Manual d3 Engine-30.08.08

GREAVES COTTON LTD Operating Instructions for Diesel Diese l Engine D3 Series

Please read prior to putting Generating set into service

GREAVES COTTON LTD Operating Instructions for Diesel Diese l Engine D3 Series

Please read prior to putting Generating set into service

DIESEL ENGINE D3 SERIES

USER'S MANUAL GREAVES DIESEL DIESEL ENGINE – D3

0/2

PREFACE This User's Manual is prepared for use by the Operating Personnel, no mailer how useful it may be in administration. These Operating Instructions Instructions are Intended to facilitate operating the engine and in in maintaining its reliable function. They accordingly explain the design, function and operation of the engine. The necessary housekeeping and servicing tasks are grouped together in a servicing schedule and described for better survey surve y in Job Sheets. Our Service Department will be glad to provide any further information you may require.

AUXILIARY POWER DIV.

Chinchwad, Pune- 411 019. INDIA Tel. : (091-020) 27473564/ 67308200 67308200 Fax: (091-020) 27472276 e-mail : [email protected]

USER'S MANUAL GHEAVES DIESEL ENGINES D3

FQRWORD This instruction book has been prepared so that the operator can understand the engine in his care, and can maintain and service it, so that maximum efficiency and utilization may be obtained. The book should be studied before the engine is run for the first time and thereafter be readily available for reference by the actual operator or servicing staff. It is therefore advisable that the book be kept at the operating site. Additional Additional copies may be purchased purchased f r o m GREAVES COTTON LTD., AUXILIARY POWER DIV., Chinchwad, Pune- 4 1 1 0 1 9 or our Agen entts

The fact that reference is made in these notes to any particular item of equipment whether imported or indigenous does not in itself imply that such equipment is an integral part of any particular engine This manual is issued for the purpose of information and instruction and cannot be taken as a specification of The engine as there would be modifications due to continuous improvements in design and manufacturi ng process. process. Some photographs which might appear little different are given only for explaining the skim/system. As a book of reference therefore, its usefulness is to enable the operator to clear up difficulties often of a minor nature without without reference reference to us.

Should any information be required our Service Department and Agents are always at the disposal of our users.

5

USER'S MANUAL GREAVES DIESEL ENGINE D3

CONTENTS 01 01.1 U1.2 01.3 01.4 01.5

PREFACE, PREFA CE, NOTES General Assembly Breakdown" Technical Status Warranty Claims Units System

Part 1; ENGINE DATA AND DESCRIPTI DESCRIPTION ON 1. 1 1.2 13

Engine Data Overall Dimensions Dimensio ns Descript ion of Engine

Part 2 : OPERATION AND POL PRODUCTS 2.1 2.1 2.2 2.3

Preparation for First- Time Operation Engine Control POL Specificati ons for Small Size Engines.

Part3

SERVICING

3. 1

Tools and Expedients

3. 1.1 3. 1.2 3. 1.3 3. 1.4

Other Additives Trouble Tracing Table Servicing Schedule Job Sheets for Servicing

6


01

DIRECTIONS

01.1

General Remarks It is assumed that the reader and user of these Operating Instructions is familiar with the basic mode of operation of a four stroke combustion engine and is able to fo llow Technical Drawings reasonably well. T h e t e x t h a s b e e n k e p t , t h e r e f o r e , a s s hort a s p o s s i b l e f o r t h e s a k e o f c l a r i t y . T h e i n f o r m a t i o n content is backed by photographs and sectional drawings.

01,2

Assembly Breakdown 1 of these Operating Instructions are broken down in the following assemblies possible;

00 01 02 03 04 05

06 07 28 09 10 11

Separate Parts Crankcase and Oil pan Cylinder Heads Crank Assembly Gear Drive. Cam shaft Fuel System Governor Lubricating system Cooling System Turbocharger Starting System Control and monitoring 1 these assemblies are shown in (he engine sectional drawings. T h e f i g u r e s ar e n u m b e r e d a c c o r d i n g t o t he c o r r e s p o n d i n g s e c t i o n s a n d i n P a r t 1 the assemblies

- according to

Example: Fig No. Section of Operating Instructions Assembly Serial No Technical Status of these Operating instructions applies to standard design al the time of going to print. Subsequent changes can result in deviations regarding the type made available Where differences result from idiomatic usage in German and Foreign language texts. the German text shall govern . Any legal or other claims are thus excluded

01.4

Warrant y claim s Within the scope of our conditions require that all requirements as to fuels, lubricants. Cooling agents and servicing instructions have been duly observed and carried out

7

USER'S MANUAL GREAVES DIESEL ENGINE D-3

01.5

Measuring Units The measuring units applied in this Operation Instructions manual are complying with the International Unit System (Sl).

Symbol

Value

Unit

Denomination

I

Length

m.

Meters

A

M2

V

Area Volume

a

Plane angle

rad

Further units

Remarks/conversions

um=0.001 mm

M3

Radian

* Degree

1 rad = 1 m/m=360

Minute Second m

Kg

Mass

Kilogram

g (Grams)

{Weight) J

Rotary mass

Kgm2

t

Time

S

Second

min (Minute)

v

Velocity

m/s

Meter per second

h (Hour) m/min(Meter per Minute}

a

Acceleration

Moment of inertia J = GD2 0.25

Meter per square Second

n

Speed

1/s

Revolution per second

f

Frequency

Hz

Hertz

i

Angular velocity

¦ rad/s

F

Force

N.

G

Weight

M

Torque

Distance change per unit of time Change of speed per unit of time Standard acceleration Due to gravity Gn=9.80665

1/min (revolution per minute) 1 Hz= 1/S O/s (degree per Second)

Newton

Vibration per second Peripheral speed at radius 1 i =2 II n u l/min applies to I = n x u 1/s 30 1N=1Kgm/s2=1Ws/m 1N=0.10197Kg G = m.g

Nm

Moment of a force on lever arm 1N=0.10197Kgm

P

Force of liquids And gases

bar

Pa (Pascal)

1pa=1N/m2

Mm WS millimeter

1bar=10 5 pa=10n/cm2

Water gauge E

Energy

W Q

Work Quantity of heat

p

Power

J

joule

Ws (watt second) KW/h (kilowatt hour)

W

Watt

=1.0 197 Kg/ cm 1J = 1 Ws = 1Nm 1kwh=3600 KJ 1W=1J/S=1 Nm/s =1Kgm2/s

T

Temperature

K

'C (degrees Celsius)

kelvin

O c =273.15K 1C=1K(As difference temperature of t

8

USER'S MANUAL GREAVES DIESEL ENGINE D 3

Prefixes The units stated overleaf may be provided with prefixes expressing a dec imal multiple or a decimal part of the basic unit Units for temperatures, angles and time (except for seconds) should be applied without a prefix The following table is giving some prefixes with abbrevations and value. Prefix

Abbrevation

Value

Mega

M

105

= 1000000

Kilo Hecto

K h

103 102

= 1000 = 100

Deca

da

101

= 10

DECl

a

10-1

= 0.1

CertTi

L

Mi Mi

10-2 10-3

= 0 01 = 0.001

Micro

10-5

= 0.000001

Equations for engine characteristic values: 1-

Mean piston speed

2.

cm = Torque

Sx n —"— mfs 30000

9550x P .....................-" Nm N Mean effective pressure

MD = 3.

1200x P .......................-" bar

pD =

N 4

Specific fuel consumption

b

B ...................

=

11

:

................. b.

g/kvVh8431 %

(calculated witn a lower cal. valuo ol J2 7 hJ/g) s

mm

Piston stroke

n

t/ mm

revolutions per minute

p

Kw

effective power

Vh B

dm3 g/h

Total swept volume fuel consumption per hour

9


1/1Part 1 1.0

ENGINE DATA AND DESCRIPTION

Views of Engine

1.1

Engine Data

1.1.1

Explanation of Model Designation

1.1.2

Cylinder Numbering

1.1.3

Construction Data

1.1.4

Adjusting Data

1.1.5

Performance Data

1.1.6

Filling Quantities

1.2

OVERALL DIMENSIONS AND WEIGHTS

1.3

DESCRIPTION OF ENGINE

1.3.0

Function of Engine

1.3.1

Cylinder Crankcase and Oil Pan

1.3.2

Cylinder Heads

1.3.3

Crank Assembly

1.3.4

Gear Drive and Camshaft

1.3.5

Fuel System

1.3.6

Lube. Oil System

1.3.7

Cool ing System

1.3.8

Turbo charging System

1.3.9

Starting System

1.3.10

Control Pane!

1.3.11

Engine Monitoring

10


1

Engine Data and Description

1.0

Views of Engine

Fig. 1

Engine TBD 3,

1

Radiator fan

7

Injector

2

Dynamo

8

Oil filler neck

3

Sump

9

Tension roller

4

Engine foot

10

Exhaust manifold

5

Starter

11

Cyl head cover

6

Turbo charger

12

Air intake manifold

11

USER'S MANUAL GREAVES GAS ENGINE G2

Engine data and description 1.0 Views of engine

Fig 1001 Generating set, A-Side 1

RADIATOR

2 3 4 5 6 7 8 9

STARTOR DYNAMO TURBOCHARGER AIR FILTER EXHAUST OUT LET FUEL FILTER COVER FOR EXHAUST MANIFOLD THERMOSTAT

12

1

Crankshaft

12

Crankcase ventilation

2

Camshaft

13

Injection pump

3

Camshaft bearing

14

Speed governor

4

Big-end bearing

15

Speed fine adjustment

5

Main bearing

16

Fuel pressure pipe

6

Flywheel

17

Injection pump drive

7 8

V-belt pulley Anti-vibration damper

18 19

Injection pump couplin Intake pipe

9

Oil pan

20

Intercooler

10

Lube oil intake pipe

21

Turbo charger

1!

Oil drain plug

22

Tacho generator

13

USER'S MANUAL GREAVES GAS ENGINE D3 1.

Engine data and description

1.1

Engine data

1.1.1 Type code

1.1.2

Number ing of cylinde r

Flywheel end

14


1.1.4 Adjusting data

TBD3 V6

Inlet valve clearance mm Exhaust valve clearance mm

1/5

TBD3V8

0.3 0.5

TBD3 V12

0.3 0.5

0.3 0.5

1.1.5 Operating data All values apply to ISO standard performances – blocked (continuous net brake power)

as per DIN 6271 and/or ISO 3046/I Intake air temperature 27° C Relative air humidit y

Atmospheric pressure

1000 mbar

60%

Other operating conditions result in changes of the operating data. (Please do also refer to test bed certificate.)

TBD3 V6

Rotational speed in min*1 Nominal speed Ignition speed Lowest idling speed Pressure in bar Compression, min. Ignition pressure Lube oil pressure max. Lube oil pressure at n= 750 min-1 `Temperatures in °C Cooling water, max. Exhaust gas, max. Lube oil, max. (in oil pan)

Oil consumption, max. g/kWh

1.1.6 Filling quantities in dm

3

TBD3V8

TBD3 V12

1500

1500

1500

115

115

115

650

650

650

23

23

23

150 3.6 0.8…3

150 3.6 0.8..3

150 3.6 0.8…3

85

85

8546

650

650

650

120

120

120

0.6

0.6

0.6

TBD3 V6

Cooling water capacity (without radiator) 20

TBD3V8

24

TBD3 V12

35

Lub oil capacity to top notch on Dipstick by first filling.

22.5

Oil change capacity

16

16

52

Lub. oil filter capacity

2

3.5

3.5

29

15

60

1.2

Engine type

Dimensions and Weights

Engine weight

Additional weight for SAE packing kg. approx. 275

Dimension in mm

A

A1

B

C

D

E

F

984

1284

910

366

1140

200

700

TBD3V6

1050 kg

TBD3V8

1250 kg

275

1154

1454

910

366

1140

200

700

TBD3V12

2100 kg

275

1600

1850

910

366

1140

200

700

Weights (kg.) Engine (dry, without extras) For flexible bearing : Cooling water and oil filled in With flywheel flange SAE 1

Subject to modification

16


1.3

Description of engine Being thoroughly informed as to the design and function of the engine provides the understanding which facilitates handling the engine.

Operating principle In the reciprocating motion of the engine pistons the following procedures take place in the individual cylinders, as is the same in any four-stroke diesel engine: On the induction stroke, the inlet valve is opened. The engine piston speeding downwards draws in air into the cylinder base (Fig. 5/1). On the subsequent upward stroke, the air is compressed, causing it to heat up. Just before top dead centre of the piston fuel is injected into the hot air by the injection pump via the injector into the cylinder combustion chamber where it ignites and burns (Fig. 5/2). This results in the pressure increasing in the cylinder combustion chamber speeding the piston downwards. This is the working stroke. The connecting rod transmits the force to the rotating crankshaft (Fig. 5/3). The subsequent upstroke expels the burnt gases through the open exhaust valve and the silencer into the atmosphere (Fig. 5/4). On the next down stroke, air is again drawn into the engine and the above procedures are repeated. The energy stored in the flywheel keeps the engine turning steadily .

Fig. 5 Function

USERS MANUAL GREAVES DIESEL ENGINE D3

1.3.01

Crankca se and oil pan These two components form the load-bearing elemen ts of the engine. They absorb the forces occurring during operation in the cylinder and at the crank assembly. In addition to the weight of the engine, the crankcase transmits to the foundation the residual forces and the support forces caused by the torque deliver ed. The crankcase accommodates the cylinder liners the crank assembly and the camshaft. The illustrations below show more details.

Fig. 8 1 2 3 4 5

Crankcase

Crankcase Cylinder liner Main bearing cover Main bearing shell Thrust bearing for crankshaft

5

Fig. 9 1 2 3

4

Oil pan

Oil pan Dipstick Oil filling neck

18


1.3.03

Crank assembly

The crank assembly is consisting of the crankshaft connecting rod, piston flywheel and torsional-vibration Damper. The cr anksha ft is provide d with unders lung bearing inside the crankcase. The counter weights, bolted on the crank webs, at ensuring the reduction in internal mass actions and therefore, the discharge of th e crankshaft bea ring The masses on 6 and 8-cylinder engines are fully conpensated .by an Additional rotating mass (mass-balancer shaft).The flywheel serves to redu ce the irre gul ar of the crankshaft rotation. A damp er, reducing torsional vibrations , is attached to the opposite end of the crankshaft. The crankshaft is driven via the connecting rods by the gas forces acting upon the pis tons.

Fig. 1031 1 2 3 4 5 6 7 8 9 10 11 12 13

Driving mechanism (Example

233 V12)

Small-end bushing Connecting rod Gudgeon pin Piston Piston rings Vibration damper Cranking disc V-belt pulley Crankpin Main bearing journal Counterweight Crankshaft Flywheel

19


1.3.02 Cyli nder head s 1.3.02- The cylinder heads dose off the combustion chamber towards the top. Each one is attached to the cylinder crankcase by means of four screws. Each cylinder head contains the inlet and exhaust valves as well as the injection valve. The inlet and exhaust valves, provided with valve-rotating appliances, a actuated by the rocker arms, mounted on the cylinder head. Particularly for cooling of the valve seat rings, coolant piped through cooling chambers arranged in the cylinder head. The cooling-water overflow bores are sealed O-rings. Please refer to the following figures for further detail

Fig. 1021 Cylinder head 1

Inlet pipe with integrally casted cooling water sampling pipe

2 3 4 5 6

Pushrod Rocker arm bracket with rocker arms Exhaust valve Injection valve Exhaust pipe

7

Inlet valve

Fig. 1022 Cylinder head (section) 1 2 3 4 5 6

Injection valve Valve springs Rocker arm Rocker arm bracket Cylinder head cover Valve clearanc e setscrew

7 8 9 10 11

Spring plate Valve turn device (Roto cap ) Exhaust valve Valve seat ring Inlet valve

20


1.3.04 Gear drive and camshaft

The camshaft is driven by the gear drive at damper end. i.e. by the crankshaft, from gear 1 via gear 2. An additional gear 3, also arranged on the crankshaft, serves as a drive for lubricating-oil pump 4. A gear is also mounted on the crankshaft at flywheel end on 6 and 8-cylinder engines. The additional balancing shaft, provided for these number? of cylinders respectively involved, is driven by this gear. (Example, see Figure 1032).

Fig. 1041 Gear drive

1 Crankshaft gearwheel 2 Camshaft gearwheel 3 Oil pump drive gear wheel on crankshaft 4 Lube oil pump

21

1

Fig. 1032 Mass balance (8-cylinder engine)

2

Mass balance shaft

3

Drive gear

4

Intermediate gear

5

Crankshaft gear

6

Crankshaft

Fig. 1033 Piston 7

Gudgeon, pin

8

Piston

9

Oil scraper ring

10 Plain compression ring 11 Trapezoidal ring 12 Locking ring 13 cooling chamber for piston cooling

22


The cams of the camshaft 5 driven by the gear drive actuate the inlet and exhaust valve 1 (exhaust valve shown) via mushroom tappets 4, pushrod 3 and rocker arm 2.

Fig. 1042 Valve drive 1 2 3 4

Exhaust valve Rocker arm Pushrod Mashroom tappet 5 Camshaft

23


1.3.05

Fuel system In order to drive the engine, at every second revolution fuel is injected into the cylinder chamber just before the piston reaches top dead centre. The fuel ignites and burns in the compressed-heated air. By means of the feed pump 8 the fuel is pumped from tank 1 into the injection pump 6 via filter 5. At high pressure the fuel is pumped to the injection valves 9. By means of the injection nozzles the fuel is squirted very finely into the combustion chamber. For the purpose of cooling the injection pump 6 more fuel than required for injection is pumped through the system by the feed pump 8. The surplus fuel is returned to the service tank via an overflow valve at the injection pump. Any fuel spillage emerging from the injection valves is fed back to the tank via a separate pipe.

Fig. 1051 Fuel system 1. Tank 2. Overflow pipe 3. Leak-off line 4. Injection pressure line 5- Fuel filter 6. Injection pump 7. Overflow valve 8. Feed pump 9. Injection valve 10. Fuel pre-filter 24


The balance weights are driven by the crankshaft via gearwheels 3 and 4, the object of the balance weights being to ensure smooth running of the engine.

Fig. 10 Gear drive for balance weights 1 2 3 4 5

Crankshaft Flywheel Crankshaft gearwheel Balance weight gear Balance weight

The cams 2 of the camshaft 1 driven by the gear drive actuate the inlet and exhaust valve 5 (exhaust valve shown) via the pushrod 3 and rocker arm 4.

Fig. 11 Controlling the valves via the camshaft 6 Camshaft 2 Cams 3 4 5

Pushrod Rocker arm Inlet and exhaust valve


Fig. 1052 Injection pump on engine 1 2 3 4 5

Cylinder head Intake pipe Injection pump with governor Stop linkage Electric speed adjustment device

Fig. 1053 Injection pump 1 2 3 4 5 6 7 8 9

Fuel supply from filter Overflow valve (Fig.1051, pos.7) Governor Speed adjustment lever Fuel supply Fuel feed pump {see also Fig.1055) Lubricating oil return Pipe to filter Camshaft for injection pump

10 11 12 13 14 11 16 17

26

Roller tappet Piston Control sleeve Control rod Pump cylinder Inlet drilling Delivery valve Pressure connection to the injection valve


Single acting

Fig. 1054 Injection valve 1 Holder for in ection valve 2 Delivery pipe connectio n 3 Edge-type filter 4 Leak-off connection 5 Compression spring 6 Nozzle holder 7 Thrust piece 8 Cap nut 9 Nozzle body 10 Nozzle needle

Fig. 1055 Fuel feed pump 1 2 3 4 5 6 7 8 9 10

27

Delivery pipe connection Plunger chamber Roller tappet Piston rod Piston spring Intake valve Intake connection Intake chamber Piston Delivery valve

USERS MANUAL GREAVES DIESEL ENGINED3

Fig. 1056 Fuel filter with filter cartridge 1 2 3 4 5

Fuel inlet pipe Vent screw Fuel return pipe Filter head Filter cartridge

28


1.3.06

Governor The function of governor is to hold the set engine speed as constant as possible even when there is a change in engine loading. This governor, working by measuring centrifugal forces, is mounted on the injection pump. Any change in load on the engine causes initially a difference between the power required by the engine and the power momentarily produced by the engine. This difference must be compensated for by the energy of the rotating masses (flywheel and crank assembly). This taking or giving of energy from the rotating masses changes their rotational speed, i.e. changes the engine speed. The variations from the set engine speed are measured by the governor and are converted into mechanical adjusting movements. In the Injection pump these adjusting movements ensure that the quantity of fuel supplied to the engine (= quantity of energy) is again adapted to the changed load on the engine. As a result, the variations from the set engine speed are again finally, fully or partially eliminated. (Depending on the speed drop setting on the governor.)

Fig. 1061 Speed governor Bosch EP / RSV 1 2 3 4 5 6 7 8 9

Fish plate Governor cover Lower filling limit Guide lever Governor lever Tension lever Supplementary idling spring Spring retainer Full load stop

10 11 12 13 14 15 16 17

Adjusting pin on centrifugal pendulum Governor housing Flyweight Injection pump camshaft Swivel lever Rocker Injection pump control rod {adjusting movement) Governor spring 29


Fig. 1062 Speed governor Bosch EP / RSUV 1

Speed adjustme nt device

10

Supplemen tary idling spring

2

Lower filling limit

11

Guide lever

3 Stop motion rods

12

Spring retainer for

4

Injectio n pump

compensation

control (adjusting moveme nt)

13

Maximum filling limit

5

Fish plate

14

Flyweights

6

Starting spring

15

Govern or cover

7

Swivel lever

16

Governor housing

8

Tension lever

17

Drive gear wheel

9

Governor spring

(speed increasing device) 18

30

Injection pump camshaft


1.3.07

Lub. oil system

To reduce the friction existing between parts in sliding contact with each other and to carry off the heat, all bearings and the inside walls of the cylinder liners are supplied with lubricating oil. This oil is drawn from the oil sump 1 by the lube oil pump 2 and delivered to the oil galleries through the oil cooler, the oil filter. From the galleries the lube oil reaches the individual bearings on the crankshaft, the camshaft and also lubricates the rocker arms. A further pipe supplies the injector nozzles which inject lube oil on the inside walls of the pistons for cooling. The oil which is slung off by the main big-end bearings lubricates the inside walls of the cylinder liners. The oil draining off then collects in the oil pan from where it is reintroduced into the lube oil circuit.

Fig. 1071 Schematic diagram of lub. Oil system 1

Oil pan

11

Big-end bearing

2

Lube oil pump

12

Camshaft bearing

3 4 5 6

Cooling oil pump Suction pipe Oil cooler Bypass pipe for oil cooler

13 14 15 16

Injection nozzle Piston Mushroom tappet Pushrod

7

Lube oil change filter

17

Rocker arm

8 9

Bypass valve Gallery

18 19

Exhaust turbocharger Pipe to injection pump

10

Crankshaft bearing

20

Return to oil pan

31


Dry sump lubrication

Dry sump lubrication is of advantage on engines subject to a large inclination, so that it is impossible for the lube oil pump range to run dry. The elementary lube oil circuit is shown in Fig. 29. In addition, a suction pump 2 incorporating three gearwheels is provided which draws off the lube oil from the two suction spaces 3 of the oil pan 4. and returns it to the centre portion of the oil pan via the return piping 5. From here, the engine oil pump I delivers the lube oil to the lube oil circuit of the engine and to the cooling oil nozzl es for piston cooling.

Fig. 30 Dry sump lubrication

1 2 3 4 5 6 7

Engine oil pump Three-gear suction pump Suction spaces Oil pan Return piping Cooling oil pump Suction piping

Fig. 32 Engine oil pump 1 Housing 2 Drive gearwheel 3 Pump gearwheel 4 Cooling oil pump gearwheels

32


Fig. 1075 Lub. oil filter 1 2 3

]]

1 2 3

Fig. 1076 Oil cooler Oil cooler cartridge Oil cooler housing Cooling water pipe

33

Filter cartridge Filter head Excess pressure valve,


1.3.06

Cooling system The thermal energy generated during fuel combustion can only be partly converted into mechanical energy. By means of the fresh water, cooling the combustion chamber walls, part of the residual heat is eliminated and in a heat exchanger or a finned radiator passed on to a corresponding fluid raw water, ambient temperature). A further part of the waste heat is absorbed by the lub oil by means of the piston cooling (turbocharged engine) and bearing friction. In the oil cooler this heat is passed on to the fresh water. The decision for a particular cooling system depends on the given conditions at the place of operation. The following scheme shows diagrams for indirect cooling, fan cooling and outer skin cooling. The coolant's direction of flow is indicated by arrows in illustrations.

Fig. 1081a Indirect cooling (diagram) 1 2 3 4 5 6

Thermostat Expansion tank for Intercooler circuit Expansion tank for engine circuit Intercooler Cooling water supply cylinder bank - B Oil cooler

7 8 9 10 11 12

34

Cooling water pumps Cooling water supply cylinder bank - A Outer skin cooler for intercooler circuit Outer skin cooler for engine circuit By-pass line Venting pipe


Fig. 1082 Heat exchanger 1 2 3 4 5 6

Header Expansion space Cooling water filler neck Water level mark Tube bundle Cooling water outlet to engine

Fig. 1083 Fresh water pump 1 2 3 4 5 6 7 8

35

Intake bend Cooling water outlet to A - bank Pump housing V-belt pulley Ball bearings Axial sealing ring Impeller Cooling water outlet to oil cooler (B - bank )

Fig. 36 Lube oil centrifuge 1 2 3 4 5 6 7

Housing Housing cover Rotor Hollow shaft Nozzle Paper sleeve Pressure valve SECTION A - B

Fig. 37 Engine oil cooler

1 2 3 4 5 6 7 8 9

36

Cooling water inlet Cooling water outlet Headers Cooling shell Tube bundle Bypass valve Water drain Oil drain Bypass line


Centrifugal Pump (Raw Water) Stork KGEC 11.3

Fig. 1084 Centrifugal pump (Raw water) 1 2 3 4 5 6 7 8 9 10 11 12

Flap valve Gasket Ball bearing 6303 Ball bearing 6203 Shaft Oil seal Mechanical seal Gasket Key for impeller Impeller Washer Pump assembly KGEC 11.3

37


Fig. 1085 Thermostat 1 2 3 4 5 6

Cooling water inlet Thermostat By pass to water pump To cooler Thermo element Valve disc

38


1.3.09

Turbo-charging The purpose of turbo-charging the engine is to boost the output without altering the speed. To achieve a higher output for a given capacity, added heat must be introduced into the operating process for each operating cycle i.e. an increased amount of fuel must be burnt. This can only be achieved, however, when at the same time a greater weight of air is available. This is achieved by charging the cylinders with a higher pressure.

Fig. 1091 Turbo-charging system 1 2 3 4 5 6 7 8 9 10

Air filter

Turbocharger-blower Turbocharger-turbine Intercooler Exhaust gas Charge air Inlet valve Exhaust pipe Outlet valve Coolant or cooling

39


Fig. 1092 Exhaust turbocharger 1 3 5 7 9 11 13 15

Turbine Compressor Compressor impeller Axial bearin g Lub. oil connect ion Axial seal ing turb ine side Exhaust outlet Lub. oil return pipe

2 4 6 8 10 12 14

Lub. oil inlet Intake air inlet Axial sealing compressor side Radial bearing Heat shield Turbine wheel Exhaust inlet

Fig. 1093 Supply lines to intercooler 1 2 3

40

Intercooler Intake air pipe from turbocharger Raw water supply


1.3.10

Starting system The starter is designed to speed up the crankshaft of the engine to ignition speed. When this speed is reached, an inflammable fuel/air mixture has been formed inside the engine cylinders. This fuel/air mixture ignites and brings the engine into operation.

Electric starting The starter pinion is driven by an electric motor via a disc clutch that can axially be shifted. By means of the meshing rod the meshing relay presses the starter pinion in the gear rim of the flywheel and thus drives the crankshaft. Only then is the full starter torque transmitted by the disc clutch in order to prevent the tooth flanks from being damaged. As soon as the engine starts the disc clutch is released via the steep-angle thread and the starter pinion is disengaged.

Fig. 1101 Electric start

1 2 3 4 5 6 7 8 9

Electrical connections Starter pinion Driving shaft leading to the starter pinion Clutch housing Steep-angle thread sleeve of the clutch Meshing rod Steep-angle thread Clutch discs Rim gear of the flywheel

41


1.3.11

Engine control and monitoring Depending on the design the engine can be operated e.g. when starting, changing speed or stopping it, directly or by remote control. The engine speed can be actuated manually or by means of an electrical device. The same is true for stopping the engine. In general the engine is started electrically. Remote control is possible via the electrical control elements. A pressure switch within the oil circuit serves for monitoring the oil pressure. The cooling water temperature is controlled by means of a temperature switch. When the limiting values are reached this is indicated both acoustically and optically or the engine is automatically being shut down by the shutdown solenoid. In a similar way operating data like e.g. speed, oil temperature, cooling water temperature, lub oil pressure etc. can be monitored. Operating data indicator can be mounted to the engine or be a part of the control panel for remote control.

Fig. 1111 Control panel (examples) 1

Tachometer

2 3 4 5 6 7

Lub. Oil pressure Ammeter Water temperature Lub. Oil temperature Stop switch Pilot lights 42


Fig. 1113 Cooling water temperature sensor 1- Cooling water sampling pipe 2-Cooling water temperature sensor

H Fig. 1113 Cooling water temperature sensor 1- Hand stopping button 2- Stopping lifting solenoid

43


STARTING THE ENGINE (1)

The Tri-Panel can start an engine in the following ways. For manual start configurations the engine can be started by pressing the START button.

(2)

To manually start the engine presses th e START button. The Tri -Panel will initiate a start sequence which will include a heating period, fuel pump on, a cranking period and an oil monitor delay period. The starting sequence status is shown on the LCD upper window.

(3)

If the engine start is succe ssful the ENGIN E RUN output is activ ated. If the start was u n s u c c e s s f ul t h e T r i - P a n e l w i l l e x p e c t t h e S T A R T b u t t o n t o b e p r e s s e d a g a i n f o r m a n u al configurations.

(4)

If the engine starts independent ly the Tri -Panel detects the condition and begins monitoring. The PREALARM output is activated to give warning of an uncontrolled engine. Should a fatal fault condition arise, or the engine is run outside the set operating values the Tr i -Panel is unable to halt the engine.

STOPPING THE ENGINE (1)

The Tri-Pane l stops the engine by control ling the fuel solenoi d.

(2)

To manually stop an engine. Press the STOP button. HALT is shown on the LCD upper window during the halt phase.

(3)

If the START button is pressed during cool down the Tri -Pane! returns to the ENGINE RUN mode but now requires a press of the STO P button to stop the engine. A manual start always requires a manual stop.

(4)

Activating EMERGENCY STOP stops the e ngine immediately . When EMERGENC Y STOP or t h e S T O P b u t t o n i s a c t i v a te d f o r 1 0 o r m o r e s e c o n d s t h e T r i - P a n e l w i l l d i s p l a y E S T O P o n t h e LCD upper window. The EMERGENCY STO P must be deactivated before the engine restart. The engine can not be restarted during this period.

(5)

At the end of HALT the Tri -Panel checks for complete engine rest and continues to contra! t h e f u e l s o l e n o i d f o r 1 0 s e c o n d s a f te r e n g i n e r e s t t o p r e v e n t s u d d e n e n g i n e r e s t a r t . T h e engine can not be restarted during this period.

(6)

if the fuel soleno id does not operate properly the Tri -Panel will be unable to stop the engine. If the engine fails to stop, the Tri-panel will ac tivate the alarm output and di splay STOP in the LCD upper window.

44


STARTING AND STOPPING SEQUENCE

(1)

The starting sequence is initiated by pressing the START button.

(2)

The start sequence continues with a HEATING phase. The heating period is specified during setup. If the engine temperature is below 30°C, the HEATER output is activated. If the engine temperature is above 30°C, the heating phase is omitted. HEAT is shown in the LCD upper window during the heating phase. Heat is usually set to off. The heating period can be cut short by pressing the "START" button. There is always a short delay between the heating and fuel pump phases.

(3)

The start sequence continues by energizing the alternator via the CHARGE LAMP. The lamp will glow indicating lack of charging current. When the engine is running and the battery is charging the charge lamp will extinguish.

(4)

The FUEL PUMP is controlled according to the PUMP type specified in setup. There is always a short delay between fuel pump and the cranking phases.

(5)

The current engine valves are checked prior to cranking. If oil pressure is detected, a PAUSE state is entered until the oil pressure reduces below the oil pressure threshold specified in setup. This ensures that the cranking will not occur into an already rotating engine. PAUSE is shown on the LCD upper window for 60 seconds. A fail to START alarm activates the ALALRM output if the condition persists.

(6)

The start sequence continues with a cranking phase. The CRANK output is activated until the engine starts or until the crank period specified in setup expires. The engine is considered to have started when the engine speed exceeds the crank -disconnect speed. The crank disconnects speed, or CREV, is specified in setup. CRANK is shown in the LCD upper window during cranking.

(7)

For a manual configuration if the engine does not start successfully the START button must be released and pressed again.

(8)

Regular sensor and engine condition checks are made during the startup sequence. The displays show the current status. During the CRANK and PAUSE phases, the displays switched off.

(9)

As the engine starts the Tri-Panel enters the DELAY phase. The oil pressure in a starting engine takes time to rise to a satisfactory level. The engine speed also takes time to stabilize and usually overshoots the normal engine operating speed momentarily. The DELAY phase allows time for the engine to settle before actively monitoring engine conditions. DELAY is shown in the LCD upper window during monitor delay.

The type and time out of DELAY is specified during setup. The auto selection monitors rising oil pressure and times out when the oil pressure is above the low oil pressure set point, plus 2 seconds. The maximum time out is 30 seconds. If a time is selected the Tri-Panel will start monitoring the engine after the time out period. During DELAY the engine speed is constantly monitored. If the speed overshoots the over speed point by 25% or more a HIREV alarm occurs. The engine will be stopped. The ALARM output will be activated. HIREV will be shown in the LCD upper window.

45


If an engine value is initially too low or too high its value is shown red but no alarm is raised. If the abnormal condition is present at DELAY time out then the engine is stopped and the ALARM output activated. The LCD upper window will show the cause of the abnormal condition. (10)

With the completion of DELAY the unit enters the ENGINE RUN phase. The ENGINE RUN output is activated. The Tri-Panel continuously monitors the engine for abnormal conditions. The engine RPM is shown in the LCD upper window during ENGINE RUN.

(11)

The ENGINE HOURS are incremented every six minutes while engine is running. The hour glass icon and total engine hours flashes while the engine is running and the total engine hours are shown in the LCD lower window. Battery charging is constant ly monitored for under and over voltage conditions. If an abnormal condition is detected the PREALARM output is activated and cause of the alarm is shown in the LCD upper window. For a low voltage the message is LVOLT. For high voltage the message is HVOLT. Battery alarms do not stop the engine.

(12)

(13)

The engine may be stopped as a result of an alarm conditio n or a stop signal. In any event the engine is brought to rest by entering the HALT phase. HALT causes the FUEL supply to be shut off. The engine is monitored for zero engine speed and zero oil pressure. HALT is shown in the LCD upper window during the HALT phase. If the engine stops, as it should, HALT continues to control the FUEL output for 10 seconds after engine rest to ensure the engine does not restart. At the expiry of HALT the unit enters STANDBY mode. If the engine does not stop the ALARM output is activated. FSTOP is shown in the LCD upper window. Operator intervention is required for an FSTOP condition.

(14)

If the engine is stopped by an alarm both the PREALARM and ALARM output will be activated. The cause of the alarm will be shown in the LCD upper window. The cause of the alarm must be rectified before the Tri-Panel can be reset. Reset is achieved by pressing the STOP button after the HALT time out phase. Each behaves differently depending on the configuration and initial starting method.

(15)

If the engine is stopped by a stop signal it will be one of two types. • •

A manual stop signal from the STOP button An EMERGENCY STOP signal.

(16)

If the engine was started by a press of the START button and the engine is stopped by a press of the STOP button the unit will enter the HALT phase. After the halt time out, the unit returns to STANDBY. This applies for both automatic and manual configurations.

(17)

If the engine was started by a press of the manual START button and the engine is stopped by the EMERGENCY STOP switch the unit will enter the HALT phase. After the HALT time out the unit will enter the ESTOP mode. When the EMERGENCY STOP is deactivated the unit returns to STANDBY. This applies for both automatic and manual configurations.

46


ALTERNATOR WIRING

WIRING OVERVIEW

47


CLEARING ALARMS (1)

When an alarm occurs : • • • • •

(2)

The The The The The

cause of the alarm is shown in the LCD upper window. gauge shows the current status. PREAL ARM output is activated. ALARM output activated. engine is usually stopped.

From the alarm shown on the LCD upper window determine and rectify the cause of the Alarm.

(3)

Wait for the Tri-Pa nel to exit the HALT phase.

(4)

Deacti vate the EMERG ENCY STOP switc h if i t is activated.

(5)

Press the STOP button.

(6)

The Tri-Pa nel will return to STAND BY mode. SPECIFICATIONS

Dimensions • • •

width height depth

: 280 mm : 118mm : 60 mm

• • • •

Operating voltage 8 to 32 V DC Negative Earth Standby current 20 mA Operati ng current 570 mA

• •

Transient protected Rever se-voltage protected

• • •

Protected against short -circuits Protected against over current Maximum load 500 mA

•

RS485 twisted pair link (option)

Power Supply

Inputs

Outputs

Communications

Environmental conditions • • • •

Operating 10 °C to 60°C Storag e 20°C to 70°C Humidity 85% RH at 50°C (non-con dens ing) Splash-proof

48


(1) The Tri-Panel incorporates many self check and system check features. They ensure that faults which may cause engine damage or pose a safety risk are detected and alarms raised. The pre-alarm is the primary warning output for this purpose. If the pre-alarm is activated the cause should be investigated and rectified right away. The table below will be of some assistance in trouble shooting based on the alarm conditions.

ALARM SUMMARY

NAME

CONDITION

REMEDY

ERROR 1:2

Tacho uncalibrated

Calibrate Tacho

ERROR 1:3

System not set up

Set up Tri-Panel

START

Engine did not start

Check engine for correct operation

FSTOP

Engine will not stop

Check fuel control

HIREV

Engine went over speed

Check governor

TACHO

Tacho input not available

Check alternator and engine wiring

ESTOP

Emergency stop activated

Deactivate emergency stop

UREV

Engine was running too slowly

Check governor

OREV

Engine was running too fast

Check governor

OIL

Low oil pressure detected

Check oil level, sensor, wiring

TEMP

High temperature detected

Check coolant, airflow, sensor, wiring

LVOLT

Low battery charge

Check battery condition, alternator

HVOLT

High battery charge

Check voltage regulator

HALT

Engine stopping

Wait for engine to stop

49


Part 2

Operation and POL products

2.0

Prevention of accidents, safety instructions

2.1

Prior to first-ti me operati on

2.1.0

General

2.1.1

Cooling water

2.1.2

Fuel

2.1. 3

Lubricating oil

2.1.4

Starting air

2.1.5

Special measures for operation in winter

2.2

Engine control

2.2.1

Prior to starting

2.2.2

Starting engine

2.2.3

Setting speed

2.2.4

Stopping engine

2.2.5

Instructions for prolonged storage

2.2.6

Restarting after prolonged storage

2. 3

POL specifications for small size engin es

50


2

Operation and POL products

2.0

Prevention to accidents, safety instructions The legal regulations for prevention of accidents (obtainable from professional associations or specialized dealers) must generally be observed. These regulations depend on the site, type of operation as well as the operating and auxiliary materials being used. Special protecting measures, depending on each operation involved, are stated in the description of work and marked with

The following prescriptions are generally valid •

For the staff: The engine may only be operated or maintained by trained staff. Unauthorized persons are not permitted to enter the engine room. Wear tight-fitting clothes and ear protection during engine operation in the engine room. Trained staff only may be engaged for repairs or maintenance operations.

•

For the engine room: Ensure sufficient ventilation (do not cover ventilating vents). Install first-aid boxes and appropriate fire extinguishers. Their content and readiness for service must be checked regularly. Combustible substances may only be stored inside the engine room if they are needed for operation of the installation Smoking and naked flames are prohibited inside the engine room.

•

For operation and maintenance of the engine: Start the engine only if all protecting appliances are attached and if the j cranking device has been removed. Ensure that nobody stays within the danger zone. Cleaning, maintenance and repair operations should only be carried out if the engine is stopped and secured against starting.

51


2.1

Preparation for first -time operat ion and for starti ng-up after several idle days

2.1.0

General The following operations and checks described below are necessary for efficient operation as well as for accident prevention. It is above all the correct functioning of crank assembly and speed governor that is necessary for the trouble-free operation. Clean new lines and tanks before filling with fuel, coolant and lubricating oil. After filling please check pipes and tanks for fuel and cooling water for leakage. Prior to first-time operation please check alignment of the engine and proper mounting of the foundation. Please clean engine - only then can leakages be identified and localized unmistakably. If the engine was preserved, please pay attention to section 2.2.6 "Restarting after preservation".

2.1.1

(Cooling water * ) The engine cooling system shall only be filled with treated coolant according to section 2.3 up to the lower limit in the filler neck {for filler neck see Fig. 2001) and bleeded (for bleed plugs see Fig. 2002) Since the operating temperature of the engine is kept as high as possible (approx. 85° C cooling water temperature) unsuitable cooling agents can cause deposits and corrosion damage. Please check pipes and engine for leakages after filling.

Fig. 2001 Filler neck

Fig. 2002 Bleed plugs for cooling system

52


If a Gilkes or Steime! raw water pump (Fig. 2003) is attached to the engine the pump housing must be filled with water through the filler tube (1)- Due to the centrifugal forces the water forms the water ring during operation. It is necessary for the suction effect of the pump. This is why the raw water pump has to be filled once again each time it was drained.

Fig. 2003 Raw water pump

2.1.2

Fuel * •

Fill fuel tank with proprietary fuel complying with DIN 51601 requirements (see section 2.3)

•

Loosen banjo bolt 1 and operate hand priming pump 2 until fuel emerges free of bubbles, tighten banjo bolt again.

Fig. 2004 Hand priming pump 1 2

Pressure connection Hand priming pump

53


•

Loosen bleed screws 3 on fuel filter, operate hand priming pump 2 until fuel emerges free of bubbles. Continue to operate priming pump while tightening bleed screws 3. Note : In case of a reversible dual fuel filter the above applies to both chambers (cock position : vertically upwards).

•

Loosen overflow valve 4 on the injection pumps and operate hand priming pumps 2 until fuel emerges free of bubbles. Continue to operate priming pump while tightening again overflow valves 4.

Fig. 2005 Dual fuel filter

Fig. 2007 Injection pump

3 Bleed screw

4 Overflow valve

2.1.3

Lubricating oil

*

Do not use lub oil other than specified in section 2.3.1. The viscosity depends on t he ambient temperature. The following table gives the corresponding viscosity required for different ambient temperatures. Brand

Ambient temperature

SAE 40 SAE 30 SAE 10W SAE 20W20

constantly above 30°C between 0°C and 30°C constantly below 0°C between -10°C and +10°C

Caution!

Wrong viscosity can result in starting difficulties or very low oil pressure.

54


Loosen plug 1 and fill in lub. oil up to the upper dipstick mark 2. After short engine operation refill lub. oil up to the upper dipstick mark.

Fig. 2008 Oil filler neck 1 2

Plug Dipstick

* Please refer to POL specification 6.000.0.00 5.4431 e, given in this operating instructions manual. This POL specification is being updated every year and can be obtained from Greaves after-sales services at the beginning of each year.

2.1.4

Startin g air In case of an air-started engine fill up the starting air receiver with starting air compressor or carbonic acid bottle (carbonic dioxide). The starting air pressure must be 30 bar.

Caution ! The starting air receiver must not be filled with oxygen or inflammable gases due to danger of explosion.

Open valves of the air bottle and check lines for leakage. Air leaks waste energy and cause premature wear of the starting air compressor.

55


2.1. 5

Special measures for operation in winter

• Winter engine oil Effect in time oil change and use oil of low viscosity. See prescription 6.000.0.005.4431 of this operating instruction . • Winter-grade fuel In winter, use winter-grade diesel fuel only, otherwise the fuel may cloud and block the system, which may even occur with winter-grade fuel when frost is severe. Therefore, when only summer-grade fuel is available or winter-grade fuel must be used in severe cold, mix it with kerosene or normal gasoline in accordance with the table below. The admixture of gasoline, however, is permissible for one tank charge only. Caution : prepare the blend in the tank itself fill in gasoline first, then add diesel fuel.

Caution ! Smoking and each use of an open flame is strictly forbidden. The blend is as easily inflammable as pure gasoline. Danger of explosion!

Ambient temp. limit down to

Summer-grade diesel fuel %

Kerosene or Gasol ine % *)

Winter grade diesel fuel %

-1 0°C( +1 4°F)

90

10

100

-1 4°C( +7°F )

70

30

100

- 20°C (- 4°F)

50

50 * * )

80

20

50

50 * *)

- 30°C (- 22°F)

Kerosen e or Gasoline % *)

For using a commercial additive, please consult your service points. *) **)

never use premium fuel not allowable for gasoline admixture A mixture containing filling station fuel should only be used in case of need, otherwise difficulties may occur due to vapour bubble formation. Due to the additives the engine output will be lower than with Diesel fuel. For that reason only the urgently needed additives shall be added.

56


2.2 2.2.1

Engine control Prior to start ing • • •

Slightly open drain valve of the starting air compressor (air starting) Check engine stopping device for easy movement Switch on engine room ventilation, if available

Caution ! Remove any objects that have been put down on the engine. It is particularly dangerous to leave anything in the crankcase saddle. It may result in serious accident and damage. 2.2.1.1

Checking supply of POL products In order to prevent operational failures and stoppages, it is necessary to ensure that all POL products are available in sufficient quantities. Since the level of these products decreases as a result of consumption, evaporation or leakages, their level should be checked daily. It should be ensured that use is made only of correct, clean POL products, meeting the requirements of section 2.3 • Checking the fuel supply Check the fuel level in the service tank and replenish if necessary. Depending on the size of the tank and the engine load, the service tank must be replenished several times per day. Caution ! When refuelling, smokin g and all any naked flames are strictly forbidden due to the explosion hazard. The same applie s to the switching on and off of electric appliances of all types. • Open cooling water valves (raw water circuit) if attached. • Checking the coolant level Check coolant level in radiator 1 by opening radiator cover 2. When the engine is cold the coolant should reac h the under mark (arrow). When coolant is lacking, fill in coolant up to the corresponding mark.

Note : When refilling coolant at normal running temperature, let the engine run in order to prevent sudden drop in temperature of the engine. In the event of a frequent cooling water shortage check the cooling system for leakage. Compensate losses due to evaporation by means of water that is free of lime. In case a considerable amount of cooling water is filled in, check the percentage of the corrosion agent (0. 5% up to 1.5%) and of the anti-freezing agent (at least 33%).

Fig. 2009 Cooler 1 2

57

Filler neck Cooler cap


• Checking the lub. Oil level Pull out dipstick 2 and wipe dry with a clean rag. Reintroduce dipstick 2 and wait for a short time until dipstick is wet with oil. Pull out dipstick again and check lub. oil level.

Caution ! Do not keep dipstick upwards, as otherwise the oil running down would falsify the measuring result. When the lower dipstick mark is reached, top up oil.

Fig. 2010 Oil Filter 1 Plug 2 Dipstick

Check battery Remove plugs (Item 1) and measure density of electrolyte with hydrometer. Electrolyte density 1.23 to 1.28 kg/I is normal. If electrolyte density is less than 1.21 kg/I recharge the battery. The water level should be approx. 15 mm above the plate edge, if not, top up using distilled water. If necessary, connect battery charger to battery (positive to positive and negative to negative) and recharge battery. The recharging current is equai to 1/10 of battery capacity number e.g. for 145 AH - rechar ging current is 14.5 ampere.

Caution ! Hydrogen-oxygen mixture (oxy-hydrogen gas) is released during recharging. No naked flames, no smoking. The plugs (Item 1) must be open. After recharging, replace plugs, clean battery terminals and grease with antiacid grease.

Note : Unused batteries must be recharged every 4 to 6 weeks.

Fig. 2011 Battery 1 2

Plugs Battery terminals

58


2.2.2

Starting the engine •

Set speed governor to low engine speed

•

Switch on monitoring device (in case of a key-operated switch; position 1)

•

If fitted, position switch "Betrieb - Stop" (Operation - Stop) to "Betrieb" (Operation)

•

Start engine by means of starter switch (In case of a key-operated switch; press key inwards and turn it to the right as far as it will go)

•

As soon as engine starts release switch. The s tarter switch automatically returns to position "Betrieb" (Operation)

Caution ! Should the engine race (ever increasing speed) or the oil pressure does not develop adequately, stop engine immediately and close fuel cocks. During operation maintain key-operated switch on position 1, otherwise (position '0') the monitoring facility will be out of circuit.

Fig. 2012 (Examples) Switch and control board

Engine start with flame starting system •

Turn key-operated switch to position I

•

Draw out push-pull switch up to first notch (Preheating of the flame glow plug)

•

When the corresponding temperature (pilot lamp flashes up) has been reached draw out push-pull switch as far as possible (starting position)

•

When engine- starts press push-pull switch inwards to stop limit.

59


2.2.2.2

Emergency start with Hansa quick starter

1.

Remove cylinder head cover from the cylinder with which the quick starter is connected.

2.

Crank the engine until both valves are closed (push rods can be easily turned, ignition top dead centre). Continue cranking until the starting mark "S" on the V-be!t pulley (Fig. 2013) and the mark on the indicator coincide. Remove cranking bar and replace cylinder head cover.

3.

In order to open ihe starting valve of the cylinder head loosen lock nut 1 and unscrew threaded spindle 2 as far as it will go (Fig. 2014).

4.

Switch on monitorin g device (in case of key operated switch : position 1) and position injection pump control rod to complete filling.

5.

Remove cap 3, loosen valve seat of the main valve by means of tightening the nut 5, back off nut 5 again.

Fig. 2013

Note : cap 3 blocks the main valve, tighten cap again only after, starting the engine. 6.

Check whethe r cap screw 6 is tightened (handtight only).

7.

Loosen screw 7, place igniti on film strip (max, length 1,5 m) over the film strip fork 8. Rescrew and tighten screw 7 again.

8.

Strike (storm proof) match and throw it through bore 9 into the pressure container. Close aperture 9 by means of lever 10. The engine starts due to the developing pressure.

Fig. 2014

Caution ! Keep away from the safety valve 11 as there is danger of accident due to gases emerging under high pressure 9.

Once the engine has started, close starting valve on the cylinder head (main valve spindle 2) and tighten lock nut 1. Dismantle Hansa quick starter and oil all threads and conical items.

Fig. 2015

60


2.2.3

Speed Adjustment After cold start of the engine wait a few minutes until running the engine at full load and speed; increase speed and load gradually.

Manual speed adjustment device (Fig. 2016) Loosen lock nut 1 and operate handwheel 2 until the required speed is attained. Tighten lock nut 1 again.

Electrical speed adjustment (Fig. 2017) Operate speed switch unti! the required speed is attained. The highest and lowest adjustable speed is blocked by means of limit switches.

Fig. 2016 Manual speed adjustment device 1 Lock nut switch for speed adjustment 2 Hand wheel

Fig. 2017 Switch for speed adjustment

Checking operating values Checking the operating values is an important preventive measure with regard to the reliability of the engine. By means of periodical controls, malfunctions can be recognized in time, thus avoiding damages. The test report gives the normal operating values read off in order to be able to determine gradual changes by comparing them with previous test results over a long period of time. Data to be controlled and indications as to possible sources of error are mentioned below:

Lub. oil pressure (Pressure gauge 2) Possible reasons for an inadequate lub. oi! pressure : • • • • • •

Lub. oil too hot (oil cooler or cooling system clogged, engine overloaded) Oil control valve 3 seizes Lub. oil filter clogged Lub. oi) too thin (wrong viscosity, oil change) Pressure gauge faulty Too high bearing claeranco on driving mechanism

Possible reasons for a too high lub. oil pressure : • • • •

Lub. oil (still) too cold Oil control valve 3 seizes Lub. oi! too thick (wrong viscosity, oil change) Pressure gauge faulty

61


Cooling water temperature (thermometer 1) Possible reasons for high cooling water temperat ure Engine overloaded Cooling water level too low V-belt for water pump drive is broken or loos e Cooler clogged Thermostat faulty Possible reasons for low cooling water temperature: Thermostat faulty

Fig. 2018 Control board 1 2

2.2.4

Fig. 2019 Lub oil filter

Cooling water temperature Lubricating oil pressure

3 Oil pressure valve

Stopping the eng ine In order to prevent heat from being retained in the cylinder liners and cylinder heads, avoid stopping the engine at full load. Allow the engine to run at low speed and output for approx. 5 minutes before stopping it. 1.

Shut down engine by pressing stop push-button on monitoring panel.

2.

Switch off monitoring appliances by means of ignition-lock key on switch position .

3.

The engine can also be stopped manually (Fig. 2020) using the solenoid.

4.

If the engine be stopped for a long time, close the fuel cocks.

Fig. 2020 Manual stopping device

62


2.2.5

Engine preservat ion If the engine is taken out of service for a longer period, it must be preserved in order to prevent corrosion damage. This also applies if the engine is put into service later than 3 months after delivery. See Job Sheet No. 3.3.003 for preservation instructions.

2.2.6

Engine operation after preservation The anti-corrosion agents used for preservation influence the way the engine runs and therefore have to be removed prior to operation. Clean engine and remove protecting grease from the blank parts, e.g. control rod. Remove covers and blank flanges from intake and exhaust pipe. Fill engine cooling system with clean cooling water without admixture (section 2.1.1) Empty fuel filter and fuel tank (see also Job Sheet No. 3.2.053), fill in fuel (section 2.1.3) followed by bleeding of the fuel tank. Clean air-filter (job sheets 3.2.002 D), Drain lub oil filter (see Job Sheet 3.2.025) and fill in lub. oil (section 2.1.3). Carry out the operations and checks described in section 2.2.1 and start engine (section 2.2.2). For about 15 minutes, let the engine run at low speed and output, then stop it and drain off water. Fill in cooling water in accordance with section 2.1.1.

63

USERS MANUAL GREAVES DIESEL ENGINE D3 POL-Specification small-size engines

G R E A V E S

2/14 Oct 97

1.000.0.0054401

----------------------------------- ------------------------------------------------------------------- ---------------- --- ---------------------------------Lubricating oil grades

B=

GENERAL Distrillates as per DIN 51601 IMDF as per MDF as per Normal and heavy-duty operation in vehicles BS 2869 class A1 OR A2 BS 2869 BS 2869 installations and generating sets ASTM-D 975 No. 1 D and/or 2D __________ Class B 1 Class B 2 to-1. 5 to 0.5 to-1 CHPM/heat pumps

Fuel

Sulphur contents in % by weight

Type of application

-----------------------------------TBD

Explanations

API-CF-4

Application in combined heat and power modules Emergency CHPM GENERAL power heat GENERAL EMERGENCY POWER Supply supply pumps ------------------------ -------------- ---------------------------------------------------- Operation in emergency generating sets B B B In case of operating periods less than 20h/ month

turbo charged

please consults our factory. B

B

B

Oil change every 6 months at least

---------------------------------------------------------------------------------------------------------Oil change interval in operating hours

250

250

250

250 or ace. to analysis

125

Engine type Lubricating oil grade (See overleaf)

125

Lubricating -oil viscosity The class of lubricating oil viscosity depends on the prevailing ambient temperature Ambient temperature Class of viscosity Above 30°C

SAE 40

0 - 30º C below 0ºC

SAE 30 SAE 10W

-10ºC to 10º C

20W- 20

Special regulations, enclosed to the operating instructions manual, may be valid for engines with manual starting appliances Multi-grade oils are only provided for use in automotive engines Only Multi-grade oils. Perfec tly meeting the requ irements of spec ifications MIL- L-21O4C/D and API-CD to CD+ may be used. Multi-grades oils are not permissible, when using MDF fuels

Lubricating oil change

Limiting values for analysis mm max Viscosity at 100° mm7 /s(cSt) DIN 51562 The lubricating - oil level must regularly be checked and completed up to SAE 20W 20 7.0 11.0 the top dipstick mark SAE 30 9.5 14.0 In cases of operation involving a mostly constant engine load (e.g. CHPM) SAE 40 11.0 17 0 the oil change interval may be extended, if the optimum oil-change interval Flashpoint ºC 200 ISO2719 has been determined by a series of used- oil analyses. Oil companies and Fuel contents % by vol. 6 technical institutions may be asked to carry out these analyses or Greaves solid foreign matters against reimburse ment of the costs involved The lubricating oil must be (Heaptane) % by weight 1.5(2)" DIN51365 changed, in any case, if the results of the used- oil analysis are exceeding Water contents % by weight 0.2 ISO3733 one or several limiting values stated in the opposite table Base number (TBN) % 50% of value when new AST M664 ____________________________________________________________________________ 1) The values in brackets are permissible in exceptional cases only. _________________ Cooling water

Admixture, initial and subsequent dosage of the anticorrosion agent as well as regular

Clean water with the lowest possible lime contents should be used as a Cooling water within the limiting values mentioned below for analysis. The analysis values may be 10% higher or lower than the liming values An anticorrosion agent approved by Greaves . must be added to the cooling water

concentration checks should be performed according to the instructions of the respective manufacturer. Caution No chemical anticorrosion agents should be used for internally galvanized piping

Water quantity PH value Contents of chlonde IONS Contents of sulfate ions Total contents of anions When using antifreeze Total (german) hardness (gernan) cart nate hardness when using chemical anti-corrosion agents Total German hardness

mm

max

7

9 100 100 150

Mg/1 Mg/1 Mg/1

3

dGH dKGH

3

dGh.

0

Anticorrosion agents Only water of this quality should

Chemical anticorrosion agents may also be used with water from desalinization and vaporizations. Instalations (not valid for TBD3)

min

|

max

acc to the

ins tru cti on of the manufacturer . should be mixed involved with One of the ___________________________________________________________________ additives m e n t io n e d Antifreeze/frost protection down to 2Oº overleaf c. An antifreeze concentration of at least 33% 5QO /o 33% should be compli ed with during the Whole year to prevent corrosion Damage

12

12

Caution Replace antifreeze every 2 years and chemical anticorrosion agents every year. Water quality is to be determined by consulting the water-works or Warranty claims concerning damage caused by POL- products can only using Greaves test kit case 6 088 801.6020 4 When in doubt, have be met. if above regulations are carefully observed and adhered to the water analyzed in chemical laboratory See next page for cooling-water additives Never use non-analyzed water'

64


Benefits

NALFLEET 9-111

ENGINE COOLING SYSTEM TREATMENT

Protects all metals in engine cooling systems including copper, copper alloys, lead solder and aluminium from corrosive attack.

Reduces maintenance time and costs.

Protects against liner pitting and cavitation-erosion. Water pump lubricant.

Liquid form for simple application add directly to the engine radiator or cooling system. Treated water does not cause dermatitis or other skin conditions.

Keeps engines free from heat absorbing sludge and mineral scale deposits-prevents over heating. Extends antifreeze life

Does not affect nonmetallic materials in engine cooling systems and rubber gaskets or hose.

Principal Uses

Nalfleet 9-111 functions as a protective film forming corrosion inhibitor and scale suppresant. It is effective in hot and in cold fresh water and is fully compatible with glycol/water mixtures. It also contains an anti-incrustant to prevent deposition on hot surfaces and keep waterways in radiators clear.

It is approved for use in an engine cooling system circulating as the heating medium for generator producing fresh water for drinking and culinary purposes, provided the recommended dosage rates are adhered to.

General Description

Nalfleet 9-111 has the following typical characteristics. Color : Dark blue

Odor : None Solubility in Water Soluble in small proportions.

Feeding

Nalfleet 9-111 may be fed directly from drums but because of the alkalinity of the neat product plastic taps should be used for dispensing.

Empty and fresh the cooling system thoroughly before commencing as much old rust as possible. If the system is exceptionally rusty it is advisable to repeat this procedure after the first week or two of treatment.

Nalfleet 9-111 should be added after the circulation of the cooling water system.

Dosage

The concentration of Nalfleet 9-111 in the cooling water should be in the proportion of 1 part Nalfleet 9-111 in 125 parts cooling water by volume {8 liters/tonne).

Nalfleet 9-111 should be added fresh after every 'B' check.

Storage & Handling

Nalfleet 9-111 may cause irritation to skin and eyes Avoid contact with skin and eyes or cloths. Prolonged or repeated breathing of vapor should be avoided This chemical is to be used with adequate ventilation. Do not take internally.

Keep away from heat, sparks and open flames. Keep drums closed when not in use. In case of contact, wash skin with soap and water, for eyes immediately flush with large amounts of water for at least 15 minutes and get medical attention. Remove contaminated clothing and wash before reuse. 65

All POL-products mentioned below are meeting our requirements according to the manufacturers even if some engine oils do not comply with classifications as per API and or Mil in certain In view of the la rg e number oil products, it is impossible for us to men

B Engine oil

FIRM

API CF-4

portion all the products appearing as suitable ones. This is why other POL -products which are data not stated here, may be used provided that they meet our requirements Each manufacturer cases i s s o l e l y r e s p o n s i b l e f o r t h e c o n s t a n t q u a l i t y o f h i s P O L - p r o d u c t s a t t h e i n t e r n a t i o n al l e v e l

Antifreeze

Agip

Agip Antifreeze Plus

Aral

Aral-K uhlerfrostschutz

Avia

Avia FROSTSCHUTZ

bavwa

Fricifir

Chemical anticorrosion agent Supplier Denomination

c

BP

M m x c/5

BP Anti-Frost

Castrol R X-SUPER PLUS 15W/40

Castrol

Castrol Antl-Free?c

Pern

Pretty Filter

naifloc

Chevron'' Glysantin

Deutzpr 0m KG

EH

Forte

O m Naftlesl Cooianl Condrtione*

m

Coolant Flush

g

GlaceK

Esso

Esso Kuhlerfrostsohutz

Fina

Fina Termidor P 100

Fuchs

Fncofm

>C

m

I

IND Mobjl

IND-MOBIL DELVAC SUPER 1300i I5 W- 40

Motur

MOTUL HP4D 15W40

Frostschutz 500

BHG

Fricofin

Snell

GlycosheH

Texaco

Texaco Frostschytz

Total

Total Frostfree

veedol

Veedol Antifreeze

Winte shall

Kuhle'schutz • SHIM>()!<•

66


LUBRICATION FOR GREAVES ENGINES

m


LUBRICATION FOR GREAVES ENGINES LUBRICATING OIL CHANGE PERIODS ARE RECOMMENDED FOR GUIDANCE. THESE PERIODS CAN BE ALTERED DEPENDING UPON THE WORKING CONDITIONS, ENVIRONMENT, QUALITY OF LUB. OIL AND MAINTENANCE OF THE ENGINE. THE LIFE OF LUB. OIL AND FUEL FILTER ELEMENTS DEPENDS ON THE QUALITY OF LUB. OIL AND DIESEL USED RESPECTIVELY. REGULAR OIL CHANGE AND GOOD PREVENTIVE MAINTENANCE GIVE THE ENGINE LONG LIFE AND SMOOTH WORKING.

RECOMMENDED LUB. OILS i) ii) iii) iv) v)

API - CF4 OR EUIVALENT CASTROL RX-SUPER PLUS 15W-40 IND-MOBIL DELVAC SUPER 1300 15W-40 elf PERFORMANCE 3D 15W-40 IOCL SERVO PREMIUM CI4 15W-40

67

USER'S MANUAL GREAVES DIESELENGINE D3

Part 3 3.1

Servicing Tools and expedi ents

3.1.1

Other additi ves

3.1.2

Trouble tracing table

3.1.3

Servicing schedule

3.1.4

Job sheets for servicing

68


3.

Servicing Unavoidable pollution of the environment which can enter the engine through the POL products (air, fuel, lubricating oil, grease and coolant) as well as other loads in operation can endanger satisfactory operation of the engine. Servicing has the task of preventing these dangers and responsible servicing enhances the safe reliable operation and life of the engine, thus saving costs.

3.1

Tools and expendien ts for servicing The following tools and expedients are required for carrying out the servicing tasks.

1.

Set of tools Servicing set

6.000.0.018.500.7

2.


6.000.0.018.501.7

3.

Set of tools Supplementary kit

6.232.0.018.009.7

4.


6.234.0.018.003.7

69


1.

Set of tools Servicing set Order No. 6.000.0.018.500.7

Item Qty.

Description

Part No.

1

1

Tool case

6.085.610 .2001.3

2 3 4 5 6 7 8 9 10 11 12 13 14 15

1 1 1 1 1 1 1 1 1 1 1 1 1 1

6.086.417.0101.2 6.086.417 .0131.7 6.086.417.0141.5 6.086.417.0192.2 6.086.424 .0013.2 6.086.424.0015.2 6.086.424 .0017.2 6.086.424.0019.2 6.086.424 .0022.2 6.086.424.0024.3 6.086.424 .0027.2 6.086.445.0112.2 6.086.445.1120.2 6.086.460.5000.9

16 17

1 1

Wrench 10 x 12 DIN 3110 Wrenc h 13 x 17 DIN 3110 Wrench 14 x 15 DIN 3110 Wrench 19 x 22 DIN 3110 Socket insert 13 x 12.5 DIN 3124 Socket insert 15 x 12.5 DIN 3124 Socket insert 17 x 12.5 DIN 3124 Socket insert 19 x 12.5 DIN 3124 Socket insert 22 x 12.5 DIN 3124 Socket insert 24 x 12.5 DIN 3124 Socket insert 27 x 12.5 DIN 3124 Cross handle A 12,5 x DIN 3122 Extension B 12.5 x 125 DIN 3123 Screwdriver A 0,8 x 5,5 x 125 DIN 5265 Set of feeler gauges 0,2-0, 45 Square spanne r, spanner openi ng 3,5

70

6.086.104 .0004.0 6.086.422.2000.1

USER'S MANUAL

2.

GREAVES DIESEL ENGINE D3

Set of tools Servicing set Order No. 6.000.0.018.501.7

Item

Qty.

Description

Part No.

1

1

Tool case

6.085.610.2001.4

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Wrench 10 x 12 DIN 3110 Wrench 13 x 17 DIN 3110 Wrench 14 x 15 DIN 3110 Wrench 19 x 22 DIN 3110 Wrench 24 x 27 DIN 3110 Socket insert 13 x 12.5 DIN 3124 Socket insert 15 x 12.5 DIN 3124 Sock et insert 17 x 12.5 DIN 3124 Socket insert 19 x 12.5 DIN 3124 Socket insert 22 x 12.5 DIN 3124 Socket insert 24 x 12.5 DIN 3124 Socket insert 27 x 12.5 DIN 3124 Cross handle A 12,5 DIN 3122 Extensio n B 12.5 x 125 DIN 3123 Extension B 12.5 x 250 DIN 3123 Universa l joint C 12.5 DIN 3123 Head of ratchet 12. 5/0 - 400 Nm Pipe handle Torque wrench 0-210 Nm Extension lever 0-420 Nm Screwdriver A 0.8 x 5.5 DIN 5265 Set of feeler gauges 0.05 1 mm Square spanner , spanner opening 3.25

6.086.417.0101.2 6.086.417.0131.7 6.086.417.0141.5 6.086.417.0192.2 6.086.417.0242.7 6.086.424.0013.2 6.086.424.0015.2 6.086.424 .0017.2 6.086.424.0019.2 6.086.424 .0022.2 6.086.424.0024.3 6.086.424.0027.2 6.086.445.0112.1 6.086.445 .1120.2 6.086.445.1120.1 6.086.445.2120.1 6.086.440.9000.1 6.086.440.9002.2 6.086.440.1021.1 6.086.440 .9002.5 6.086.460.5000.9 6.086.104.0 001.0 6.086.422.2000.1

71


Special tool set, item number Item

6.232.0.018.009.7

Description

Part No.

1

Tool box C 1613/01

6.085.610. 2001.6

2

Screwdriver A1 x 7 x 150

6.086.460.5001.0

3

Screwdriver 2 DIN 5262

6.086.461.1002.1

4

Plier C 19 DIN 5256 (for piston pin retaining ring) Piston ring pliers 110 - 150 RD

6.086.009.0000.2

Testing device CH 1612/4 (to check the cylinder liner set back and upper distance of piston) Dial guage A 10 DIN 878 (to testing device CH 1612/4) Overflow pipe CH 1612/6 (to check injection timing) Overflow cup 1774/21.2 (to overflow pipe CH 1612/6) Screwdriver insert SW 8, square 12.5 (for fastening bolt of injection um ) Socket wrench insert CH 1983.1/6 21 x 24 (for pressure pipe connection on injection pump)

6.088.801.2031.4

5 6

7 8 9 10

11

72

6.087.105.1000.3

6.086.001.0002.1 6.088.801.4010.7 6.088.801.4010.8 6.086.425.0008.1

6.088.801.4011.0


Set of tools - Servicing set 6.234.0.018.003.7 Tool case

6.085.610. 2003.5

Hydrometer Cooling water test kit Strap wrench for disposable filter Square spanner for Zinc protection

6.0759.80.0.0001 6.088.801.6020.4 6.086.442.1000.1 6.086.423 .0001.4

73

USER'S MANUAL GREAVES DIESEL ENGINE D3 3. 1. 2 Fault-Tracing Table The fault-tracing table lists faults in engine operation with a description of how they may occur and their causes. The potential causes are given in the order in which the true cause is likely to be localized with the least effort. The sections given under "Rem edy" contain information on how to remedy the fault. The cause; of deviations in lube oil pressure, lube oil temperature and coolant temperature as well as information on how to remedy them are given in Job Sheets 3.1.4.2 and 3.1.4.3.

n e h W n r u t t o n s e o d e d n t e i g r a n t E s

causes e t e i n t i i n g g w i t f e o n a s r e e t o f d a e p o n t i g s n r E O

e d v e e i h e p c / s a t t u o p n t s u e o o d d e e i i n f i g c n e p E s

y l r a l u g e r r i g n i n n u r e n i g n E

g n i k c o n k e n i g n E

g n i t a e h r e v o e n i g n E

g n i t a r e p o p o t s e n i g n E

s a g t s u a h x e l a s g m n r i o r o n l b o A c

d e e p s r e v o e n i g n E

. l i o b u l n i r e t a W

No control current Battery discharged Insufficient fuel Monitoring system has tripped

workshop

Engine too cold

74

Turbocharger defective

workshop

Starting system defective

workshop

Oil cooler leaking

workshop

Governor defective or governor linkage sticking

workshop

Defect at crank assembly

workshop

Cylinder line in crankcase leaking

workshop


3.1.3

Servicing schedule The following table shows the servicing tasks, subdivided according to servicing intervals. The servicing work has to be carried out at the latest as soon as the operating hours, indicated in the columns on the left page, have been reached. The servicing tasks must be repeated according to the given number of operating hours.

for the first time on

Checking exhaust back pressure

3.2.033

Engine oil change Checking V-belt drive Replace engine oil filter cartridges

3.2.001 3.2.003 3.2.025

commissioning only once after 50 operating hours for continuous operation daily 250h 1000 h

for emergency & stand

2000 h Servicing tasks

X X X X

X

X X X X

X

X X according to

requirements

to be repeated every X

No. of Job Sheet

operation.

•Engine oil change

3.2.001

Checking coolant level prior to starting engine and checking coolant temperature during operation Checking oil level and oil pressure Check battery Checking maintenance indicator on the air filter

3.1.4.2

Replace exhaust gas filter (after visual check)

3.2.002A

Replace dry-type air filter clement (Note maintenance indicator)

3.2.002B

Clean after cooler & heat exchanger

3.2.003

X

Checking any resetting valve clearance Checking exhaust back pressure Renew sparking plugs @250 Hrs Checking monitoring Lubricating the bearings (generator type T1) * Tightening torques of main screw connections in Nm Engine preservation ** Cleaning heat exchanger & After cooler. Cleaning exhaust-gas heat exchanger Checking control unit for ignition point and coils as well as cleaning impulse solenoids

3.2.028 3.2.033 3.2.052 3.2.059

X X

monthly 1 year

3.1.4.3 3.1.-1.4 3.1.4.5

X

X

3.:2.060

3.3.001 3.3.003

3.3.007 3.3.008 3.3.009

• Determine service life of lubricating oil according to POL products specifica tion 6.000.0.005.4432 e of this operatin g instruction. **Caution: Cylinder-head screws, bearing cover and connecting-rod bolts should never be retightened •

•

In case of higher cooling-water temperature, check heat pieces visually and clean, if necessary. Monitor H 2S, CH4, H 2O, Content in gas line

75

X X

USER'S MANUAL GREAVES DIESEL ENGINE D3 3.1.3.1

Overhauls

The reliability of the engine is affected over long periods by wear and corrosion. In order to avoid engine failures, we suggest to carry out the overhauls indicated in the following table. The first overhaul operations must be performed after 10.OOO operating hours or, if not reacted, after 2 years. The work sequence is described in the Workshop Manual, which can be obtained n our Spare Parts Department. Inspection Operating hours Checking bearing clearance on turbocharger Replacing exhaustgas filter (probe end) after at the latest or earlier depending on the blackening degree (visual check) Replacing exhaustgas filter (pump end) after at the latest or earlier depending on the blackening degree (visual check) Replacing exhaustgas pump Carry out measurement of harmful constituents * Overhauling cylinder heads Cleaning combustion chamber Checking cylinder liners Cleaning oil cooler Checking rocker arms and rocker -arm bracket Cleaning and checking cooling-water regulator Replacing cooling-water hose* and expansion joints Cleaning and checking gas-pressure regulator, gas solenoid valve and mixing valve Checking ignition unit * Replacing starter wearing parts * Checking exhaust installation for wear

5 000h X 10 000 h X X X X X X X X X X X X X

Partial overhaul Replacing pistons Replacing cylinder liners Cleaning and checking oil relief valves Replacing crankshaft seals, checking axial clearance Checking big-end bearings, replace connecting rod bushes, if necessary Exchanging anti -vibration dampers (Holset)

20 000 h X X X X

Basic overhaul Measuring crankshaft (grind, if necessary) Replacing main and connecting-rod bearings Overhauling starter (Bosch) Checking gear drive Checking control unit, replacing wearing parts Replacing oil pump

•

40 000 h X X X X X

The harmful constituents should be measured with electronic measuring appliances by MWMstaff only. It is recommended to measure the harmful constituents after the first 5000 h and/or to have the O2 - regulating unit checked and measured by the TOV and to replace defective parts, if necessary.

The above-mentioned operating-hour 4ntervals are average values and valid for standard operating conditions and appropriate maintenance in accordance with the descriptions. These are standard values without warranty obligations. Deteriorating operating conditions are caused by •

frequent starting

•

long operating periods at zero load

•

extremely rapid and frequent load charges

•

frequent operation at overload

The execution of the repairs (maintenance and overhauls) requires skill and special knowledge. Should you have no skilled staff at your disposal, our After-Sales Service Department will be pleased to give you information about maintenance contracts involving various work scopes.

76


3.1.4

Job Sheets for Servicing For a better survey, the jobs are subdivided and described on Job Sheets. When carrying out these jobs a good knowledge of the various functions of the engine and how they interact is necessary. Information to this extent is provided in part 1 and part 2 of these Operating Instructions. The Job Sheets describing the jobs are numbered. The individual Job Sheets contain the following information: •

Description of job involved and Sheet No.

•

Servicing interval

•

Remarks on tools, fixtures and expedients requir ed

•

Information on any spare parts required

•

General servicing directions

•

Step-by-step description of servicing procedures

•

Figures illustra ting the text

•

Important items in these figures are numbered

•

Necessary reference relating to further Job Sheets

The object of the Job Sheets is to facilitate preparations and for implementing actual servicing tasks.

77


TBD3

If the engine is used for standby or emergency service, corrosion may occur due to condensation of water. In order to prevent this and to test the operational readiness of the engine, a trial run should be performed once in a month. Starting the engine 1.

Check the supply of POL products (Section 2.2.1.1)

2.

Open the cooling water cocks and, if fitted, switch on pump sets.

3.

Open the fuel supply.

4.

Switch on monitoring system {for key-operated switch : position 1 fig. 1) and set speed governor to low speed.

5.

If fitted, set switch 1 "Betrieb - Stop" (Operation - Stop) to "Betrieb" (Operation) and start engine by means of the starting switch (for key - operated switch : press key inwards and turn clockwise as far as possible)

u

Caution : if the engine races out of control (engine speed continues to rise) or if no oil pressure is built up, switch off the engine immediately and close the fuel supply. During operation, keep key-operated switch in position 1, Position O means that the monitoring system is out of operation. 1.

Running the engine

Just after starting, run the engine at 1/3 load only. After approximately 10 minutes it can be run at 3/4 load and after a further 5 minutes at full load (nominal output). When the engine has reached normal running temperature, check the operating values (section 2.2.3.1). Before stopping the engine, let it run for another approx. 10 minutes at 1/3 load. 2.

Stopping the engine

Press manual stopping device (Fig. 3) in stop-direction until flywheel stands still or set instrument panel lever to "Stop" (item 1 or 2). If fresh water pump units are fitted, they should run for a few more minutes after stopping in order to prevent the buildup of heat at the cylinder liners and cylinder heads. Close fuel and cooling water cocks and switch of f monitoring svstem.

78

GREAVES

Job Sheet

Date

first time after

Engine type

Job Sheet No

TBD3

3 14 1

5.97

Page

after and every

Trial run

1

month

of I

1 page

need thoroughly prior to beginning

Necessary tools

Necessary materials and auxiliaries

Spare Table No.

If the engine is used for standby or emergency service, corrosion may occur due to condensation water. In order to prevent this and to test the operational readiness of the engine, a tri al run should be performed once a month Starting and monitoring of engine

Engine Protection Unit

1

Check the supply of POL products (Section 2 . 2 . 1 . 1 )

2

Open the cooling water cocks and, if fitted, switch on pump sets. Open the fuel supply. To start the engine switch ON the control supply key

3 4

switch. Press the bypass button and start the engine from start push button. The bypass button may be released when the engine achieves oil pressure. Caution : n' the engine races oui of control (engine speed continues to rise) or if no oil pressure is built up, switch off the engine immediately and close the fuel supply During operation, keep key-operated switch in position 1, Position O means that the monitoring system is out of operation 1.

1-RPM Meter 2- L O Pre Gauge 3-W T Gauge 4-Ammeter 5 - L O T Gauge (optional) 6- Stop push button 7-Warning Lamp

Running the engine

Just after starting, run the engine at

1 / 3 load only After

approximately 10 minutes it can be run at 3/4 load and after a further 5 min utes at full loa d (nominal output) W hen the engine has reached normal running temperature, check the operating v a l u e s ( s e c t i o n 2 . 2 . 3 1 ) B e f o r e s t o p p i ng t h e e n g i n e , l e t i t r u n for another approx 10 minutes at 1 / 3 load 2.

Stopping the engine

T h e e ng i n e is s t o pp e d f r o m t h e s t o p p u s h b u t t on o n t h e Instrument panel by putting the switch in OFF position E rig i n e Protection Description Th e e n g i n e m o u n t e d s w i t c h e s c o n s i s t o f l o w l u b o i l p r e s s u r e switch (operating at 1 5 t C 0 5 bar f all in g pressure), high water t e m p e r a t u r e s w i t c h ( o p e r a t i n g a t 9 6 D e g C ) 2 D e g C r i s i ng t e m p e r a t u r e ) t h a t s t o p s t h e engine if either of the conditions are achieved The condition annunciated by a hooter and displayed by respective DC lamp For generator set supplied with control panel by GDEU the engine protection comes integral with panel control with circuit. If fresh water pump units are fitted they should run for a few more minutes after stopping in order to prevent the buildup of heat at the cylinder liners and cylinder heads. Close fuel and cooling water cocks and switch off monitoring system.

79

Job Sheet

Engine type Date

First time after

TBD3 after and every

Checking the battery

Job sheet No.

3.1.4.4 Page 1

of 1 page

daily read thoroughly prior to beginning

Necessary tool*

Hydrometer Cloth

6.0759.80.0.0001


Spares Table No

Distilled water Anti-acid grease Bosch No. 5 700 102 005

When the engine is not operating, the battery supplies current to consumers and delivers the high power required for starting. The capacity of the battery deteriorates during long periods of nonoperation or as the result of excessive loading. For these reasons the battery must be checked at the intervals indicated in the servicing schedule.

Caution: The charging gases are explosive. Do not, in any case, manipulate naked flame, produce sparks or smoke in the vicinity of the batteries. Wear protecting glasses when working on batteries being connected to the charger. Allow frozen batteries to thaw before charging. Checking battery and recharging it, if necessary 1. Wipe battery using a humid cloth. Remove corrosion marks and rinse the poles using a solution composed of water and natron and coat with acid-resisting grease. Check, whether connecting terminals are tightened. 2. Unscrew batte ry-cell ca ps (item 1) and measure electrolyte density of the battery using a hydrometer (item 2). Electrolyte density: 1.23 to 1.28 kg/I normal Electrolyte density below 1.21 kg/I recharge. Reference temperature 20°C. 3. Unscrew all battery-cell caps (item 1) and fill up, if necessary with distilled-water to approx. 15 mm above plate edge. 4. If the battery has to be recharged, disconnect battery cables (beginning with negative pole) and connect battery charger. Positive to positive pole and negative to negati ve pole. Switch charger on and recharge battery. The charging current represents 1 / 1 0 th of the numerical value of the battery capacity, e. g. 143 Ah = charging current of 14.3 A. The battery is charged when the acid density and charging voltage do not rise any more within 2 hours. 5. Switch off and disconnect charger. Close all battery-cell caps and connect battery cables (beginning with positive pole). Note: Recharge stopped batteries every 4 to 6 weeks.

80

GREAVES

Job Sheet

Date

first time after

after and every

06.86

Engine type TBD3

Checking dry air filter for dirt (Visual check on Necessary tools maintenance indicator)

read thoroughly prior to beginning


Set of tools

Cleaning agent Compressed air Gaskets

Job Sheet No. 3.2,002 D Page 1

Spare Table No.

79 -

In dry-type air filter, the intake air is directed through a paper filter insert retaining the dirt particles. The filter gets clogged as a result of the dirt particles accumulated inside the filter insert, thus increasing the vacuum downstream of the filter. This vacuum is measured inside maintenance sensor. In case of excessive vacuum i.e. a contaminated dry-type air filter, the maintenance sensor incorporated in the switchboard switches a signal lamp on. It is now time to perform maintenance operations or after one year at the latest. Filter element 3 must be replaced to make the engine ready for operation again. In order to increase the service life of the filter element a prefilter is installed in front of the filter. It retains the coarser particles of dirt of the intake air. Caution! Operations may be performed on the air filter only if the engine is stopped. "Risk of accidents" Check dust collector 1 mounted on Pre-filter s clean pre-filter Check dust quantity in dust collector 1. When the mark 2 is reached, empty dust collector 1 and carry out the following operations : 1. 2. 3. 4.

Loosen clamping screw 3 and remove pre-filter Clean air intake openings 4 and dust discharge slot of the dust collector 1 by means of a piece of wire. Clean all parts with a detergent solution and dry them. Reassemble in reverse sequence. Pay attention to seal

Check maintenance indicator, renew dry air filter eleme nt Check sight glass 6 of the maintenance indicator while the engine is out of operation. If the red mark continues to be seen, carry out the following operations : 1. 2.

Remove nut 7, cover 8 and renew filter element 9. Reassemble in reverse sequence. Pay attention to seal 10.

Cleaning the dry-type filter element (only in exceptional cases) 1.

Remove filter element as described under "Renewing filter element".

2.

With the clean room closed the filter element is to be blown out in longitudinal direction of the folds a nd afterwards from inside.

Note : The filter elements can also be washed out with detergent 053 or P 3 RST (Messrs. Henkel). We advice however, not to do so for reasons of safety. Beating the filter element is not recommended either. 3.

Reassemble in reverse sequence.

Note : Afler having cleaned the filter element 5 times, or every 2 years, at the latest, the filter element has to be renewed.

81

GREAVES

Job Sheet

Date

first time after 60h

5.85

after and every 500 h

Necessary tools

Job Sheet No. 3.2.003

TBD3


Checking V-belt drive/Lubricating raw water pump

Tool set Cranking bar Grease gun

Engine type

Necessary materials and auxiliaries Lithium saponified grease

Page

of 1 page Sparc Table No. 1

57 59 65 67 69 89

-

The V-belt drives on the opposite end of the main P.T.O. are used to drive the raw water pump (Fig. 1, Item 1), fresh water pump (Fig. 1, Item 2) and alternator (Fig. 1, Item 3) The V-belt tension is correct when the V-belt can be pressed in 1 to 2 cm with the thumb (Fig. 1 arrows). Otherwise (he V-belt must be readjusted.

Checking and resetting V-belt tension 1.

Remove V-belt guard

2.

Check V-belt tension (Fig. 1, arrows) if required :

3.

Loosen screws 4 on tensioning roller bracket or alternator

4.

Regulate tension by moving the tensioning roller or alternatoraccordingly

5.

Tighten screws 4

Observe tightening torques of the screw connections (Job sheet 3.3.001) Caution !

Tensioning the V-belt excessively aggravates wear just as much as slack V-belts. As soon as cracks or other signs of wear are noticed the V-belt must be b e changed. chan ged. For F or checking che cking the V-belt all over, crank the engine. Lubricating the raw water pump

Fill the grease nipples (Fig. 2 or 3, arrows) with lithium saponified grease (multi-purpose grease) by means of a grease gun.

82

GREAVES

Job Sheet

Date 4.38

first time after 500 h

Checking zinc protective coating Necessary tools

Square wrench 11 mm : 14 mm Fresh water containers

Job Sheet No. 3.2.005 of read thoroughly prior Page 1 page 1 to beginning


Engine type TBD3


1 Sealing ring 2 Sealing rings * Zinc paint * Zine paint

6.0492.01.5.4249 6.0492.06.5.0331 6.1489.01.0.8044 6.1489.01.0.8054

Spare Table No.

63 75

* Quantity as required

Due to the aggressive substances contained in the cooling water, (he cooling water passages are exposed to corrosion. To avoid destruction of the walls, plugs with a zinc protective coating are provided in the cooling water and raw water circuits. Since the zinc zinc protective coating (base metal) will decompose with time, it must be checked at the intervals given in the servicing schedule.

Removing and fitting zinc protective coating 1. 2. 3. 4. 5. 6. 7.

Close the raw water inlet and return cock. Drain water from engine (drain cocks are identified by item 1 in the illustration, also not forgetting to drain the other side of the engine) Remove plugs with zinc protective coating (identified by arrows in the illustratio ns) and check condition. If heavily decomposed, renew. Refit plugs with new sealing rings Close drain cocks Open raw water cocks, open cock under funnel (Item 3) and fill raw water pump. Then reclose cock under funnel. Bleed system at plugs (identified Item 2 in illustrations)

83

Job Sheet

GREAVES

Date

first time after

1.86

60 h

Engine type D3 TBD3

Job Sheet No. 3.2-025

of read thoroughly prior Page 1 1 page to beginning Necessary materials and auxiliaries Spare Table No.

Replacing engine oil filter cartridges Necessary tools

Tool set Oil pan For reversible filter : Cock wrench SW 17


Filter cartridge 6.0541.29.7.0048 = 6 Cyl. Filter Filter cartrid cartridge ge 6.0541 6.0541.29. .29.7.00 7.0039 39 = 8 + 1 2 Cyl. Cyl. or (in case of a reversible duplex filter): 2 filter filter cartridges cartr idges 6.0541.18.8.0008 6.0541.18.8.0008

47 -

Within the lub. oil circuit, the oil filter is installed in such a way that all particles of dirt are kept away from the bearings. These particles clog the filter. As a result the oil pressure decreases. Therefore, the filter cartidges have to be replaced from time to time. If a reversible duplex fuel filter is mounted, the filter cartridges can be replaced while the engine is in operation, provided that the corresponding filter chamber has been switched off (see Fig. 3) During normal operation, both filters must be in operation.

Replacing filter cartridges 1.

Loosen filter cartridge 1 with strap wrench and unscrew it.

2.

Clean seal seat and oil seat of new filter cartridge slightly.

3.

Fill the new filter element/s with fresh oil up to full and quickly tighten it to the filter head. (Some amount of oil may fall down)

4.

Screw filter cartridge until seal contacts, then tighten manually. Do not use tools!

5.

Check filter for leakage with engine running.

Cock position 1 : left filter closed Cock position 2 : Both filters open Cock position 3 : right filter closed

84

GREAVES

Job Sheet

Date

first time after

Engine type D3 TBD3

after and every

1.86

1000 h

Job Sheet No. 3.2.028A Spare Table No.


Page

Checking and readjusting valve clearnce (6 cylinder engine)

1


Necessary tools

Set of tools

19 21

Turning rod Inlet and exhaust valves can only reliably close tightly if there is a certain clearance set between camshaft and valve stem inside the valve-drive unit. Valves which do not close tightly may cause the valve seat and valve plate to burn off. On the other hand, excessive valve clearance would cause considerable wear. Maintaining the valve clearance of the correct setting increases service life and engine reliability.

Checking and adjusting of valve clearance (on cold engine) 1. 2.

3.

Screw out bolts 1 on all cylinder heads and remove cylinder head covers. Crank engine in direction of rotation until valve 2 close in cylinder A1; then, crank crankshft further by approx. half a turn, this position corresponding to ignition TDC. Check valve clearance between rocker arms and valve stem end with corresponding feeler gauge.

Valve clearance for :

Inlet valve 2

Exhaust valve 3

naturally-aspirated engine

0.2 mm

0.3 mm

turbocharged engine

0.3 mm

0.5 mm

The feeler gauge should be inserted with a cert ain amount of force. In case of deviation the valve clearance must be readjusted. Loosen locking nut 4 and setting screw 5. Screw in setting nut by screw driver until (he feeler gauge begins to clamp. Tighten locking nut and check valve clearance as above. Checking and/or adjusting sequence : The checking and adjusting of the valve clearance is effected as per the ignition sequence, starting with cylinder A 1 as described in section 2. After having checked and/or adjusted the valve clearance on cylinder A1, the engine is to be checked further, progressively, in firing order and direction of rotation for additional checks as follows:

Checking and/or setting sequence (ingnition TOC)

Flyweel end Beginning of the second

Ignition TDC

A1

B2

A3

B1

A2

see also figure 2 Beginning of the first Crankshaft rotaion

Beginning of the second Crankshaft rotaion

6.

85

Fix cylinder-head covers, taking care of gaskets.

B3

GREAVES

Job Sheet

Date 1.86

Engine type Job Sheet No. D3 3.2.028B TBD3 of read thoroughly prior Page to beginning 1 1 pages Necessary materials and auxiliaries Spare Table No.

first time after

Checking readjusting valve clearance (8 + 12 cylinder- engine) Necessary tools

19

Set of tools fuming rod

21

Inlet and exhaust valves can only be reliably closed tightly if there is a certain clearance set between camshaft and valve stem inside the valve-drive unit. Valves which do not close tightly may cause the valve seat and valve plate to bum off. On the other hand, excessive valve clearance would cause considerable wear,. Maintaining the valve clearance of the correct setting increases service life and engine reliability. Checking and adjusting of valve clearance (on cold engine) 1.

Screw out bolts 1 on all cyl inder heads and remove cylinder head covers. 2. Crank engine in direction of rotation until cylinder A1 reaches ignition TDC. Cylinder A1 is placed on ignition TDC when valves A4 on 8-cylinder engines or A6 on 12-cylinder engines are overlapping, i.e. when exhaus t valve 3 closes and inlet valve 2 begins to open (Loadchange TDC) 3. Check valve clearance between rocker arms and valve stem end with corresponding feeler gauge. Valve clearance for : Inlet valve 2 Exhaust valve 3 Checking and/or setting sequence (ignition TDC) 8 Cylinder Fly wee I end first

4. 5.

Beginning of the Crankshaft rotation

0.2 mm 0.3 mm

naturally-aspirated engine turbocharged engine

-Beginning of the second Crankshaft rotation 12 Cylinder

0.3 mm 0.5 mm

The feeler gauge should be inserted with a certain amount of force. In case of deviation the valve clearance must be readjusted. Loosen locking nut 4 and setting screw 5. Screw in setting nut by screw driver until the feeler gauge begins to clamp. Tighten locking nut and check valve clearance as above. Checking and/or adjusting sequence : The checking and adjusting of the valve clearance is effected as per the ignition sequence, starting with cylinder A 1 as described in section 2. After having checked and/or adjusted the valve clearance on cylinder A1, the engine is to be checked further, progressively, in firing order and direction of rotation for additional checks as follows:

Ignition TDC A1

B2

A3

B1 A4

B3

A2

B4

A4 B3 Valve over lapping 8 - Cylinder engine see also figure 2

A2

B4 A1

82

A3

B1

A1 B5 A5 B3 A3 Ignition TDC Valve over A6 A2 A2 B4 A4 lapping

6.

86

B6 A6 B2 A2 B4 A4 B1 B1 A1 B5 A5 B3 A3 B6

12 - Cylinde r e ngine see also fig. 2 Fix cylinder-head covers, taking care of gaskets.

GREAVES

Job Sheet

Date 5.85

first time after

2000h

Necessary tools

T8D3


Fuel filter Fig. 1 Filter cartridge Fuel fitter Fig. 4 Filler element For single-stage filter For duplex filter


Engine type


Renewing fuel finer cartridges of fuel fitter element

Set of tools

and every

Page of 1 2 Page Spare Table No.

29 6.0541.18.8.0004 6.0541.14.0.0003 1 each 2 each

In order to prote ct the fuel injection pumps and injectors, a fuel filter is incorporated in the fuel system upstream of the pumps and injectors. A contaminated filter element reduces the flow of fuel and must therefore be replaced after the above-mentioned operating hours . If a reversible fuel filter is provided, the filter cartridges may also be renewed while the engine is running. Caution! Only when the filter elements are changed must the corresponding filters be shut down. During normal operation leave both filter in circuit! Fitter switching diagram, see figure 5. Renewing fuel filter cartridge (Filter Fig. 1} 1. 2. 3. 4. 5.

Close fuel cocks Loosen filter cartridge 1 with strap wrench and remove it. Coat seal of the new filter cartridge with fuel. Screw filter cartridge into filter h ead down to the real, then tighten by 1/2 a turn. Do not use tools. Bleed the fuel filter (see last paragraph)

Renewing the fuel filter element ( Filter Fig. 2....4) 1. 2. 3. 4. 5. 6.

Close fuel cocks. Unscrew wing screws, item 2, and take down cover item 3, taking care of gasket Slacken centre screws, item 4, and take down cover, item 5. Take filter elements, item 6, out of filter housing and clean inside of filter housing. Insert new filter elements into housing and reattach cover in the reverse sequence, taking care of gaskets. Vent fuel titter (see last paragraph)

Right - hand filter in operation

87

Both filters in operation

Left-hand fitter in operation

GREAVES

Job Sheet

Date 5.85

first time after alter and every 2000H

Renewing fuel filter cartridges of fuel filter element.

Engine type TBD3

read thoroughly prior 6a beginning

Necessary tools

Set of tools


Fuel fitter Fig. 1 Filter cartridge 6.05 41.1 8.8. 0004 Fuel! filter Fig. 4 Fitter element 6.05 41.1 4.0. 0003 For single -stage litter 1 each For duplex filter 2 each

Job Sheet No. 3-2053 Page 2

of I 2 pages

Spare Tab»c No-

29 - _

Cleaning fuel pre filter (fig. 6) 1.

Close fuel cocks

2.

Loosen knurled nut 7 and put strap aside- Remove sightglass 8 and filter element 9.

3.

Clean a(l parts with fuel, use a soft brush in order to remove strong dirt.

4.

Reassemble in reverse sequence. For bleeding open fuet cocks, loosen banjo bolt 10 and operate hand fuel pump until fuel emerges free of bubbles. Continue pumping while tightening banjo bolt again.

Bleeding the fuel fitter 1.

Open bleeding screws 11 and operate hand fuel pump until fuel emerges free of bubbles. Continue pumping while tightening bleeding screws 11 again.

2.

Check filter for leakage during operation.

88

GREAVES

Job Sheet

Date

first time after


1.86

read thoroughly prioi to beginning

Checking monitoring and engine stopping device. Necessary tools

Heatable container Thermometer (up to 100 °C) Tool set Wrench SW 27

Engine type D3 TBD3

Necessary materials and auxiliaries Molybdenum sulfide spray or Lithium saponified grease Lub. oil

Job Sheet No.

Page

3.2.055 of

1 1 page Spare Table No.

41 - ... 89 - ...

In order to avoid damages resulting from the malfunction of lubrication or cooling, monitoring devices are mounted on the engine. In case of an excessive cooling water temperature or a too low oil pressure, warning devices (pilot lamp, siren) are switched on or the engine is shut down via the shutdown solenoid. Checking and lubricating manual shutdown device Press shutdown button 1 in direction of arrow and release again. The shutdown device automatically returns to starting position. If this is not the case, check rods for smooth working. Lubricate joints 2 and tie rod 3 of the solenoid with molybdenum sulfide or oil. Checking oil pressure monitori ng device Mole : if a timing relay is installed the reactions of the monitoring device may delay for 15 sec. (maximum). Switch on monitoring devic e (in case of key-operated switch : pos. 1) and put switch "Operation - Stop" to "Operation". The pilot lamp "oil pressure" flashes up and the siren sounds. Operate switch "Siren off" and the siren is shut off. If the pilot lamp does not light up, check fuses 4 in the instrument panel or change the bulb. If this is of no use, short circuit connection 5 on the oil pressure switch on - it it is a unipolar connection - ground them. If the pilot lamp lights up, renew oil pressure switch. If not, check cable connection. After checking, switch off monitoring device. Checking cooling water monitoring device Switch on monitoring device (in case of key -o perated switch : pos. *) and position switch "Operation-Stop" to "Operation". Short-circuit conn ection on te mperature sensor or - if it is a unipolar connection - ground it. Pilot lamp "cooling water temperature" lights up, siren sounds. If this is not the case, renew fuses 4 in the instrument panel or change the bulb. If still not illuminating, check cable connections. Drain off cooling water (drain cocks 7), pinch off cable connections on temperature sensor 6 and dismantle temperature sensor. Repinch temperature sensor, suspend in a water bath and heat it. At approx. 95°C pilot lamp must light up and siren sound. If this is not the case, renew temperature sensor. Checking shutdown solenoid Short-circuit connection on oil pressure switch or temperature sensor 6. The shutdown solenoid is in "Stop" position. If this is not the case, operate switch "Engine - Stop". If the shutdown solenoid passes to position "Stop", check cable connection. If this is of no use, renew shutdown solenoid.

89

Job Sheet

GREAVES

Date 5.85

first time after

after and every

Engine type

2000 n

TBD3 read thoroughly prior to beginning

Cleaning the intercooler. Necessary tools Container, size at least 500 mm x 200 mm x 200 mm Tool set Hexagon socket wrench SW 6

Necessary materials and auxiliaries Approx, 20 dm3 Henkel neutralizing agent P3-croni Approx, 20 dm3 Henkel detergent solution P3T1166 (Messrs. Henkel, 4000 Dusseldorf)


Page of 1 1 page Spare Table No.

77 - ...

The intercooler serves for cooling the air coming from the turbocharger, whereby the weight of the air inside the cylinder is further increased. As a precondition the walls of the cooling lubes must be free of dirt and deposits. At the same time, the flow resistance of the air is increased due to deposits on the air end of the cooling tubes and thus the amount of turbo charging air diminished.

Cleaning the intercooler 1.

Drain engine cooling water.

2.

Remove fresh water pipes 2.

3.

Loosen hose clamps 3, unscrew bolts 4 and remove inlet pipes 8 and elbow 7

4.

Remove raw water connections 5.

5.

Unscrew bolts 6 and mounting bolts on intercooler frame (Fig. 2,arrow), lift off intercooler.

6.

Remove the air circulation 11

Note : The cooling fins on the air end are very delicate. Cover flange surface with a board or the like. 7.

Unscrew mounting bolts 9, remove head pieces 10.

8.

Place the nest of tubes into a container with detergent solution P3T - 1166, Henkel (concentration as per information of the manufacturer). Foaming of the solution characterizes the reaction. When the reaction is completed, i.e. after 15 minutes at the latest, take the nest of tubes off the detergent and clean the cooling fins with a duct cleaner. The nest of tubes is then washed out with clean water and put into a neutralizing agent consisting of P3-Croni (Henkel) for approx. 10 minutes. Finally, wash out the nest of tubes thoroughly with water. Check the soldered connection of the nest of tubes and, if necessary, resolder. Reassemble in reverse sequence. Renew gaskets.

90

GREAVES

Job Sheet

Date

first time after

after and every

Engine type

2000 h

TBD3

5.85


read thoroughly prior Page to beginning 1 Necessary materials and auxiliaries Spare Table No.

Necessary tools

as required

89 - ...

Ball bearing grease Ft 1 v 34 (Messrs. Bosch)

A charging alternator is required for supplying power to the electric loads on the engine, such as starter, indicator and operating systems. Since the battery has a limited capacity, it is recharged by the charging alternator which is driven by the engine through a V-belt. The rotor of the charging alternator has ball bearings at both ends. These bearings must be lubricated at the intervals given in the servicing schedule.

Lubricating bearings Screw in the grease cups 2 turn. If the grease cups have already been screwed in as far as they will go, unscrew and re-pack with ball bearings grease. Screw in Stauffer boxes until you strike an obstacle, then screw in by two further rotations.

Caution!

91

GREAVES

Job Sheet

Date

first time after

after and every

06.86

Engine type D3 TBD3


Tightening torques of main screw connections in Nm

Necessary tools

Job Sheet No. 3-3.001 Page 1

Necessary materials and auxiliaries * Tightening torque specification for cylinder head bolts: Lubricate screw thread and contact surface (do not use Molykote). Tighten the bolts crosswise to 20 Nm, and then tighten further in three stages (100 Nm, 200 Nm, 400 Nm) • With washer ? with lock washer.

92

of 3 pages

Spare Table No.

GREAVES

Job Sheet

Tightening torques of main screw connections in Nm Necessary tools

Date

first time after

after and every

Job Sheet No. Engine type

6.86

TBD3 Necessary materials and auxiliaries * 60°(1 hexagon)

93

3.3.001 Page of 2 3 pages Spare Table No.

GREAVES

Job Sheet

Tightening torques of main screw connections in Nm

Date

first time after

Job Sheet No.

after and every

3.3.001

6.86

Engine type D3 TBD3

Necessary tools

Necessary materials and auxiliaries Set of tools

94

Page of 3 | 3 pages Spare Table No.

GREAVES

Job Sheet

Date

first time after

after and every

Engine type

5.85

TBD3 read thoroughly prior to beginning Necessary materials and auxiliaries

Anti-corrosion treatment for engines not yet installed Necessary tools

Job Sheet No. 3.3.003 A Page 1 of 2

Spare Table No.

Set of tools Spray gun Tilt (waterproof)

Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV Anti-corrosion oil for lubricating oil system, e.g. Messrs. Fina; Rusan 20 W 20 Anti-corrosion oil for fuel system, e.g. Messrs. Castrol : Rustillo DWX 32 Anti-corrosion agent cooling water, e.g. Messrs. Khubier-Chemie : Puriton 4110 Talcum powder

In case of engine not installed and commissioned within a period of 3 months, an anti -corrosion treatment is lo be carried out to prevent corrosion. Anti-corrosion treatment of the engine 1.

2. 3. 4. 5.

6. 7

8.

9. 10.

11.

95

Mark position of the flywheel or of the crankshaft flange. There might be first beginnings on the cylinder liners in the height of the piston rings, therefore the position of the piston should be changed after each anti -corrosion treatment. Fill fuel mixture consisting of 9 parts Diesel fuel and 1 part anti-corrosion oil in fuel filter. Wash and/or rinse out of sump and additional devices with own oil filling with Diesel fuel. Screw -in oi l discharging screw No. 1 and tighten it. Fill anti-corrosion oil in the engine (inlet connection 2) and/or spray it in the additional devices. In case of engines equipped with a hand pump, pump the 'filed in anti-cor rosion oil through the engine by means of a hand pump and race the crankshaft by hand so that all bearings and liners are slightly wet. In case of engines not equipped with a hand pump, the anti-corrosion oil has to be passed through the oil system by means of the mounted lubricating oil pump, in the following manner. Remove blind flange on intake - and exhaust pipe. If the starter is mounted and a battery is available, turn the crankshaft by the starter. Attention: Ignition of the engine is allowed, but only with minima! speed until the oil pressure is built up. If the engine is not equipped with a starter, race the crankshaft serveral times by truning. In case of supercharged engines the turbine wheel must be raced several times by hand. Remove cylinder head cover 3, spray in valve springs and rocker arms with anti-corrosion oil, install cylinder head cover. Remove injection nozzles 4 and bring the corresponding piston to BDC. Spray anti-corrosion oil in the combustion rooms through the opening on the cylinder head. Re install injection nozzles. In case of engi/ies equipped with a compressed air start, remove starling star and starting line on the cylinder head. Spray in starting star and openings of the starting line in the cylinder head with anti-corrosion oil. Reinstall removed parts . Unscrew oil discharging screw 1 and drain anti -corrosion oil. Tighten oil dischrging screws 1. The fuel mixture can remain in the system. Fill cooling water mixture consisting of 20 parts cooling water and 1 part anti-corrosion agent in the engine and circulate the cooling water mixture in the engine by a separate pump. Then drain the cooling water mixture and let the draining cocks 5 opened. The intake and exhaust openings are to be closed so that external weather influences are kept away from the engine inside.

GREAVES

Job Sheet

Date 5.85

first time after

Engine type TBD3


Anti-corrosion treatment for engines not yet installed Necessary tools Set of tools Spray gun Tilt (waterproof)

after and every


Job Sheet No.

3.3.003 A

Page of page 1 2 Spare Table No.

Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV Anti-corrosion oil for lubricating oil system, e.g. Messrs. Fina; Rusan 20 W 20 Anticorrosion oi l for fuel system, e.g. Messrs. Castrol : Rustillo DWX 32 Anti-corrosion agent cooling water, e.g. Messrs. KhubierChemie : Purrton 4110 Talc um powder.

Representing the outer parts of engine 1.

Degrease all bright outer parts of engine and clean with fuel,

2.

Coat the bright items, e.g. linkage 6 with protectin g grease.

3.

Dust all rubber items (hoses, anti-vibration mounting pads) with talcum powder.

4.

Check paintwork for damage and, if necessary repair

5.

If possible locate engine in storage area, spray with preserving oil (spray gun) and cover with tarpaulin.

6.

Note date of preservation and fix message "do not turn crankshaft" at a prominent point on the engine.

96

GREAVES

Job Sheet

Date 5.85

first time after

after and every

Engine type

TBD3

Job Sheet No. 3.3.003 B

of read thoroughly prior Page to beginning 1 2 pages Necessary materials and auxiliaries Spare Table No.

Treating the installed engines against corrosion for lengthy standstill periods Necessary tools


Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV Anti-corrosion oil for lubricating oil system, eg. Messrs. Fina; Rusan 20 W 20 Anti- corrosion oil for fuel system, e.g. Messrs. Castrol: Rustilk) DWX 32 Anti-corrosion agent cooling water, e.g. Messrs. Khubier-Chemie : Puriton 4110 Talcum powder

If the engine is kept out of operation for a fairly long period of time, an appropriate treatment against corrosion should be done.

Treating the engine against corrosion 1.

Drain engine oil (drain plugs 1), then screw in and tighten drain plugs again.

2.

Unscrew , drain and reattach oil- filter cartridge 2. Tightening procedure for filter cartridge : screw in filter cartridge until gasket touches slightly, then, tighten, turning by approx. half a turn manually and using no tool.

3.

Fill engine with anticorrosion oil (filling neck 3).

4.

Drain cooling water (drain cock 5) and fill engine with mixture com posed of 20 parts of cooling water and 1 part of anticorrosion agent. Vent at venting screws 6 and fill in with mixture through filling neck up to lower mark. Drain fuel out of tank, make a mixture composed of 9 parts of fuel and 1 part of anticorros ion oil and fill it into tank.

5.

6.

Start engine, wait until oil pressur e gauge indicate s pressure and then, increase speed to approx. 2/3 of nominal speed. Allow engine to run for about 15 minutes without load.

7.

Stop engine

8.

Remove air filter.

9.

If the engine is equipped with Nova starting appliances, close starting air receiver, remove starting-air line up 3 stream of main valve and fill approx. 0.25 dm o f anticorrosion oil into starting line. Connect starting line again.

10.

Crank engine using starting appliances while holding stop lever 4 on stop position. Spray anticorrosion oil into open air-intake pipes, using a spraying gun, during the starting process.

11.

Attach air filter.

12.

Drain anticorrosion agent out of fuel tank, oil pan and cooling system.

13.

The intake and exhaust line being already laid must be closed so as to keep external atmospheric influences away from the engine interior.

97

GREAVES

Job Sheet

Date

first time after

after and every

5.85

Treating the installed engines against corrosion for lengthy standstill periods Necessary tools


Engine type

Job Sheet No.

TBD3

3.3.003 B

Page 2 of 2



Spare Table No.

Protective grease e.g. Messrs, Fucfis KG; Antikorit-MV Anti-corrosion oil for lubricating oil system, e.g. Messrs. Fina; Rusan 20 W 20 Anti-corrosion oil for fuel system, e.g. Messrs- Castrol : Rustillo DWX 32 Anti-corrosion agent cooling water, e.g. Messrs. Khubier-Chemie : Puriton 4110 Talcum powder.

Preserving the outer parts 1.

Coat all bright items, e.g. control linkages (Fig. 4} with pro tecting grease.

2.

Dust all rubber items (hoses, anti-vibration mounting pads) with talcum powder.

3.

Check paintwork for damage and, if necessary, repair.

4.

Locate engine in storage area, spray with preserving oil (spray gun) and cover with tarpaulin.

5.

Note date of preservation and fix message "do not turn crankshaft" at a prominent point on the engine.

Caution! Repeat preservation after at least 3 months

98

GREAVES

Job Sheet

Cleaning fresh water recooler (indirect cooling)

Date

first time after after and every

9.84


Necessary tools

Tool set Brush Stud, min. 100 mm long, M 8

Engine type TBD3

Necessary materials and auxiliaries 1 O-rings 2 O-rings 1 O-ring 1 Sealing ring 1 Sealing ring 1 Sealing ring Wevolic 2 Sealing compound Fuel

6.0493.10.4.1405 6.0493.10.4.1655 6.0493.10.5.0803 6.0492.01.0.1418 6.0492.01.0.0814 6.232.0.850.004.4 6 0153.70.1.0205 6.0153.70.1.0205

Job Sheet No. 3.3.007 A Page or 1 2 pages Spare Table No. 63 -

For the protection of the engine, the cooling system is divided into a raw water circuit and a fresh water circuit. The fresh water absorbs the heat given off by the engine and passes it on to the raw water in the heat exchanger. Efficient exchange of heat is only ensured when the walls of the tube bundle in the heat exchanger are free of dirt and scale.

Removing and cleaning the tube bundle 1.

Close the raw water cocks.

2.

Drain cooling water at drain cocks (Fig. 1, item 1 for fresh water, item 2 for raw water). Collect the fresh water for reuse.

3.

Remove fuel filter (Fig. 2) with mounting bracket and place on engine.

Caution! Do not kink the hoses! 4.

Remove raw water connections (Fig. 1, item 4) and fresh water return (Fig. 3, item 1)

5.

Remove flange connector for fresh water return (Fig. 3 arrow)

6.

Unscrew bolts mounting headers (Fig. 1, item 3) and adjusting screw (Fig. 1 item 5), Remove headers.

7.

Withdraw tube bundle (Fig. 4) from shell and clean in fuel with brush. Check the solder joints on the jacket (Fig. 4, arrows) and re-solder if necessary.

8.

Clean the remaining parts in fuel. Check the supply lines for fouling and clean if necessary.

9.

Remove gasket {Fig. 5, arrow) on flange connector for fresh water return, clean seat and apply new gasket with sealing compound (bond only the end face).

10.

Renew all the other seals, applying grease to the O-rings.

99

Job Sheet

GREAVES

Date 9.84

first time after

after and every

Job Sheet No. 3.3.007 A

TBD3 read thoroughly prior to beginning

Cleaning fresh water recooler (indirect cooling)

Necessary tools Tool set Brush Stud, min. 100 mm long, M 8

Engine type D3

Necessary materials and auxiliaries 4 O-rings 2 O-rings 1 O-ring 1 Sealing ring 1 Sealing ring Wevolic 2 Sealing compound Fuel

6.0493.10.4.1405 6.0493.10.4.1655 6.0493.10.5.0803 6.0492.01.0.1418 6.232.0.850.004.4 6.0153.70.1.0205

Page 2

of 2 pages

Spare Table No. 63 -

11.

Screw in the stud M8 x 100 (or longer) into the adjusting tapping of the tube bundle and mount the header on the tube bundle (Fig. 6)

12.

Unscrew stud and fit adjusting screw.

13.

Coat sealing surface (Fig. 7, arrow) of the header with sealing compound, place tube bundle in shell (Fig. 7) and screw in the mounting bolts loosely.

Note : The sealing compound is necessary for heat insulating purposes, since greatly differing temperatures arise in the shell and header. 14.

Coat the sealing surface of the second header with sealing compound and fit header.

15.

Fit flange connector, ensuring proper location of gasket. If required, realign tube bundle by turning the header (Fig. 7)

16.

Tighten the headers.

17.

Refit fuel filter, raw water and fresh water connections.

18.

Filter the fresh water through a cloth and refill, bleed by means of the bleeder plugs ( Fig. 9, Pos. 1) and top up fresh water up to the bottom mark (Fig. 8).

100

GREAVES

Job Sheet

Date

first time after

after and every

TBD3

5.85

Job Sheet No. 3.3.007 B

of read thoroughly prior Page to beginning 1 1 page Necessary materials and auxiliaries Spare Table No.

Cleaning fresh water re cooler (indirect cooling) Necessary tools Set of tools Brush (Nylon) Round iron 150 mm long, 5 mm Rubber arch

Engine type

1 set of gaskets Fuel

6.234.0.013.005.7

63 -

The cooling system of the engine is divided into a raw water circuit and a fresh water circuit. The fresh water absorbs the heat given off by the engine and passes it on to the raw water in the heat exchanger. Efficient exchange of heat is only ensured when the walls of the tube bundle in the heat exchanger are free of dirt and scale. Removing and cleaning the tube bundle 1. 2. 3.

Close the raw water cocks. Drain cooling water at drain cocks (Fig. 1 for fresh water, Item 2 for raw water). Collect the fresh water for reuse. Remove fuel filter (Fig. 2) with mounting bracket and place on engine. Caution! Do not kink the hoses!

4. 5. 6. 7. 8.

9.

Remove raw -water connections (item 3) Unscrew fastening screws (Item 4) from both head pieces (Item 5) and take down head pieces. Insert 2 rods irons (5mm dia.) on left-hand and right hand side of the tube nest (bracket) Extract tube nest from its seat by knocking gently (mallet) and lift it off the housing at rod irons. Clean tube nest in fuel, using a nylon brush (inside the tubes), then rinse with pure water. Check soldering joints of jacket (Item 6) and re solder, if necessary. Clean head pieces and screws in fuel as well. Check cooling-water lines for contamination and clean, if necessary. NOTE :

10. 11.

12.

Replace all seals and O-rings. Coat O-rings with grease. Pay attention to proper attachment when mounting tube nest (Item 9) Assemble in reverse sequence. Filter fresh water through cloth and fill up again; vent at venting screws (Item 7) and top up with fresh water up to bottom mark (Item 8) Open the raw water cocks. Fill the raw water pump.

101

Manual d3 Engine-30.08.08

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