engine
PT
Pressure transmitter
AT1/AT2 Option:
- Typhon valve
- Relief valve with pipe connection
Contents
15. Combustion air system
General:
To obtain good working conditions in the engine room and to

ensure trouble free operation of all equipment attention
shall be paid to the engine room ventilation and the supply of
combustion air.
The combustion air required and the heat radiation of all
consumers/heat producers must be taken into account.
Air intake from engine room (standard): - Fans are to be designed for a slight overpressure in the
engine room.
- On system side the penetration of water, sand, dust, and
exhaust gas must be avoided.
- When operating under tropical conditions the air flow
must be conveyed directly to the turbocharger.
- The temperature at turbocharger filter should not fall below + 10 C.
- In cold areas warming up of the air in the engine room
must be ensured.
Air intake from outside:
- The intake air duct is to be provided with a filter. Penetration of water, sand, dust and exhaust gas must be
avoided.
- Connection to the turbocharger is to be established via an
expansion joint (to be supplied by the yard). For this purpose the turbocharger will be equipped with a connection
socket.
- At temperatures below + 10 C the Caterpillar Motoren/
Application Engineering must be consulted.
Radiated heat:
see technical data

To dissipate the radiated heat a slight and evenly distributed
air current is to be led along the engine exhaust gas manifold starting from the turbocharger.
47
Contents
16. Exhaust system
Position of exhaust gas nozzle:
Exhaust compensator:
A nozzle position of 0, 45 and 90 is possible.
Diameter DN
Length [mm]
Weight [kg]
6 M 20 C
400
365
31
8/9 M 20 C
500
360
42
Design of the pipe cross-section:
The pressure loss is to be minimized in order to optimize fuel

consumption and thermal load of the engine.
Max. flow velocity: 40 m/s (guide value).
Max pressure loss (incl. silencer and exhaust gas boiler):
30 mbar
(lower values will reduce thermal load of the engine).
The aforesaid value is also applicable as value for the total
flow resistance of plants with separate intake air filter!
Notes regarding installation:
- Arrangement of the first expansion joint directly on the

exhaust gas nozzle
- Arrangement of the first fixed point in the conduit directly
after the expansion joint
- Drain opening to be provided (protection of turbocharger
and engine against water)
- Each engine requires an exhaust gas pipe (one common
pipe for several engines is not permissible).
If it should be impossible to use the standard transition

piece supplied by Caterpillar Motoren, the weight of the
transition piece manufactured by the shipyard must not exceed the weight of the standard transition piece. A drawing
including the weight will then have to be submitted approval.
48
Contents
16. Exhaust system

Resistance in exhaust gas piping
Example (based on diagram data A to E):

t
= 335 C, G = 25000 kg/h
l
= 15 m straight pipelength, d = 700 mm
3 off 90 bend R/d = 1.5
1 off 45 bend R/d = 1.5
Pg = ?
p
L'
L
Pg
=
=
=
=
0.83 mm WC/m
3 11 m + 5.5 m
l + L' = 15 m + 38.5 m = 53.5 m
p L = 0.83 mm WC/m 53.5 m = 44.4 mm WC
t
G
p
d
w
l
L'
L
Pg
=
=
=
=
=
=
=
=
=
Exhaust gas temperature

Exhaust gas massflow
Resistance/m pipe length
Inner pipe diameter
Gas velocity
Straight pipe length
Spare pipe length of 90 bent pipe
Effective substitute pipe length
Total resistance
(C)
(kg/h)
(mm WC/m)
(mm)
(m/s)
(m)
(m)
(m)
(mm WC)
49
Contents
16. Exhaust system

(preliminary)
Exhaust sound power level Lw not attenuated [1 x 1 m from open pipe]

The noise measurements are made with a probe inside the exhaust pipe.
6 M 20 C (1140 kW/1000 rpm)
160
150
140
LwOct [dB]
(reference 10-12 W)
137
138
138
130
136
132
129
126
120
123
119
110
100
0.031
0.063
0.125
0.25
0.5
f [kHz]
f [kHz]
f [kHz]
8 M 20 C (1520 kW/1000 rpm)

160
150
LwOct [dB]
(reference 10-12 W)
140
130
136
138
138
136
133
130
127
120
125
121
110
100
0.031
0.063
0.125
0.25
0.5
9 M 20 C (1710 kW/1000 rpm)

160
150
LwOct [dB]
(reference 10-12 W)
140
130
136
138
139
137
134
131
128
127
123
120
110
Tolerance + 2 dB
50
100
0.031
0.063
0.125
0.25
0.5
Contents
16. Exhaust system
Silencer:
Design according to the absorbtion principle with wideband attenuation over a great frequency range and low
pressure loss due to straight direction of flow. Sound absorbing filling consisting of resistant mineral wool.
Sound level reduction 25 dB(A), alternatively 35 dB(A).
Max. permissible flow velocity 40 m/s.
Silencer with spark arrester:
Soot separation by means of a swirl device (particles are

spun towards the outside and separated in the collecting
chamber). Sound level reduction 25 dB(A) or 35 dB(A). Max.
permissible flow velocity 40 m/s.
Silencers are to be insulated by the yard. Foundation brackets are provided as an option.
51
Contents
16. Exhaust system
Silencer/Spark arrestor and silencer:
Installation: vertical/horizontal
Flange according to DIN 86044
Counterflanges, screws and gaskets are included, without
supports and insulation
Silencer
Spark arrestor and silencer
Attenuation
25 dB (A)
35 dB (A)
DN
kg
kg
6 M 20 C
400
850
544
2934
550
3686
680
8/9 M 20 C
500
950
594
3184
710
3936
800
Exhaust gas boiler:
Each engine should have a separate exhaust gas boiler. Alternatively, a common boiler with separate gas sections for
each engine is acceptable.
Particularly when exhaust gas boilers are installed attention
must be paid not to exceed the maximum recommended
back pressure.
52
Contents
16. Exhaust system
Cleaning the turbocharger compressor: The components for cleaning (dosing vessel, pipes, shut-off
valve) are engine mounted.
Water is fed before compressor wheel via injection pipes
during full load operation every 24 to 48 hours.
Cleaning the turbine blade and
nozzle ring:
At heavy fuel operation only.

The cleaning is carried out with clean fresh water "wet
cleaning" during low load operation at regular intervals, depending on the fuel quality, 250 to 500 hours.
Duration of the cleaning period is approx. 20 minutes. Fresh
water of 1.5 bar is required.
During cleaning the water drain should be checked. Therefore the shipyard has to install a funnel after connection
point C36.
C36 Drain, 25
C42 Fresh water supply,
16,
with quick coupling
device
Water flow
[l/min]
Injection time
[sec]
6 M 20 C
4-6
3 - 4 x 30 *
8/9 M 20 C
6 - 10
3 - 4 x 30 *
* with 3 min waiting period at a time
Dirty water tank

53
Contents
17. Air borne sound power level

(preliminary)
The airborne noise of the engines is measured as a sound power level according to EN ISO 9614-2/
Accuracy class 3.
6 M 20 C (1140 kW/1000 rpm)
130
125
120
LwOct [dB]
(reference 10-12 W)
115
114
110
105
111
110
108
111
110
111
108
107
100
101
95
90
0.031
0.063
0.125
0.25
0.5
16 f [kHz]
8 M 20 C (1520 kW/1000 rpm)

130
125
120
LwOct [dB]
(reference 10-12 W)
115
115
109
110
111
108
110
109
100
110
107
105
100
102
95
90
0.031
0.063
0.125
0.25
0.5
16 f [kHz]
9 M 20 C (1710 kW/1000 rpm)
130
125
LwOct [dB]
(reference 10-12 W)
120
119
115
114
110
105
114
114
111
112
110
108
104
101
100
95
90
Tolerance + 2 dB
54
0.031
0.063
0.125
0.25
0.5
16 f [kHz]
Contents
18. Foundation
Resilient mounting
Gensets have to be resiliently mounted.

This provides an activ insulation against forces generated by the engine as well as protection against
vibration from rigidly mounted main engines.
The ship's foundation does not require machining. Unevenness is to be compensated by welding
plates (to be provided by the shipyard). The resilient element includes horizontal and vertical stopper
(fail-safe design).
Major components:
- Resilient elements for active insulation of dynamic engine forces
- Flexible pipe connections for all media
- Welding plates
Number of resilient elements:
6 M 20 C: 12
8/9 M 20 C: 14
Structure borne sound level Lv, expected (measured in the test cell)
110
97
100
Lv Oct [dB]
(reference
5*10-8 m/s)
90
80
70
82
91
70
81
76
78
77
74
59
60
72
62
50
50
above
58
52
40
45
below
30
20
0.031
0.063
0.125
0.25
0.5
Frequency [kHz]
55
Contents
18. Foundation
Foundation plan
6 M 20 C
Alignment tolerance, vertical + 1,0 mm
Resilient element with fail-safe

design (horizontal and vertical
stopper)
56
Contents
18. Foundation
Foundation plan
8 M 20 C

stopper)
57
Contents
18. Foundation
Foundation plan
9 M 20 C

stopper)
58
Contents
19. Control and monitoring system

Engine control panel
Detail X: Equipment for local engine control
59
Contents

Genset control
*) = not delivered by Caterpillar Motoren
60
Contents
Engine monitoring
61
Contents

Monitoring: M 20 C aux. genset
Measur.point
Monitoring point
Action
OA
OA
MS
1105
Luboil pressure
PAL
1106
Luboil pressure
PALL
1112
Luboil differential pressure

selfcleaning filter
Luboil pressure prelubrication
Luboil temperature engine
inlet
Luboil level sump tank
Luboil level sump tank
FW pressure high temp. circuit
engine inlet
FW press. low temp. circuit
cooler inlet
FW temp. high temp. circuit
engine outlet
FW temp. high temp. circuit
engine outlet
Fuel oil pressure engine inlet
Fuel oil pressure pressure
pump
Fuel oil differential pressure
duplex filter
selfcleaning filter
circulating pump
before and after circulating
pump
Fuel oil viscosity engine inlet
Fuel oil viscosity engine inlet
Level of leak fuel
Fuel level mixing tank
Starting air pressure engine
inlet
Shut down air pressure on
engine
Exhaust gas temp. after
turbocharger
Exhaust gas temperature after
turbocharger
1142
1202
1311
1312
2102
2112
2211
2213
5102
5105
5111
5112
5115
5116
5251
5252
5301
5333
6101
6105
8221
8221
PDAH
OA
PL
Sensor
Fitted
A
Remarks
Separate
B
B
B
TAH
OA
LAL
LAH
OA
OA
B
B
PAL
OA
PAL
OA
TAH
OA
Starting interlock
PAL
OA
MS
OA
PAL
OA
PDAH
OA
PDAH
OA
B*
PDAL
OA
B*
PDAL
OA
B*
VAH
VAL
LAH
LAL
OA
OA
OA
OA
A*
A*
PAL
OA
PAL
OA
OA
TAH
OA
OA
MS
TAHH
9404
Engine overspeed
9405
Engine speed
stop starting air
* located in the fuel pressure system
62
Abbrev.
B
A
B*
Starting stand-by pump from

pump control
Starting stand-by pump from

pump control
1 Sensor f. 5251, 5252

1 Sensor f. 5251, 5252
B
B*
Only thermocouple
B
B
Contents

Monitoring: M 20 C aux. genset
Measur.point
9409
9419
9503
9561
Monitoring point
9611
Sensor
Action
Fitted
Remarks
Separate
Working hour meter/engine
Engine speed
NI
Stop lever in pos. operation
Genset ready for operation
Barring gear engaged
Start interlock
Electronic units/terminal point

X1/voltage failure
RPM switch/voltage failure/
wire break
9601
Abbrev.
OA
OA
B
With electronic governor
only
With electronic governor
only
9615
Failure electronic governor
OA
9616
Failure electronic governor
OA
MS
OA
Dependent from system
OA
Dependent from system
Viscosity control, voltage

failure
Fuel oil preheater, voltage
failure
9761
9775
Additional monitoring for DE-drive

Measur.point
Monitoring point
2321
5102
8211
8231
9429
9622
Sensor
Action
Fitted
FW pressure high temp.
circuit engine inlet
Oil ingress in fresh water
cooler outlet
Fuel oil pressure engine inlet
Exhaust gas temp. per cyl.
Exhaust temperature before
turbocharger
Turbocharger speed
Exhaust gas temp. average
equipment, voltage failure
2103
Abbrev.
PALL
OA
MS
QAH
OA
PAL
T
OA
OA
A
A
TAH
OA
Separate
For DE-drive only

B
S
S
Remarks
Only thermocouples
A
OA
Abbreviations
B
A
= Binary sensor
= Analogue sensor
LAH
LAL
NI
PAL
PALL
PDAH
PDAL
=
=
=
=
=
=
=
Level alarm high

Level alarm low
Speed indication
Pressure alarm low
Pressure alarm low low
Pressure difference alarm high
Pressure difference alarm low
OA
AD
MS
QA
QAH
S
TAH
TAHH
VAH
VAL
=
=
=
=
=
=
=
=
=
=
Visual and audible alarm

Autom. speed/load reduction
Autom. engine stop
Measurement alarm
Measurement alarm high
Speed
Temperature alarm high
Temperature alarm high high
Viscosity alarm high
Viscosity alarm low
63
64
Exhaust gas temperature after turbocharger
Start air pressure
Luboil pressure
Freshwater pressure HT
Freshwater pressure LT
2)
1)
Alternatively 144 x 144

Only 96 x 192 with exhaust gas monitoring
Option
Sensor Signals from the

engine
Turbocharger speed (optional for DE)
mV mA
(0 - 10 V)
Gauge board (fitted on engine)

Fuel pressure
0 - 10 V
Remote indicator
option
Charge air pressure after intercooler
Engine speed
1)
2)
* not Caterpillar Motoren supply
Shut down air pressure
Exhaust gas temperature after cylinder
Monitor
*
2)
Charge air temperature before engine
Remote 96 x 96
Display
Charge air temperature before intercooler
Freshwater temperature after intercooler
Freshwater temperature at engine outlet HT
Freshwater temperature at engine inlet HT
Differential pressure luboil filter
Luboil temperature at engine inlet
Mean injection pump rack position
Differential pressure fuel filter
Fuel temperature at engine inlet
At the engine
Indicators
m
Contents
Local and remote indicators

Remote indication interfacing
Remote indicator
engine speed
option
Signal type
4-20 mA
(mA)
Analog-monitoring
equipment *
mA V
RPM switch
unit
Contents
Protection system
Operating voltage: 24 V DC
Type of protection: IP 55
Protection against false polarity and transient protection provided.
Designed for:
3 starting interlock inputs

6 automatic stop inputs
1 manual stop input
The input and output devices are monitored for wire break.
Rpm switch unit system
Designed for:
3 rpm switching points
Analogue outputs for speed:
1 x 0-10 V, 1 x 4-20 mA, 1 x frequency
65
Contents

Protection system
Rpm switch unit
66
Contents
Start/stop logic
67
Contents
20. Diesel engine management system DIMOS
DIMOS is a computer aided maintenance and spare part management system for Caterpillar Motoren
diesel engines. The DIMOS-system will include a data base which is filled with information derived
from the operating instructions and the spares catalogue of your respective engine type. This system
enables to administration and check the following three major subjects:
1. Maintenance
2. Material management
3. Statistics
These four major subjects are provided with many internal connections, so that no double inputs are
required. All you need for running the DIMOS-system is commercial PC hardware.
The advantages are evident:
Precise follow-up regarding the maintenance intervals as specified by Caterpillar Motoren. No
scheduled date will be forgotten and no history file will be missed.
Immediate access to maintenance and component information.
Quick and simple modification of data is possible at any time.
Extensive and permanently up-to-date decision documents for maintenance with precise updating
of terms.
A lot of paper work can be omitted, and this means a considerable saving of time.
This can be taken from the DIMOS database as well as from the CD-Rom and the standard documentation.
From various single information to an integrated system

Engine operating
instructions
Engine spare parts

catalogues
Maintenance
schedule
Maintenance
job cards
DIMOS
O
Maintenance
planning
68
T
Work order
creation
P
History and
statistics
T
Inventory and
purchase
Contents
21. Standard acceptance test run
The acceptance test run is carried out on the testbed with customary equipment and auxiliaries using
exclusively MDO and under the respective ambient conditions of the testbed. During this test run the
fuel rack will be blocked at the contractual output value. In case of deviations from the contractual
ambient conditions the fuel consumption will be converted to standard reference conditions.
The engine will be run at the following load stages acc. to the rules of the classification societies.
After reaching steady state condition of pressures and temperatures these will be recorded and registered acc. to the form sheet of the acceptance test certificate:
Load [%]
Duration [min]
50
30
85
30
100
60
110
30
In addition to that the following functional tests will be carried out:

- governor test
- overspeed test
- emergency shut-down via minimum oil pressure
- start/stop via central engine control
- measurement of crank web deflection (cold/warm condition)
After the acceptance main running gear, camshaft drive and timing gear train will be inspected
through the opened covers. Individual inspection of special engine components such as piston or
bearings is not intended, because such inspections are carried out by the classification societies at
intervals on series engines.
Engine movement due to vibration referred to the global vibration characteristics of the engine:
The basis for assessing vibration severity are the guidelines ISO 10816-6.
According to these guidline the MaK engine will be assigned to vibration severity grade 28, class 5.
On the engine block the following values will not be exceeded:
Displacement
Vibration velocity
Vibration acceleration
S eff
V eff
a eff
< 0.448 mm
< 28.2 mm/s
< 44.2 m/s2
f > 2 Hz < 10 Hz
f > 10 Hz < 250 Hz
f > 250 Hz < 1000 Hz
69
Contents
22. Engine International Air Pollution Prevention Certificate
The MARPOL Diplomatic Conference has agreed about a limitation of NOx emissions, referred to as
Annex VI to Marpol 73/78.
When testing the engine for NOx emissions, the reference fuel is Marine Diesel Oil (Distillate) and the
test is performed according to ISO 8178 test cycles:
D2:
E2:
E3:
Auxiliary genset
Diesel electric on controlable pitch propeller
Fixed pitch propeller at variable speed
Output [%]
100
75
50
25
10
E2+E3 weighting factor
0,20
0,50
0,15
0,15
D2
0,05
0,25
0,30
0,30
0,10
weighting factor
Subsequently, the NOx value has to be calculated using different weighting factors for different loads
that have been corrected to ISO 8178 conditions.
An EIAPP (Engine International Air Pollution Prevention) certificate will be issued for each engine
showing that the engine complies with the regulation. At the time of writing, only an interim
certificate can be issued due to the regulation not yet in force.
According to the IMO regulations, a Technical File shall be made for each engine. This Technical File
contains information about the components affecting NOx emissions, and each critical component is
marked with a special IMO number. Such critical components are injection nozzle, injection pump,
camshaft, cylinder head, piston, connecting rod, charge air cooler and turbocharger. The allowable
setting values and parameters for running the engine are also specified in the Technical File.
The marked components can later, on-board the ship, be easily identified by the surveyor and thus an
IAPP (International Air Pollution Prevention) certificate for the ship can be issued on basis of the
EIAPP and the on-board inspection.
70
Contents
23. Painting/Preservation
Inside preservation
N 576-3.3
Up to 1 year, engine protected from moisture.
- Main running gear and internal mechanics
Outside preservation
N 576-3.1 - Tectyl light
Europe
Storage in the open, protected from moisture, up to 1 year
Appearance of the engine:
- Castings with red oxide antirust paint
- Pipes and machined surfaces left as bare metal
- Attached components with colours of the makers
N 576-3.2 - Tectyl heavy-duty
Overseas
N 576-4.1 - Clear Varnish
Clear varnish painting is applicable within Europe for land transportation with protection from
moisture. It is furthermore applicable for storage in a dry and tempered atmosphere.
Clear varnish painting is not permissible for:
- Sea transportation of engines
- Storage of engines in the open, even if they are covered with tarpaulin
VCI packaging as per N 576-5.2 is always required!
Durability and effectiveness are dependent on proper packing, transportation, and storage, i.e. the
engine must be protected from moisture, the VCI foil must not be torn or destroyed.
Checks are to be carried out at regular intervals.
If the above requirements are not met, all warranty claims in connection with corrosion damages
shall be excluded.
71
Contents
23. Painting/Preservation

- Surfaces sealed with clear varnish
- Bare metal surfaces with light preservation
N 576-4.3 - Painting
- No VCI packaging:
Short-term storage in the open, protected from moisture, max. 4 weeks
- With VCI packaging:
- Surfaces mostly painted with varnish
- Bare metal surfaces provided with light or heavy-duty preservation
N 576-5.2 - VCI packaging
Storage in the open, protected from moisture, up to 1 year.
Applies for engines with painting as per application groups N 576-4.1 to -4.4
Does not apply for engines with Tectyl outside preservation as per application groups N 576-3.1 and 3.2.
Description:
- Engine completely wrapped in VCI air cushion foil, with inserted VCI-impregnated flexible
PU-foam mats.
N 576-5.2 Suppl. 1 - Information panel for VCI preservation and inspection
Applies for all engines with VCI packaging as per application group N 576-5.2
Description:
- This panel provides information on the kind of initial preservation and instructions for inspection.
- Arranged on the transport frame on each side so as to be easily visible.
N 576-6.1 - Corrosion Protection Period, Check, and Represervation
Applies to all engines with inside and outside storage
Description:
- Definitions of corrosion protection period, check, and represervation
72
1393
1902
2053
6 M 20 C
8 M 20 C
9 M 20 C
1600
1400
1505
m
Contents
24. Lifting of gensets
73
Contents
25. Engine parts
Cylinder head, Weight 121 kg
Piston with connecting rod, Weight 57 kg
74
Cylinder liner, Weight 60 kg
07.06.2007
10:16 Uhr
Seite 1
M 20 C Project Guide Generator Set
M-20-C-GenSet.qxd:Layout 1
Caterpillar Marine Power Systems

Headquarters
Europe, Africa, Middle East
Americas
Asia Pacific
Caterpillar Marine
Power Systems
Neumhlen 9
Caterpillar Marine
Power Systems
Neumhlen 9
MaK Americas Inc.
Phone: +49 40 2380-3000

Telefax: +49 40 2380-3535
Phone: +49 40 2380-3000

Telefax: +49 40 2380-3535
Caterpillar Marine Trading

(Shanghai) Co., Ltd.
25/F, Caterpillar Marine Center
1319, Yanan West Road
200050 Shanghai/P. R.China
Phone: +86 21 6226 2200
Telefax: +86 21 6226 4500
For more information please visit our website:

www.cat-marine.com or www.mak-global.com
3450 Executive Way

Miramar Park of Commerce
Miramar, FL. 33025/USA
Phone: +1 954 447 71 00
Telefax: +1 954 447 71 15
Subject to change without notice.

Leaflet No. 219 06.07 e L+S VM3
Caterpillar Marine Asia

Pacific Pte Ltd
14 Tractor Road
Singapore 627973/
Singapore
Phone: +65 68287-600
Telefax: +65 68287-624
2007 Caterpillar All Rights Reserved. CAT, CATERPILLAR, their respective logos,
Caterpillar Yellow and the POWER EDGE trade dress, as well as corporate identity
used herein, are trademarks of Caterpillar and may not be used without permission
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07.06.

M 20 C Project Guide Generator Set

Caterpillar Marine Power Systems

Europe, Africa, Middle East

MaK Americas Inc.

Phone: +49 40 2380-3000

Phone: +49 40 2380-3000

Caterpillar Marine Trading

For more information please visit our website:

3450 Executive Way

Subject to change without notice.

Caterpillar Marine Asia

Information for the user of this project guide

Caterpillar Motoren GmbH & Co. KG

General data and outputs

Restrictions for low load operation

Load application and recovery behaviour

Genset dimensions and weights

Required dimensions of generator

Space requirement for dismantling of charge air cooler and

Fuel oil system

Lubricating oil system

Cooling water system

Flow velocities in pipes

Starting air system

Combustion air system

Air borne sound power level

Control and monitoring system

Diesel engine management system DIMOS

Standard acceptance test run

2. General data and outputs

2. General data and outputs

Lubricating oil consumption

Nitrogen oxide emissions (NOx-values)

11.5/11.3 g/kWh at 900/1000 rpm

Generator according to cycle D2:

10.5/10.0 g/kWh at 900/1000 rpm

General installation aspect:

3. Restrictions for low load operation

Cleaning run of engine

Cleaning run after partial load operation

Emergency start in the event of black out

4. Load application and recovery behaviour

Reference values for load steps, depending on bmep at continuous rating

Load increase referred to continuous rating

Limiting curve for

Limiting curve for

Limiting curve for

BMEP at cont. rating of diesel engine

6 M 20 C, 1140 kW, 1000 rpm, bmep = 24.2 bar

1. max. load from

4. Load application and recovery behaviour

380/343 375/350 360/335 380/320 380/351 400/340

Fresh water cooling

6. Genset dimensions and weights

Dependent on generator maker/type

Cylinder Liner in transverse direction

Genset centre distance of 2 gensets

7. Required dimensions of generator

Generators structural requirements for MaK diesel gensets M 20 C

* Bore distances without tolerances + 0.8 mm,

- Mounting flap for anti-condensation heater is required above the mounts

8. Space requirement for dismantling of charge air cooler and

Charge air cooler cleaning