Deutz Engine S-BV6-8-9M628 Operation Manual Deutz Engine S-BV6-8-9M628 Operation Manual

Operation Manual

S/BV6/8/9M628

0297 7945 en

Engine Serial Number:

Please enter engine serial number here. In this way, questions concerning Customer Service, Repairs and Spare Parts can be more easily dealt with.

In view of continuos design improvements or changes, the technical specifications and the illustrations shown in this Operation Manual are subject to alteration. Reprinting and reproduction, in part or in whole, are subject to our written approval.

S/BV 6/8/9 M 628

This Operation Manual is destined for the following engine:

● Engine model:

● Type of application:

● Name of installation:

● Power: kW

● Speed: / rpm

● Date of commissioning: . .

Please enter the relevant data here. This you will facilitate dealing with questions concerning customer service, repairs and spare parts.

Give these data to the respective SERVICE dealership whenever you are asking for service performance.

DEUTZ AG Service engineering Service documentation Deutz-Mülheimer Straße 147-149 D - 51057 Köln Tel. (0221) 822 - 0 Fax (0221) 822 - 5358 Telex 8812 - 0 khd d http://www.deutz.de

Page II 0297 6153-0112 © 1000

Medium-sized and large engines

● Please read all the information contained in this manual, and follow the instructions carefully. You will avoid

accidents, retain the manufacturer’s warranty, and will be able to use a fully functional and operational engine.

● This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined

by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely by the user.

● The term „intended use“ shall also include compliance with the operating, maintenance and repair

conditions specified by the manufacturer. The engine may be used, maintained and repaired only by persons who are familiar with the work concerned and who have been properly informed of the risks involved.

● Make sure that these operating instructions are available to everyone involved in operating, maintaining,

and repairing the engine, and that they have all understood the contents.

● Non-compliance with these operating instructions may result in engine malfunctions and even damage or

injury to persons; the manufacturer will accept no liability in such cases.

● Proper maintenance and repair work depends on the availability of all requisite equipment, tools and special

implements, all of which must be in perfect condition.

● Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled

properly.

● The relevant accident prevention regulations and other generally recognized rules relating to safety

engineering and health and safety at work must all be complied with.

● Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are

used.

● Engine repairs must correspond to the intended use. In the event of modification work, only parts approved

by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will preclude any liability of the manufacturer for resultant damage.

The warranty expires in case of nonobservance of these regulations!

Foreword

Dear customer,

The engines of the DEUTZ brand have been developed for a broad spectrum of applications. A comprehensive range of different variants ensures that special requirements can be met for the individual case involved.

Your engine has been equipped to suit your own particular installation, and accordingly not all of the devices and components described in these operating instructions will actually be fitted to your engine.

We have endeavoured to present the differences involved as clearly as possible, to make it easier for you to find the operating and maintenance instructions you need for your own particular engine.

Please read this manual before you start up your engine, and follow the operating and maintenance instructions meticulously.

If you have any questions, just get in touch with us, and we will be pleased to answer them for you.

Yours sincerely, DEUTZ AG

Medium-sized and large engines

Page IV 0297 6153-0199 © 0199

Medium-sized and large engines General

DEUTZ engines

are the culmination of long years filled with research and development work. The in-depth know-how thus acquired, in conjunction with high standards of quality, is your guarantee for engines manufactured for long lifetime, high reliability and low fuel consumption. And of course, stringent criteria of environment-friendliness are met as well.

Care and maintenance

are crucial factors in ensuring that your engine satisfactorily meets the requirements involved. Compliance with the specified maintenance intervals and meticulous performance of care and maintenance work are therefore absolutely essential. Special attention must be paid to any more critical operating conditions deviating from the norm.

DEUTZ AG

In the event of malfunctions, or if you need spare parts, please contact one of our responsible service agencies. Our trained and qualified staff will ensure fast, professional rectification of any damage, using original parts. Original parts from DEUTZ AG have always been manufactured to the very latest state-of-the-art. You will find details of our after-sales service at the end of these operating instructions.

Careful when the engine is running!

Carry out maintenance or repair jobs only when the engine is at a standstill. If you remove any protective features, fit them back in position after completing your work. Always wear tight-fitting clothing if you are working on the engine while it is running.

Safety

You will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safety instructions to your operating staff as well. In addition, comply with the statutory general safety and accident prevention regulations applying in your country.

Instruction

You will find this symbol next to instructions of a general nature. Follow these instructions carefully.

Asbestos

The seals and gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair jobs.

Medium-sized and large engines

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Page VI 0297 6153-0199 © 0199

Inhaltsverzeichnis Indice Table des matières Indice Inhoudsopgave

Оглавление

Guide to this Manual 1

Hinweise zur Benutzung der Betriebsanleitung Avvertenze per l‘utilizzo delle istruzioni per l‘uso Indications relatives à l’utilisation des instructions de service Indicaciones para el manejo de las Instrucciones de Operación Aanwijzingen voor het gebruik van de handleiding

Указания по пользованию настоящей Указания по пользованию настоящей

Layout and Description of Engine 2

Aufbau und Funktion des Motors Struttura e funzioni del motore Constitution et fonctionnement du moteur Construcción y funciones de partes del motor Samenstelling en werkwijze van de motor

Kонст укция и функция двигателя

Specification Data 3

Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens

Тенические данные

Operating the Engine 4

Anleitung zum Betrieb des Motors Istruzioni per il servizio del motore Instructions relatives à l’emploi du moteur Instrucciones para la operación del motor Handleiding betreffende het werken met de motor

Инст укця по эксплуатации двигателя

Engine Operating Media 5

Einweisung in die Arbeitssysteme der Motorbetriebsstoffe Introduzioni ai sistemi operativi del materiali di esercizio del motore Instructions concernant les systèmes opératoires des carburants-moteur Aclaraciones para los sistemas de medios de servicio para el motor Instructies betreffende brandstof-, smeerolie- en koelsysteem

Пояснения к системаи эксплуатацион-ных мате иалов длв двигателей

Engine Operating Media Treatment 6

Vorschriften über Betriebsstoffe Prescrizioni relative a mezi di esercizio Prescriptions applicables aux carburants Prescripciones para medios de servicio Voorschriften inzake brandstof-, smeerolie- en koelmiddel

П едписания по эксплуатацион мате иалам

Trouble-shooting 7

Betriebsstörungen und ihre Beseitigung Disfunzioni di esercizio e loro eliminazione Pannes et leurs remèdes Perturbaciones de servicio y su eliminación Bedrijffstoringen en het verhelpen daarvan

Hеисп авности и их уст анение

Maintenance Schedules and List of Job Cards 8

Instandhaltungs- Intervallpläne und Arbeitskartenübersicht Schemi degli intervalli di manutenzione, visione d‘insieme delle schede di lavoro Plans des intervalles d’entretien et vue d’ensemble sur les fiches de travail Tables de mantenimiento periódico y recopilación de fichas de trabajo Onderhoudsschema en werkkaarten

Г афик инте валов техобслуживания и обзо абЧих ка т

Job Cards JC

Arbeitskarten AK Schede di lavoro SL Cartes de travail CT Fichas de trabajo FT

Werkkaarten WK

PабоЧие ка ты AK

Inhaltsverzeichnis Indice Table des matières Indice Inhoudsopgave

Оглавление

Guide to this Manual 1

Указания по пользованию настоящей Указания по пользованию настоящей

Layout and Description of Engine 2

Aufbau und Funktion des Motors Struttura e funzioni del motore Constitution et fonctionnement du moteur Construcción y funciones de partes del motor Samenstelling en werkwijze van de motor

Kонст укция и функция двигателя

Specification Data 3

Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens

Тенические данные

Operating the Engine 4

Инст укця по эксплуатации двигателя

Engine Operating Media 5

Пояснения к системаи эксплуатацион-ных мате иалов длв двигателей

Engine Operating Media Treatment 6

П едписания по эксплуатацион мате иалам

Trouble-shooting 7

Betriebsstörungen und ihre Beseitigung Disfunzioni di esercizio e loro eliminazione Pannes et leurs remèdes Perturbaciones de servicio y su eliminación Bedrijffstoringen en het verhelpen daarvan

Hеисп авности и их уст анение

Maintenance Schedules and List of Job Cards 8

Г афик инте валов техобслуживания и обзо абЧих ка т

Job Cards JC

Arbeitskarten AK Schede di lavoro SL Cartes de travail CT Fichas de trabajo FT

Werkkaarten WK

PабоЧие ка ты AK

Inhaltsverzeichnis Indice Table des matières Indice Inhoudsopgave

Оглавление

0 Table of Contents

Inhaltsverzeichnis Indice Table des matières Indice Inhoudsopgave

Оглавление

Section:

1 Guide to this Manual

1.1 General

1.2 Trouble - shooting

1.3 Planned Mainenance

1.4 Identification of Spare Parts

1.5 Specification Data

1.6 Job Card No.

1.7 Standard Tools

1.8 Special Tools

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1.9 Index of DEUTZ Assembly Groups

2 Layout and Description of Engine

2.1 01 Cylinder Head

2.2 02 Crankshaft System

2.3 03 Engine Frame

2.4 04 Timing System

2.5 05 Speed Control System

2.6 06 Exhaust / Turbocharging System

2.7 07 Fuel System

2.8 08 Lubricating Oil System

2.9 09 Cooling Water System

2.10 10 Pneumatic System

2.11 11 Engine Protective System

2.12 12 Engine Auxiliaries

2.13 13 Engine Assemblies and Subassemblies

2.14 14 Cutaway View of Engine

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Table of contents

3 Specification Data

3.1 Model Designation

3.2 Designation of Engine Ends and Sides and Related Definitions

3.3 Basic Data

3.3.1 Design Data

3.3.2 Operating Data

3.3.3 Setting Data for Saftey Switches

3.4 Weights of Main Engine Components

3.5 Tightening Specification for Heavy - duty Screwed Joints

3.5.1 Tightening Schedule

3.5.2 /3. Tightening Instructions

3.5.4 Hydraulic Tool for Annular Nuts

3.6 List of Compounds ( Sealing, Locking, Lubricating, Heat Conduction )

3.7 Use of Liquid Nitrogen

3.8 Dye Checking of Metal Surfaces with Distillate Fuel

4 Operating the Engine

4.1 Preparatory Work before Operating the Engine with Distillate Fuel

4.1.1 Preparatory Work before Operating the Engine with Heavy Fuel or MDF Blend

4.2 Running the Engine with Destillate Fuel

4.2.1 Running the Engine with Heavy Fuel or MDF Blend

4.3 Attendance in Service

4.4 Stopping the Engine Running on Destillate Fuel

4.4.1 Stopping the Engine Running on Heavy Fuel or MDF Blend

4.5 Checking Combustion by Indicator Diagrams

4.6 Run- in instructions

4.6.1 Drive type ”Fixed-pitch propeller and comparable drives ”

4.6.2 Drive type ”C.P. propeller with shaft generator, electric generators and comparable drives”

4.7 Running the Engine with Defective Turbocharger

4.8 Emergency Operation

5 Engine Operating Media Systems

5.1 Fuel System

5.2 Lubrication Oil System

5.3 Cooling Water System

5.4 Pneumatic System

5.5 Injection Pump Plunger Sealing System

5.6 Injection Nozzle Cooling

5.7 Symbols Used in Piping Diagrams 0

Section:

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6 Engine Operating Media

7 Trouble - shooting

7.1 Summary of Potential Troubles

7.2 General

7.3 Trouble Chart

8 Maintenance Schedules, List of Job Cards and Job Cards

8.1 Summary of Maintenance Schedules

8.1.1 Initial Maintenance jobs

8.1.1.1 - Engines running in countinuos operation, e.g. marine engines,

>300 hour / year

8.1.1.2 - Engines running in standby operation, e.g. emrgency generating sets,

< 300 hours / year

8.1.2 Daily maintenance jobs

These jobs are described in Section 4.3, as well as in the Brief instructions under Section * ”Monitoring of Engine Operation”.

8.1.3 Periodic maintenance jobs for engines running in continuous operation > 300 hours / year, e.g. marine engines.

This schedule forms part of Brief Instructions*

8.1.4 Periodic maintenance jobs for engines running in continuous operation < 300 hour / year,

wich are exclusively or most of the time in standby mode, e.g. emergency generating sets. This schedule forms part of Brief Instructions*.

8.2 List of Job Cards

by maintenance groups

8.3 Job Cards

by maintenance groups

01.00.00 Cylinder Head

02.00.00 Crankshaft System

03.00.00 Engine Frame

04.00.00 Timing System

05.00.00 Speed Control System

06.00.00 Exhaust and Turbocharging System

07.00.00 Fuel System

08.00.00 Lubricating Oil System

09.00.00 Cooling Water System

10.00.00 Pneumatic System

11.00.00 Engine Protective system

12.00.00 Engine Auxiliaries

9 Appendix

Brief Instructions

* The Brief Instructions are attached to this Operating Manual

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Table of contents

Guide to this Manual 1

Указания по пользованию настоящей Указания по пользованию настоящей

1 Guide to this Manual

Указания по пользованию настоящей Указания по пользованию настоящей

Section:

Guide to this Manual

1 Guide to this Manual

1.1 General

Surely you expect high degrees of reliability and availibility of your DEUTZ engine as prerequisites for its economical application. Great importance was attached to these properties in the course of the engine's development. However, these properties can be upheld during the engine's entire lifespan

only, if the maintenance and servicing jobs described in this Manual are carried out punctually and fully.

It is therefore essential that you become well acquainted with the contents of this Manual not only before commissioning the new engine, but also to use it as a source of information for maintai-

ning the high value of the machine.

All safety precautions and regulations have been observed in the design, choice of materials, and manufacture of your engine. This high degree of safety and reliability will be maintained, if the servicing jobs are fully performed according to schedule by properly trained personnel, and if all guards and protective devices removed for carrying out work on the engine are afterwards refitted.

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When servicing, it is essential to observe the relevant regulations regarding accident prevention and general safety.

The Maintenance Schedules give information concerning the work involved at the prescribed intervals.

The Job Cards (Section 8) give detailed instructions for carrying out the work. The Job Cards are arranged in accordance with Maintenance Groups as per the PLanned Maintenance System 333*. On Page 1-0-05 is an alphabetical Index of DEUTZ Assembly Groups together with the relevant Job Card Nos. and Maintenance Groups.

* Institut für Schiffsbetriebsforschung, Flensburg

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1.2 Trouble-shooting

Should troubles and faults of any kind arise on the engine, please refer to Section 7, "Troubleshooting".

The Trouble Chart lists various potential causes for a certain fault, gives brief instructions for providing possible remedies, and refers to the Manual Section concerned and the Job Cards containing further details for carrying out the work involved.

1.3 Planned Maintenance

Keep a regular record of the engine's running hours and observe the schedule for maintenance and servicing accordingly

The Maintenance Schedule contains details of the maintenance work involved and the relevant Job Card Nos.

Guide to this Manual

Carry out the work detailed on the Job Card.

1.4 Ordering of Spare Parts

The Spare Parts Catalogue associated with this Instruction Manual contains the Part Nos. for the ordering of parts, and also design details , where necessary.

The Spare Parts Catalogue is arranged in accordance with DEUTZ Assembly Group Nos. These DEUTZ Assembly Group Nos. are also to be found in the Filing No. (not Job Card No.!) in the heading of the Job Cards. The number appearing between the hyphens, for example in the case of 0178-08501 1110, the -08-, is the DEUTZ Assembly Group No.

For detailed information on spare parts identification, please refer to the introductory lines of the Spare Parts Catalogue.

1.5 Specification Data

Design data, operating data, and setting data for monitoring equipment are not given in the Job Cards. Please refer to Section 3, "Specification Data".

Section:

1.6 Job Card No.

In addition to the Filing No., each card is provided with a Job Card No.

Typical Job Card No.: 01.02.03, where:

01 = Maintenance Group = cylinder head

02 = Subassembly = rocker arm bearings

03 = Serial No. of card

1.7 Standard Tools

Guide to this Manual

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Standard tools are those tools which are normally included in a workshop tool box.

Hammer Chisel 1 set of box wrenches 1 set of ordinary wrenches Screwdriver Small water tube pliers Nippers Combination pliers Scriber Tape rule Various files Iron saw Centre punch Mandrel Socket-head wrench Hex. wrench Three-square scraper Non-fraying rags Wire brush Grease gun

Rubber mallet

1.8 Special Tools

Special fitting tools and devices, normally supplied along with the engine, are listed in the associated Spare Parts Catalogue under the Assembly Group No. 49.

1.8.1 These tools are available from your local Deutz distributor.

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Guide to this Manual

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1.9 Index of DEUTZ Assembly Groups as Incorporated in System 333 - Job Cards, Maintenance Groups

Assembly Group Job Card Maintenance Group

06 Big end/-bearing 02.03.02 02 Crankshaft system

02.03.03

02.04.01

02.05.01

02.06.01

10 Camshaft 04.05.01 04 Timing system

04.06.01

10 Camshaft bearing 04.01.01 04 Timing system

58 Charge air cooler 06.04.01 06 Exhaust / Turbocharging

06.04.02 system

32 Charge air system 06.02.01 06 Exhaust / Turbocharging

system

48 Charge air water detector 11.06.01 11 Engine protective system

37 Coolant circulation pump 09.07.01/02 09 Cooling water system

37 Cooling water system draining 09.00.01 09 Cooling water system

48 Crankcase oil mist detector 11.05.01 11 Engine protective system

01 Crankcase relief valve 03.01.01 03 Engine frame

05 Crankshaft coupling flange 04.16.01 04 Timing system

05 Crankshaft gear 04.11.01 04 Timing system

05 Crankshaft gear 02.01.01 02 Crankshaft system

03.08.01

05 Crankshaft deflection gauging 02.02.01 02 Crankshaft system

08 Cylinder head 01.04.01 01 Cylinder head

01.08.01

01.09.01

04 Cylinder liner 01.05.04 03 Engine frame

03.02.01

03.02.03

03.03.01

03.04.01

03.05.01

03.06.01

32 Dirt collector 10.03.02 10 Pneumatic system

41 Exhaust elbow 06.01.03 06 Exhaust / turbocharging

system

41 Exhaust manifold 06.01.01 06 Exhaust / turbocharging

system

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Guide to this Manual

Assembly Group Job Card Maintenance Group

08 Exhaust valve 01.01.01 01 Cylinder head

01.05.01

01.05.04

01.05.05

01.07.01

05 Flywheel 04.09.01 11 Engine protective system

46 Foundation bolts 03.07.01 03 Engine frame

20 Fuel feed pump 07.11.01 07 Fuel system

20 Fuel filter 07.03.02 07 Fuel system

07.10.01

29 Hydr. governor drive 05.04.01 05 Speed control system

29 Hydr. governor linkage 05.04.14 05 Speed control system

27 Hydr. speed governor 05.00.01 05 Speed control system

05.03.11

05.03.12

05.03.14

08 Inlet valve 01.01.01 01 Cylinder head

01.05.01

01.05.04

01.05.05

01.07.01

21 Injection piping 07.03.01 07 Fuel system

07.03.02

17 Injection pump 07.01.01 07 Fuel system

07.02.01/03/04/05/06/07

07.05.01

18 Injection pump removal / refitment 07.04.01 04 Timing system

22 Intake air cleaner 06.03.11 06 Exhaust / turbocharging

system

19 Injector removal / refitment 07.07.01 07 Fuel system

07.08.01

07.09.01

15 Lube oil centrifuge 08.13.01 08 Lubricating oil system

15 PLube oil filter 08.09.01 08 Lubricating oil system

08.10.01

08.20.02

14 Lube oil pump 08.01.01 08 Lubricating oil system

14 Lube oil pressure-stat 08.11.01 08 Lubricating oil system

15 Lube oil system 08.02.01 08 Lubricating oil system

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Assembly Group Job Card Maintenance Group

02 Main bearing 02.03.02 02 Crankshaft system

02.03.03

02.04.01

02.07.01

02.08.01

48 Oil level float switch 11.07.01 11 Engine protective system

48 Overspeed switch 11.03.01 11 Engine protective system

07 Piston coolant nozzle 02.15.01 02 Crankshaft system

07 Piston pin 02.12.01 02 Crankshaft system

07 Piston pin brush 02.13.01 02 Crankshaft system

07 Piston / rings 02.09.01 02 Crankshaft system

02.10.01

02.10.02

02.10.04

02.11.01

02.14.01

32 Pneumatic system 10.01.01 10 Pneumatic system

32 Pressure reducer station 10.06.01 10 Pneumatic system

48 Pressure switch 11.01.02 11 Engine protective system

11 Rocker arm 01.02.02 01 Cylinder head

01.02.03

31 Safety valve 01.12.01 01 Cylinder head

32 Starting air master valve 10.03.01 10 Pneumatic system

10.03.91

30 Starting pilot air distributor 01.02.01 10 Pneumatic system

31 Starting valve 10.11.01 01 Cylinder head

01.11.02

01.05.04

48 Temperature switch 11.01.01 11 Engine protective system

51 Thermocouples 11.01.05 11 Engine protective system

09 Timing gear train 04.04.01 04 Timing system

04.08.01

09 Timing gear train 04.04.01 04 Timing system

04.13.01

43 Turbocharger 06.05.01 06 Exhaust / turbocharging

06.06.01 system

06.12.01

06.13.01

06.13.02

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Guide to this Manual

Assembly Group Job Card Maintenance Group

11 Valve drive, bottom 04.02.01 04 Timing system

11 Valve drive, top 01.02.02 01 Cylinder head

08 Valve guide clearance 01.06.01 01 Cylinder head

08 Valve rotator 01.03.01 01 Cylinder head

01.03.02

16 Valve seat lubrication 08.14.01 08 Lubricating oil system

08 Valve seat ring 01.07.01 01 Cylinder head

01.03.01

34 Vibration damper 12.01.01 12 Engine auxiliaries

12.01.02/03

Layout and Description of Engine

Aufbau und Funktion des Motors Struttura e funzioni del motore Constitution et fonctionnement du moteur Construcción y funciones de partes del motor Samenstelling en werkwijze van de motor

Kонст укция и функция двигателя

2 Layout and Description of Engine

Aufbau und Funktion des Motors Struttura e funzioni del motore Constitution et fonctionnement du moteur Construcción y funciones de partes del motor Samenstelling en werkwijze van de motor

Kонст укция и функция двигателя

Layout and Description

of Engine

Section:

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2 Layout and Description of Engine

2.1 01 Cylinder Head

The Head iß held down on the crankcase through 4 hydraulically tightened studs.

Fitted in the head are 2 inlet valves, 2 exhaust valves, one fuel injector, a starting valve, an indicator valve and, if required, a relief valve.

The exhaust valves are equipped with rotators, the inlet valves with a seat lubrication to reduce wear. In fact, oil is injected in a metered amount into the charge air, so this seat lubrication requires no servicing. Injector and inlet/exhaust valves plus drive are protected by a rocker chamber cover. Coolant transfer from crankcase to head is made through plugged pipes within the head contour.

2.2 02 Crankshaft System

The drop-forged crankshaft is fitted in the crankcase in underslung arrangement. Main journals and crankpins are hardened and carried in complex-metal bearing shells. As required by the rated engine spee, the shaft is fitted with balance weights to reduce mass forces.

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S/BVM 628

The bearing caps are secured to the crankshaft by 2 vertical and 2 horizontal bolts, the former ones being tightened jointly by a hydraulic tool.

The flywheel is flanged to the shaft‘s driving end, the flange being fitted on the shaft by hydraulic shrinkage. Power for secundary drives can be taken off from the shaft‘s free end.

The drop-forged connecting rod big end is split in straight (horizontal) arrangement, while the small end is of the stepped type.

The two-piece pistons are fitted with 3 compression rings and one oil control ring. The former rings are located in the steel top, the oil ring in the piston skirt above the full-float piston pin.

2.3 03 Engine Frame

The crankcase is a single-piece casting. Large doors permit easy access to all motion parts. Some doors may optionally be provided with relief valves safeguarding the engine in the case of crankcase of explosions.

The standard deep ”wet-type” oil sump represents the engine‘s lube oil reservoir, from which oil is forced into the lubricating circuit by a special delivery pump. Where high or low-level tanks are utilized for oil reservoir, use is made of a flat ”dry-type” sump with connections for an oil drain (to the low-level tank) or a special suction pump (to the high-level tank) respectively.

The cylinder liner is located in the crankcase at top and bottom. The liner flange is seated on a highly waer-resistant ring pressed into the crankcase. The water jackets are sealed by one ”watercooled” Viton 0-seals at the bottom. The head/liner gasket is a steel ring.

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Layout and Description

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2.4 04 Timing System

ILocated at the engine‘s driving end and driven from a big gear on the crankshaft, the timing gear train drives, through idler gears, the camshaft, injection pumps and governor.

As determined by the engine‘s firing order, the camshaft, carried in bearing bushes, actuates the inlet and exhaust valves as well as the starting pilot air distributor, The shaft is split in two halves and can be pulled out of the engine lengthwise. Cams and bearing points are surface-hardened.

The pump chest at the engine‘s free end can mount, besides the standard lube oil delivery pump, one oil suction pump and 2 cooling water pumps. The pumps are gear-driven, i.e. the oil pumps direct and the coolant pumps through flexible couplings.

2.5 05 Speed Control System

The Engine is controlled by hydraulic governor which, through the injection pump‘s control rod, automatically meters the amount of fuel to be injected as a function of engine load.

Overall engine control is by an engine-mounted panel or seperately installed local or remote control units.

Emergency engine shutdown is possible by an automatic system or manually on the speed governor direct.

2.6 06 Exhaust / Turbocharging System

The non-insulated exhaust manifold running along the engine is lagged by an easily removable and multisplit casing. Only the water-cooled exhaust elbows from cylinder head to manifold are located outside this casing. Being connected through sliding pieces with 0-seals, the water jackets of the exhaust elbows form the cooling water manifold for the engine.

The engines are fitted with BBC turbochargers connected to the engine‘s cooling system. The compressors of these turbochargers are cleaned by a scavenging device. The charge air is cooled by water in special units.

The charge air pipe is divided into single sections for each cylinder. These sections are likewise connected through sliding pieces with 0-seals.

This new concept of exhaust manifold with cooled elbows and integral water manifold, the division of the charge air pipe, the plug-type water transfer pipes between cylinder head and crankcase and, last not least, the use of hydraulic tools for tightening the cylinder head studs/nuts significantly improve the ease in dismantling and refitting components at the engine top.

Layout and Description

of Engine

Section:

Page:

2-0-03

2.7 07 Fuel System (see also 5.1)

The following integral in-line injection pumps are provided:

6 and 8-cylinder models: 2 pumps with 3 and 4 elements respectively

9-cylinder model: 3 pumps with 3 elements each

The type of pumps chosen and the connection of the injection piping to the cylinder head sideways gave the advantage of very short injection piping.

Pump lubrication is connected to the regular motor oil circuit. In the case of engines running on intermediate fuels a sealing-oil system prevents the lube oil from being diluted by fuel.

The multi-orifice injection nozzle is located in the middle of the cylinder head and connected to the latter by a lateral injection line.

The fuel feed pump is mounted on one injection pump. Fuel cleaning is through a change-over type duplex filter.

In the case of engines running on heavy fuel, the feed pump is installed seperately. The changeover duplex filter can be preheated by having the transferred, preheated fuel flow through the filter. If available, the injection nozzles are cooled with engine lube oil or gas oil or - in exceptional cases

- even with engine coolant.

Engine:

S/BV 6/8/9 M 628

2.8 08 Lubricating Oil System (see also 5.2)

From the oil sump, or the low- or high-level oil tank, as provided, the engine mounted delivery-type oil pump forces the oil through the oil-cooler, usually also engine-mounted, and the combined oil filter (paper filter followed by edge filter) into the oil gallery integrally cast inside the crankcase.

From this gallery the oil flows on through passages in the crankcase wall to crankshaft journals and crankpins and to the nozzles provided for cooling the pistons. Passages in the crankcase front, wich are connected to the oil gallery, supply the timing gear train.

Additional bypass oil filtration is by two centrifuges attached to the crankcase doors.

Connections are also available for standby oil pumps and the electric priming pump.

2.9 09 Cooling Water System (see also 5.3)

As requiered by the particular engine application, the following standard systems can be provided:

1. Single-Circuit: This circuit serves actual engine plus lube oil and charge air cooler. The

water is cooled in a separate tubular heat exchanger.

2. Double-Circuit: One cooling circuit is provided for the engine, a second one for oil and

charge air cooler. The coolant heat dissipated is a separate tubular heat exchanger.

3. Triple-Circuit: This system is primarily used for water cooling by radiator. Engine, oil cooler

and charge cooler have a circuit of their own.

Optionally available are various versions of the above two systems

Section:

Page:

2-0-04

Layout and Description

of Engine

Engine:

S/BV 6/8/9 M 628

2.10 10 Pneumatic System (see also 5.4)

The engine is started by compressed air through starting valves in the cylinder heads, the valves being opened by pilot air from a distributor in the correct firing order. Starting air release is normally at 30 bar.

2.11 11 Engine Protective System

All engine operating media can be monitored by temperature and/or pressure switches which energize alarm and/or shutdown devices. In addition, all essential temperatures and pressures are indicated by gauges provided on panels that are either engine-mounted or seperately installed.

The exhaust temperature is indicated either by pointer thermometers or through thermocouples, which can optionally and locally be connected to a pyrometer system.

If necessary, a crankcase oil mist detector can also be provided.

2.12 12 Engine Auxiliaries

Provided for this engine family is an external vibration damper either of the viscous or rubber type. The 6-cylinder model is also available without this damper.

Layout and description of engine

Section:

Page:

2-1-01

Engine:

S/BV 6/8/9 M 628

2.13 Engine Assemblies and Subassemblies (as for the relevant location, please refer

to Section 2.14)

Assy Group No. Description

01 Exhaust manifold

02 Exhaust thermometre

03 Charge air cooler

04 Measuring instrument panel

05 Charge air pipe

06 Fuel piping

07 Engine control unit

08 Fuel filter

09 Lube oil filter

10 Lube oil filter combination

11 Fuel injection pump

12 Vibration damper

13 Cylinder liner

14 Oil dipstick

15 Connecting rod

16 Crankshaft

17 Speed governor drive

18 Oil pan

19 Flywheel

20 Timing gear train

21 Piston

22 Starting pilot air distributor

23 Camshaft

24 Air intake silencer

25 Exhaust valve

26 Pushrods

27 Exhaust turbocharger

28 Injector

29 Cylinder head

30 Valve drive

Section:

Page:

Layout and description of engine

2-1-02

Engine:

2.14 Cutaway View of Engine

S/BV 6/8/9 M 628

(8-cyl. engine)

51452 2 ©

Specification Data

Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens

Тенические данные

3 Specification Data

Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens

Тенические данные

Section:

3.1 and 3.2

Specification Data

Page:

Engine:

3 Specification Data

3.1 Model Designation: S/BV 6/8/9 M 628

S = Marine (uni-direction) M = Water cooled B = Turbocharged 6 = Generation No. V = Four stroke cycle 28 = Piston stroke in cm 6/8/9 = 6, 8 or 9 cylinders

3.2 Designations of engine sides, cylinders and rotation direction

Viewed towards the drive-side coupling flange of the engine.

1 AS Drive side Coupling side KS

2 LS Left side

3 FS Free side Opposite side to coupling KGS

3-0-01

S/BV 6/8/9 M 628

4 RS Right side

Cylinder designation The cylinders are counted and designated from

the drive side "AS"

Rotation direction The anticlockwise rotation direction is

designated "left rotation" and clockwise is designated "right rotation".

1 3

1 2 3 4

Section:

3.3

3.3 Basic Data

Power and speed see acceptance test sheets Bore 240 mm Stroke 280 mm Capacity per cylinder 12,66 litres Total capacity: 6 cylinder 75,66 litres

Compression ratio 13 : 1

3.3.1 Design Data

01 Cylinder Head

Safety valve opens at 170 ± 5 bar

02 Crankshaft System Crankshaft

main jounal dia. 210 mm running width of main bearing 70 mm crankpin dia. 175 mm running width of big-end bearings 61 mm

Specification Data

8 cylinder 101,28 litres 9 cylinder 113,94 litres

Page:

Engine:

3-1-01

S/BV 6/8/9M 628

Piston

Material, top heat-treated steel with hardened grooves

skirt forget light alloy

Pin dia. 105 mm No.of compression rings 3 No. of oil control rings 1 Mean piston speed 9,33 m/s a t 1000/min

Connecting rod

Length 504 mm Running width of small-end bush 108 mm/56 mm

03 Engine frame

Material ductile iron Cylinder spacing 370 mm

04 Timing system

Firing order 6-cyl. model, CL rotation: 1- 4 - 2 - 6 - 3 - 5

6-cyl. model, CCL rotation: 1- 5 - 3 - 6 - 2 - 4

8-cyl. model, CL rotation: 1- 3 - 2 - 5 - 8 - 6 - 7 - 4 8-cyl. model, CCL rotation: 1- 4 - 7 - 6 - 8 - 5 - 2 - 3

9-cyl. model, CL rotation 1- 3 - 5 - 7 - 9 - 8 - 6 - 4 - 2 9-cyl. model, CCL rotation 1- 2 - 4 - 6 - 8 - 9 - 7 - 5 - 3

Valve Timing (deg. crank angle)

Section:

3.3

Page:

Engine:

3-1-02

Specification Data

S/BV 6/8/9M 628

Inlet valve opens 43,5° KW p. PMS 0,2 mm clearance, engine cold Inlet valve closes 23,6° KW d. PMS

Exhaust valve opens 52,9° KW p. PMS 0,5 mm clearance, engine cold Exhaust valve closes 38,9° KW d. PMS

Starting valve opens 11° bTDC Starting valve closes 40° bBDC

05 Speed Control System

Lowest idling speed ≤ 800 801 - 900 901 - 1000/min at full engine speed 200 225 250/min

Lowest firing speed 80/min

06 Exhaust / Turbocharging System

Charge air cooler see acceptance test sheet

07 Fuel System

Injection lines 10 mm O.D.

3.3.2 Operating Data

06 Exhaust / Turbocharging System

Turbocharging System

Charge air temperature at engine inlet see acceptance test sheet

Max. intake resistance 25 mbar (250 mm of water)

Exhaust System On the 8- and 9-cylinder models, the cylinder next to the turbocharger goes to the multi-pulse unit direct, so the exhaust temperatures of this cylinder are somewhat lower (see acceptance test sheet).

Exhaust teperature after turbine see acceptance test sheet

4 mm bore

Max. backpressure 25 mbar Perm. deviation of individualtemperatu res from mean value of all cylinders: 100 % rated power + 25 °C 75 % rated power + 30 °C 50 % rated power + 50 °C

Section:

3.3

Specification Data

Page:

Engine:

3-1-03

S/BV 6/8/9 M 628

07 Fuel System

Fuel grade See Section 6 . 3 Fuel consumption See acceptance test sheet Filter mesh 7 - 60 µm Fuel pressure at inj. pump inlet at rated speed 3,0 - 4, 5 bar

Fuel temperature at inj. pump inlet See Section 6

Injection nozzle opening pressure 350 + 10 bar Type of nozzles See acceptance test sheet Combustion pressure See acceptance test sheet Permissible deviation of individual indicated firing pressure from mean value of all cylinders + 4 bar Delivery of separate fuel feed pump at 5 + 2,5 bar backpressure: 6-cyl. engine: 1,3 + 1,0 m3/h

8-cyl. engine: 1,8 + 0,6 m3/h 9-cyl. engine: 2,0 + 0,4 m3/h

08 Lubricating Oil System

Oil grade See Section 6 . 2 Filter mesh:

- paper cartridge 30 µm

- edge filter 50 µm Oil temperature at engine inlet: (oil cooler preceding charge air cooler) max. 65 °C (charge air cooler preceding oil cooler) max. 75 °C Min. oil pressure after filter:

- rated speed, engine hot 3,5 bar

- at lowest idling speed 1,0 bar Priming pressure after filter:

- before starting regular engine 0,35 bar

- engine (stationary) on > 0,35 bar (held for 3 minutes standby duty every hour)

Min. priming oil pumping at 3 bar 6-cyl. 8-cyl. 9-cyl. delivery pressure (values in 4 m3/h 5 m3/h 6 m3/h brackets are possible in case of (2,5 m3/h) (3 m3/h) (3,5 m3/h) lube oil temperatures below 50° C) Sealing-oil pressure in injection pumps min. 1 bar higher than fuel pressure Delivery pressure of mounted sealing oil pump min. 5 bar Separate sealing-oil pump (with intermediate fuel operation): Delivery pressure: 9 - 10 bar Sealing-oil delivery 6-cyl. 8-cyl. 9-cyl.

- min. 0,15 l/h 0,2 l/h 0,25 l/h

- max. 0,6 l/h 0,6 l/h 0,6 l/h level tanks:

- distillate, MDF blend min. 0,7 l/kW

- heavy fuel > 0,82 l/kW Lube oil consumption 1 g/kWh Min. oil capacity of standby engines 0,2 l/kW

Section:

3.3

Page:

Engine:

3-1-04

S/BV 6/8/9 M 628

Specification Data

Separate standby oil pump:

- capacity 6-cyl.: 24 - 30 m3/h 8-cyl.: 30 - 35 m3/h 9-cyl.: 35 - 40 m3/h

- Pressure 5 bar

Oil Sump Inclinations and Capacities

Dipstick with 3 marks

Connections for low-level tank

Max. engine installation angle α±=3° Max. sump inclination (incl. installation angle) α±= 10° Max. permanent inclination β±= 22,5° Max. temporary inclination β±=30°

(starting 22°, turbocharger will lose some oil)

6-cyl. 8-cyl 9-cyl

Top mark α=0° 615 800 895

β =0° *3

Oil capacity of deep oil sump (litres) 2) Medium mark α= ±10° *1 525 680 760

oil level

min. max.

Bottom mark α = ±10° 405 525 590

β = 0° *3

β =0°

*1) Where sump inclinations α ± are below 10°, the oil level can be kept at a corresponding level between the top and

medium dipstick mark to ensure maximum oil supply to the engine and hence increase oil change intervals . (1° less inclination allows for approx. 10 mm higher level above medium mark.)

*2) Sump lubrication for heavy fuel requires min. 0,82 lit/kW *3) Due to inclined dipstick, correct maximum distance can be obtained only with β = 0°.

Section:

3.3

Specification Data

Page:

Engine:

3-1-05

S/BV 6/8/9 M 628

6-cyl. 8-cyl. 9-cyl.

Drain A or B

Connection for inclinations α ±

10° 8% 7°

for low-level tank ("dry" sump) Drain A and B > 8° - 10° > 7° - 10°

for inclinations α ±

Oil Delivery Rate for Valve Seat Lubrication

Rated Engine Speed Delivery in drops / 4 min

1/min. 6-cyl. 8-cyl. 9-cyl.

1000 42 56 63 900 37 50 56 800 34 45 50 750 32 42 47 720 30 40 45

Admissible deviation ± 4 gocce/4 min

09 Cooling Water System

Water quality see Section 6 Engine system capacity 6-cyl.: 225 litres

8-cyl.: 275 litres 9-cyl.: 300 litres

Max. coolant temperature at engine outlet during full-load operation

(In case of 2-stage charge air cooler, measured at cooler inlet)

- with single-circuit cooling system 80°C

- with two- and three-circuit cooling system 85°C Temperature difference between full load and idling operation (at engine outlet) 8 - 12 °C Temperature difference between cooling water at engine inlet and engine outlet under full load conditions 8 - 12 °C

(In case of 2-stage charge air cooler, measured at cooler inlet) Cooling water preheating temperature

- for standby duty 50 °C

- for engines starting with blended fuel

- viscosity < 180 mm2/s at 50°C (cSt) 50 °C

- viscosity > 180 mm2/s at 50°C (cSt) 70 °C

- viscosity > 380 mm2/s at 50°C (cSt) 80 °C

- for all other engines 25 °C Max. coolant temperature at charge air cooler inlet 50 °C Max. coolant temperature at built-on oil cooler inlet 45 °C Max. raw water temperature at heat exchanger inlet 32 °C

Max. coolant pressure at engine inlet with built-on or separate pump ~ 4 bar Coolant temperature at injection nozzle inlet approx. 85°C Min. pressure of separate injection nozzle coolant pump 3 bar

Section:

3.3

Page:

Engine:

3-1-06

S/BV 6/8/9 M 628

Specification Data

10 Pneumatic System

Air receiver capacity see Classification Societies (min. 125 lit.)

Max. starting pressure 30 bar Min. starting pressure 10 bar

Section:

3.3

Specification Data

Page:

Engine:

3-1-07

S/BV 6/8/9 M 628

3.3.3 Setting data for monitoring equipment

Minimum equipment marine propulsion auxiliary stationary

engines marine engines

Data in “bar”

Pressure monitor engine speed (referring to dropping pressure) ≤ 600/min > 600/min

lube oil pressure: initial alarm – – 2,0 – main alarm (engine stop) 1,0 2,0 1,8 2,0

Temperature monitor Data in „°C“

circ. cool. water temp

circuit I 85 85 85 charge air temp., max. 65 65 65

Other monitors rated speed

overspeed protection 110 %n

110 %n

Further setting data may be obtained from the gauge point list which is included in the engine documentation.

Section:

Page:

Engine:

This page intentionally left blank

Specification Data

Section:

3.3

Specification Data

3.3.4 Arrangement of Electrical Equipment

Measuring point No. as per Function / description of the equipment or separately supplied list of of the gauge point measuring points

1.3.1 Fuel supply pressure

1.3.3 Pme monitoring

1.3.4 Full load (overload) monitoring

1.3.7 Fuel rack travel indicator

1.3.8 Monitoring of shielded injection pipings

2.3.1 Speed switch - pressure monitor bridging

2.3.2 Lube oil pressure n < 600 l/min

2.3.3 Lube oil pressure n > 600 l/min

2.3.4 Lube oil pressure

2.3.5 Lube oil temperature

2.3.7 Min. lube oil temperature

2.3.8 Differential pressure lube oil filter

2.3.9 Level - lube oil pan

2.4.1 Lube oil pressure

2.4.6 Lube oil temperature

2.4.8 Seal oil pressure

2.4.10 Lube oil pressure start inhibitor

2.4.11 Level - lube oil pan, stand-by pump ON

2.6.3 Lube oil temperature

3.3.2 Engine jacket water temperature

3.3.3 Engine jacket water pressure, circuit I

3.3.4 Raw water pressure

3.3.5 Min. engine jacket water temperature

3.3.7 Engine jacket water, circuit II

3.3.10 Speed switch - pressure monitor bridging

3.4.4 Engine jacket water temperature

3.6.4 Engine jacket water temperature

4.3.1 Max. charge air temperature

4.3.2 Min. charge air temperature

4.3.3 Water detector in charge air pipe

4.6.2 Charge air temperature

5.4.1 Exhaust gas temperature per cylinder

5.4.3 Exhaust gas temperature after turbine

6.3.1 Failure crankcase monitoring system

6.4.5 Crankcase monitoring system

7.3.1 Starting air pressure

7.3.2 Control air pressure

7.3.3 Malfunction of start air interlock (engine fails to start)

7.3.4 Switch - speed setting output

7.3.5 Switch - speed setting input

7.3.6 Switch - engine remote control unit (BVM)

7.3.6 Control unit indicator, engine-mounted/remote (SBVM)

7.3.9 Signal lamp - remote control ON

7.3.10 3/2 -way valve change-over safeguard

Page:

Engine:

3-1-09

S/BV M 628

Section:

3.3

Page:

Engine:

3-1-10

Specification Data

S/BV 6/8/9 M 628

Measuring point No. as per Function / description of the equipment or separately supplied list of of the gauge point measuring points

7.3.14 Tacho-generator monitor

7.5.8 Solenoid - emergency shutdown

7.5.9 Starting solenoid, 3/2-way valve

7.5.10 Pushbutton - delocking emergency stop

7.5.12 Speed control monitor

7.5.14 Pushbutton - stop

7.5.15 Solenoid - emergency shutdown

7.5.16 Solenoid - stop

7.5.17 Electr. 3-way valve (start inhibitor)

7.5.20 Pushbutton - start

8.1.1 Tacho-generator

8.1.2 Speed indicator

Section:

3.3

Specification Data

3.3.4.1 Exhaust Turbocharger at Driving End

Page:

Engine:

3-1-11

S/BV 6/8/9 M 628

25 437 2 ©

Section:

3.3

Page:

Engine:

3-1-12

S/BV 6/8/9 M 628

Specification Data

25 438 2 ©

Section:

3.3

Specification Data

3.3.4.2 Exhaust Turbocharger at Free End

Page:

Engine:

3-1-13

S/BV 6/8/9 M 628

25 439 2 ©

Section:

3.3

Page:

Engine:

3-1-14

S/BV 6/8/9 M 628

Specification Data

25 440 2 ©

Section:

3.4

Specification Data

Page:

Engine:

3-2-01

S/BV 6/8/9 M 628

3.4 Weight of Engine Components

(approx. kg per unit)

No. Description 6-cyl. 8-cyl. 9-cyl.

1 Engine with flywheel 9500 11500 13400

2 Crankcase w/o main bearing cap 2080 2617 3700

Crankcase w.main bearing cap 2310 2920 4030

3 Oil tank ...(wet sump) 365 430 470

Oil tank ...(dry sump) 320 380 410

4 Cylinder liner 58 58 58

5 Crankshaft w/o balance weights 790 995 1097

6 Balance weights w. bolts and washers 23 23 23

7 Flywheel dia. Ø 930 x 86 199 or 252 or 305

Ø 970 x 130 480 or 505 Ø 990 x 240 1040 Ø 1140 x 277 1452 or 1572

8 Bearing (top and bottom shell)

1 main bearing 2 2 2 1 big end bearing 1 1 1

9 Connecting rod 36,5 36,5 36,5

10 Piston without piston rings 22 22 22

11 Gudgeon pin 10,8 10,8 10,8

12 Cylinder head (compl.) 120 120 120

13 Inlet or exhaust valves 1 1 1

14 Injection valve 3,3 3,3 3,3

15 Viscous-type vibration damper

Ø 490 x 85 104 Ø 620 x 100 200 Ø 640 x 120 255

16 Extra weights (dia. x width) Ø 538 x 55 90

Ø 680 x 42,5 108

17 Torsional vibration damper, rubber-type (dia. x width)

Ø 675 x 130 – 145 - Ø 680 x 153 - 230 230

18 Turbocharger VTR 214 w/o intake air silencer 230 230 -

VTR 251 - 360 360

Section:

3.4

Page:

Engine:

3-2-02

S/BV 6/8/9 M 628

Specification Data

Item Description ca. kg

19 Coupling Series

Size 1120 1121 1300 1301

EZR 1232 133 142 181 188

EZR 1412

217 220 305 307

EZR 1422

EZR 1712

373 378 479 484

EZR 1722

EZR 2012 594 603 736 753

20 Coupling Series

Size 2100 2101 2200 2201

Rato-S 1811

141 170 141 178

Rato-S 1812

Rato-S 2011

169 207 169 216

Rato-S 2012

Rato-S 2211

205 250 205 261

Rato-S 2212

Rato-S 2411

275 330 275 346

Rato-S 2412

Rato-S 2521

318 372 339 394

Rato-S 2522

Rato-S 2611

334 402 334 420

Rato-S 2612

Rato-S 2721

Rato-S 2722

Rato-S 2811

Rato-S 2812

Rato-S 2921

Rato-S 2922

387 455 412 481

421 505 421 530

478 562 511 597

Section:

3.4

Specification Data

Page:

Engine:

3-2-03

S/BV 6/8/9 M 628

Item Description 6-cyl. 8-cyl. 9-cyl

ca. kg ca. kg ca. kg

21 Charge air piping 23 23 23

(section per cylinder)

Section:

Page:

Engine:

This page intentionally left blank

Specification Data

Section:

3.5

Specification Data

Page:

Engine:

3-3-01

S/BVM 628

3.5 Tightening Specification for Heavy-Duty Screwed Joints

3.5.1 Table

Line Constr. Joints tightened by hydraulic tool Thread Oil pressure Remarks

No. group bar

01 01 Crankcase / cylinder head M 33 x 2 835 bar Job 01.09.01 02 01 Crankcase / bearing cap (vertical) M 33 x 2 1030 bar Section 3.5.2, Job 02.08.01

Line N. cost- Joints tightened by wrench Thread Preload Tightening Tightening Remarks

No. group torque torque angle

03 01 Crankcase / bearing cap (horizontal) M 22 x 2 70 Nm - 210 ° 04 06 Big end / cap M 20 x 1,5 70 Nm - 240 ° 1° phase 90 °

05 Crankshaft / counterwheights M 27 x 2 130 Nm - 90 ° -

Nm Nm °

)

2° phase 90 ° 3° phase 60 °

07 11 Rocker bracket / cylinder head M 14 x 1,5 30 Nm - 150 ° 1° phase 30 °

08 11 Rocker shaft / rocker bracket / M 16 x 1,5 30 Nm - 240 ° 1° phase 60 °

cylinder head 2° phase 90 °

09 09 Timing chest / crankcase M 14 - 112 Nm - 10 17 Injection pump top / base M 12 30 Nm - 90 ° 11 17 Injection pump: element fastening M 12 85 Nm - 60 ° 12 17 Injection pump: cramshaft / gear M 14 x 1,5 30 Nm - 60 ° non greased 13 17 Injection pump / crankcase M 12 30 Nm - 90 ° 14 18 Injection pump drive / clutch disc M 20 x 1,5 130 Nm - 90 ° 15 18 Injection pump drive / cramshaft M 14 x 1,5 30 Nm - 90 ° - 16 09 Injection pump drive / gear M 16 x 1,5 30 Nm - 90 ° -

34 Vibration damper / crankshaft M 24 x 2 130 Nm - 90 ° -

18 19 37 Water pump / shaft M 16 x 1,5 50 Nm - 120 ° -

20 43 Turbocharger bracket / crankcase M 16 x 1,5 - 250 Nm - -

2° phase 60 ° 3° phase 60 °

3° phase 90 °

21 14 Crankshaft / gear M 10 - 50 Nm - 22 14 Gear / oil pump drive M 16 50 Nm - 90 ° -

23 19 Injector fastening M 16 x 1,5 - 120 Nm - 24 05 Flywheel / crankshaft M30 x 2 x 100 128 Nm - 75 ° 1° phase 45 °

dell’olio lubrificante

2° phase 30 °

M30 x 2 x 200 128 Nm - 150 ° 1° phase 90 °

2° phase 60 °

Section:

3.5

Page:

Engine:

Line Constr. Joints tightened by wrench Thread Preload Tightening Tightening Remarks

No. group torque torque angle

25 05 Crankshaft / gear M 12 - 120 Nm - -

26 10 Drive gear / camshaft M 10 - 70 Nm - -

27 10 Camshaft / camshaft M 10 - 70 Nm - -

28 01 Crankcase door M 10 x 30 - 70 Nm - -

29 14 Pump chest fastening M 12 - 75 Nm - 30 30 Starting control shaft / camshaft M 14 x 1,5 30 Nm - 90 ° 31 21 Injection line / cap nut 30 Nm - 30 ° -

32 M 16 x 1,5 - 250 Nm - -

09 Timing chest / crankcase

33 M 20 x 2 - 280 Nm - -

35 M 16 x 1,5 - 250 Nm - -

36 58 Charge air cooler bracket / crankcase M 12 x 1,25 - 108 Nm - -

3-3-02

S/BVM 628

Specification Data

Nm Nm °

)

37 M 10 - 70 Nm - 38 ATL VTR 251 M 10 30 Nm - 240 ° 1° phase180 °

39 ATL VTR 201 M 10 30 Nm - 150 ° 1° phase 90 °

40 M 16 x 1,5 - 130 Nm - -

41 M 20 x 2 - 280 Nm - 42 EZ 121 S M 14 20-30 Nm - 60 ° 1° phase 30 °

43 EZ 142 S M 18 x 1,5 40 Nm - 90 ° 1° phase 30 °

44 flywheel EZ 171 S M 22 x 1,5 69 Nm - 120 ° 1° phase 60 °

45 EZ 201 S M 27 x 2 128 Nm - 60 ° 1° phase 30 °

47 52 Generator M 30 x 2 128 Nm - 90 ° 1° phase 30 °

48 34 Vibration damper / crankshaft M 24 x 2 130 Nm - 120 ° D. with extra mass 49 27 Governor drive / bevel gear M 24 x 1,5 70 Nm - 90 ° -

Air cleaner 2° phase 60 °

22 (long bolts)

2° phase 60 °

09 Gear pivot pins

EZ 135 S 2° phase 30 °

Flexible coupling EZ 166 S 2° phase 60 °

63 (c/w adapter flange) /

EZ 195 S 2° phase 60 °

2° phase 30 °

2° phase 60 °

50 19 Injector / nozzle nut M 28 x 1,5 - 120 Nm - 51 EZ 121 S M 14 20 -30 Nm - 60 ° 1° phase 30 °

52 EZ 142 S M 18 x 1,5 40 Nm - 90 ° 1° phase 60 °

Flexible coupling EZ 166 S 2° phase 30 °

63 (without adapter flange) /

53 flywheel EZ 171 S M 22 x 1,5 68 Nm - 150 ° 1° phase 90 °

54 EZ 201 S M 27 x 2 128 Nm - 120 ° 1° phase 60 °

EZ 135 S 2° phase 30 °

EZ 195 S 2° phase 60 °

2° phase 60 °

Section:

3.5

Specification Data

Line Constr. Joints tightened by wrench Thread Preload Tightening Tightening Remarks

No. group torque torque angle

Nm Nm °

55 M 10 x 20 - 60 Nm - -

56 M 10 x 25 - 60 Nm - -

57 34 Vibration damper / rubber element M 12 x 140 - 170 Nm - -

58 M 14 x 35 - 220 Nm - -

59 M 14 x 50 - 220 Nm - -

60 29 Control rod / connecting linkage M 8 x 30 - 40

61 10 Camshaft / guide plate M 10 - 50 Nm - -

62 M 14 x 80 - 125 Nm - -

63 M 16 x 40 - 280 Nm - -

64 M 16 x 45 - 190 Nm - -

65 M 16 x 50 - 280 Nm - -

Page:

Engine:

Nm - -

3-3-03

S/BVM 628

)

66 M 16 x 80 - 280 Nm - -

67 43 Turbocharger assembly M 16 x 90 - 280 Nm - -

68 M 16 x 170 - 280 Nm - -

69 M 20x 1,2x45 - 700 Nm - -

70 M 20x1,5x50 - 430 Nm - -

71 M 20x1,5x65 - 300 Nm - -

72 M 20 x 50 - 380 Nm - -

73 M 20 x 160 - 380 Nm - -

74 16 Piston cooling oil nozzles M 12 x 40 - 135 Nm - -

75 47 Resilient bearing element / base plate M 27 - 1000 Nm - -

76 01 Crankcase / base plate M 22 x 1,5 - 900

+20

Nm - -

Section:

3.5

Page:

Engine:

3-3-04

S/BVM 628

3.5.2 Legend for Items 2 and 3

● Preload studs I and II hydraulically with max. 100 bar.

● Preload studs III and IV mechanically with 70 Nm.

● Tighten studs III and IV alternately through 90° + 90° + 30° = 210°.

● Tighten bolts I and II hydraulically to max. 1030 bar.

Screw nuts in place and tighten until aquarely seated.

● Lower hydraulic pressure to 0 bar, so nut will becompletely tight.

● Reincrease pressure to 1030 bar and tighten nuts until squarely seated.

Specification Data

Section:

3.5

3.5.3 Tightening Procedure

Proceed by applying lube oil or other com- pound to threads according to information given in the job cards.

Phase 1: Screw the bolts (screws, nuts) in

place

Phase 2: Preload the bolts (screws, nuts)

● Torques up to 30 Nm

Hold socket wrench with tommy bar, hands being closed together and preload bolts evenly (alternately and crosswise, where applicable). When using a plain or box wrench, the thumb should touch the wrench.

● Torques above 30 Nm

Preload bolts by torque wrench to the torque tabulated (crosswise and in stages, where applicable). If a standard tool must be used, see adjoining figure and table below with typical values

Specification Data

Page:

Engine:

3-3-05

S/BVM 628

Phase 3

● Tighten the bolts (srews, nuts)

Tighten bolts evenly to the tabulated angle (alternately and crosswise, where applicable). Use extension, if necessary. Where several bolts are involved and the angle is greater than 60°, tighten in stages of max. 60°.

Force

lever length

Preloading Lever Force

torque Length

Nm mm N

30 500 60

40 500 80

70 1000 70

130 1000 130

Section:

3.5

Page:

Engine:

3-3-06

S/BVM 628

Specification Data

Do not simply back overtightened bolts, but release them comletely and tighten again as specified.

Should necking of shank be found after several tightening procedures, renew bolt.

3.5.4 Information on the Hydraulic Tool for Annular Nuts

For equipment design, oil filling and bleeding procedures see Job Card No. 02.16.02, which also gives a list of hydraulic oils recommended.

Section:

3.6

Specification Data

Page:

Engine:

3-4-01

S/BVM 628

3.6 Sealing, Locking, Lubrication and Heat Conductor Compounds

Designation Description Application condition Use Remarks Equivalent product

Sealing compounds:

Asbestos with

It-Ö bonding agent 1,5 mm thick lube oil, gas oil

Asbestos Serpentine 2,0 mm thick Combustion gases

Gi Deutz 2b or synthetic) +110 °C with

Deutz DW 5 Paper 0,3 mm thick Air, water, lube oil,

Deutz DW 20 Leather board 1,5 mm thick Water up to 65 °C

Deutz DW 30 Gasket Exhaust system Deva metal from

loil-resistant

type

Rubber (natural Water -20 to

anti-freeze and anti-corrosive

gas oil

lube oil, gas oil

Deventer

Deutz DW 40 Gasket Asbestos w. Exhaust piping Reinz 4402 or

Deutz DW 47 compound India rubber engine from

Deutz DW 48 Compound and Terrostat 33,

Deutz DW 49 Compound Core hole plugs Fire risk Compound No. 54 from

Deutz DW 50 Compound Liquid seal Pump cases etc. Fire risk Curil or

Deutz DW 51 Compound Liquid seal Fire risk Compound Sigma from

Locking Compounds:

Deutz DW 55 Liquid single- Low viscosity Threads up to M 16, Loctite 601

Deutz DW 56 High viscosity Threads from M 10, Loctite AVX

Deutz DW 57 Low-viscosity agent Threads up to M14 Loctite 221

Amine-hardening Silicone Tough-elastic Silastik Q3-3305, black

component agent becoming bearings, bushes plastics hardening very tight gears, pins etc. on metal under air exclusion

artif. resin Ferrolastic from Diring

frame joints Fa. DOW-CORNING,

Silicone Touch-elastic Silastik 732 RTV from vulcanisate joints Dow-Corning, Brussels

Teroson fluid

agent becoming esp. studs, very tight surfaces

easily removable (adjusting screws)

Düsseldorf

black, from Teroson GmbH.,Heidelberg

Sonderhoff, Cologne

Deutz DW 59 Medium-viscosity agent Threads and surfaces Loctite 270

Deutz DW 60 High-viscosity agent Threads and faces Loctite CVX

Deutz DW 61 Activator Only with DW 56 and non-corrosive Locquic T

becoming very tight

becoming medium tight hydr. and pneum.

DW 60 for non-metallic and surface treated components

Section:

3.6

Page:

Engine:

Designation Description Application Use Remarks Equivalent Product

Lubricating Compounds:

Deutz S1 resistant Compound of thread seizure P.H. Weidling & Sohn KG

Deutz S2 Special compound Sliding compound Hydraulic system sliding Molycote G-n rapid

Deutz S4

Deutz F2 compound pound for plug/socket con- compound G-n rapid

Deutz F5 lubricant grease for all bearings,

3-4-02

Specification Data

S/BVM 628

Condition

Heat- Prevention „Never Seez“ from

or spray

Molybdic Compound Reduces / prevents Initially clean DOW-CORNING, sulfide friction and resultant components w. per- Düsseldorf

Synthetic silicone Electric insulating com- Molykote special

Acid-free Multi-purpose

(e.g. exhaust system)

seals, waisted bolts / studs

corrosion of tight-fit or tri-chlorethylene or Van Laar, components. apply compound Ratingen For temperatures very "thin":

-40 °C to +450 °C. some 0,005 mm

nections in ignition systems

-30 to +120 °C

MOLYKOTE Longterm 2 grease, extremely and couplings

Heat Conductor Compounds:

Deutz P1 copper w. oil-contai- switches Stein & Sohn, Hamburg

Extra-high pressure Bearings, splines

adhesive, good for temperatures corrosion -25 to +110 °C buona protezione inhibitor

Cond. compound: Temperature Heat compound from

ning bonding agent

Section:

3.7

Specification Data

3.7 Use of Liquid Nitrogen

Fitment of metal parts with the aid of liquid nitrogen can be carried out only in a workshop.

Beware of liquid nitrogen coming into contact with the skin. Never touch undercooled parts with bare hands. Use pliers or other suitable tool when placing parts into liquid nitrogen.

Application of liquid nitrogen

For minor work of short duration it will be sufficient to have two concentric containers of varying diameter placed into each other and to have the clearance between the two containersfilled with the mineral wool, cork meal or sand.

To begin with, pour the nitrogen into the special basin and then dip the parts into this liquid. The start of the undercooling process is indicated by heavy "boiling". Bubbles will form until the parts have assumed the nitrogen temperature of - 196° C. Once no more bubbles form, the part is ready for fitment.

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Engine:

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Quantity of nitrogen needed

Under normal conditions, one kilogram of metal to be cooled from +15° to -196° C requires the following quantity of liquid nitrogen:

Steel 0,60 litres Aluminium 0,96 litres Bronze, copper, brass 0,45 litres Cast iron 0,66 litres

Section:

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Specification Data

Section:

3.8

Specification Data

3.8 Dye Checking of Metal Surfaces

The dye checking process for detecting metal surface flaws requires the following agents:

Detergent (trichlorethylene), Diffusion fluid (red), Developer(white)

Cleaning the part

- Apply the detergent at least one hour before applying the diffusion fluid to ensure that any grease is removed from the metal surface and its flaws (cracks, fissures, etc.) (Fig. 1) (see safety instruction, page 3-6-02)

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Engine:

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S/BVM 628

Applying the diffusion Fluid

- Apply fluid by spraying gun, hair brush or by dipping part into the directionsfor use (Fig. 2).

- Wash off surface by water, so fluid will remain in the flaws only (Fig. 3).

- Wipe surface clean with a dry rag.

Applying the developer

- Once the surface is dry, apply on a thin film of developer by spray gun or hair brush.

- Let developer dry for one or two minutes.

- The "blotting paper effect" of the white developer will make the red fluid become visible in the flaws (Fig. 4).

Section:

3.8

Page:

Engine:

3-6-02

Specification Data

S/BVM 628

Appraisal

- Red lines in the white film indicate cracks.

- Red dots indicate pittings or porosity.

Hair cracks may need some hours to become visible.

A red dotted line is caused by:

● hair cracks,

● metal fatigue marks,

● non-continuous cracks.

Trichlorethylene is toxic. Ensure adequate ventilation of the workshop. Do not inhale vapours. Wear protective clothing (such as goggles, gloves) when working with trichlorethylene.

Operating the Engine

Инст укця по эксплуатации двигателя

4 Operating the Engine

Инст укця по эксплуатации двигателя

Section:

Operating the Engine

Page:

Engine:

4-0-01

S/BVM 628

4.1 Preparations for Operating the Engine on Distillate Fuel

(see also sections 7, 8.2, 8.3 and "Summerized Instructions" hereto)

A Commissioning Run-in Engines Following a Brief Idle Period B Commisioning Engines Following Overhaul Including Replacements of Pistons, Cylinder Liner

or Bearings

C Commisioning New Engines or Run-in Engines Following a Prolonged Idle Period (over 3

months)

Item Job A B C Reference

1 Depreservation Remove all preserving section 6

agent inside and outside of engine ●

2 Cylinder head Check inlet and exhaust Job 01.01.01

valve clearance ●●

Check that inlet and exhaust valves move freely ● in their guides

3 Foundation Inspect / tighten to the

bolts instructions of the ● Job 03.07.01

building contractor

4 Speed control system Check that control rod

moves freely ● Job 07.01.01

Check oil level in hydraulic governor ● Job 05.03.11

Check oil of hydraulic governor ● Job 05.03.11

Bleed hydraulic governor ● Job 05.03.12

5 Exhaust / Check oil level

turbocharging system in turbocharger ●●Job 06.05.01

Inspect turbocharger ● Job 06.06.01

Section:

Page:

Engine:

4-0-02

S/BVM 628

Operating the Engine

Item Job A B C Reference

6 Fuel system

Clean fuel service tank ●

Top up fuel service tank ●●

Clean fuel filter ●●Job 07.10.01

Test fuel injectors ●●Job 07.08.01

Check oil level in sealing oil tank ●●

7 Lube oil system

Drain fuel service tank ●●

Open shut-off valve of fuel service tank and switch on fuel feed pump (if installed) ●●●

Bleed fuel system ●● Job 07.03.02

Top up lube oil reservoir ●

Check up lube oil reservoir ●●●

Service lube oil filter combination ●● Job 08.10.01

Switch on priming pump and keep priming pressure for min. 3 minutes ●●● > 0,35 bar

Switch on priming pump (if standby oil pump) ●●●

8 Cooling water system Top up water level ●

Check up water level in header tank ●●●

Bleed water system, if need be ●●

Section:

Operating the Engine

Page:

Engine:

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Item Job A B C Reference

8 Cooling water system Treat water

with additives ●● Section 6.4

Open valves in all water pipework and check for correct valve pos. ●

Switch on water preheater, if provided ●●

Standby sets: Check that preheating temperature (if provided) ●●●Section 3.3.2

Clean separate raw water filter (if provided) ●●●

9 Pneumatic system Check that master and

starting valves Job 01.11.01 move freely ●●Job 10.03.01

Drain condensate from dust coll. ●●Job 10.03.02

Drain condensate from pressure reducer station ●●Job 10.06.01

Clean / install running -in screen upstream ●●Job 10.03.91 of master valve

Drain water from air receivers ●●●Job 10.01.01

Check pressure in air receivers ●●●Job 10.01.01

10 Engine protective system Separate pumps: check

pressures / temperatures in operating media (fuel etc.) ●●●

Test audible and visual alarms ●●●

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Operating the Engine

Section:

Operating the Engine

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4.1.1 Preparation for Operating the Engine on blended Fuel (heavy Fuel)

(see also sections 7, 8.2, 8.3 and "Summarized Instructions" hereto).

A Commissioning run-in engines following a brief idle period

B Commissioning engines following overhaul including replacements of pistons, cylinder

liner or bearings

C Commissioning new engines or run-in engines following a prolonged idle period (over 3

months)

Item Job A B C Reference

1 Depreservation Remove all preserving agent

linside and outside of engine ● Section 6.5

2 Cylinder head Check inlet and exhaust Job 01.01.01

valve clearance ●●

Check that inlet and exhaust valves move freely in their guides ●

3 Foundation bolts Inspect / tighten to the

instruction of the ● Job 03.07.01 building contractor

4 Speed control system Check that control rod

moves freely ● Job 07.01.01

Check oil level in hydraulic governor Job 05.03.11

Change oil in hydraulic governor ● Job 05.03.11

Bleed hydraulic governor ● Job 05.03.12

5 Exhaust / turbocharging Check oil level

system in turbocharger ●●Job 06.05.01

Inspect turbocharger ● Job 06.06.01

Check scavenging water ●●Job 06.13.03 quantity

Section:

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4-0-06

S/BVM 628

Operating the Engine

Item Job A B C Reference

6 Fuel system

Clean fuel service tank ● Top up fuel service tank ●● Clean fuel filter ●●Job 07.10.01 Test fuel injectors ●●Job 07.08.01

Check oil level in sealing oil tank ●●

Preheat fuel service tank ●●● Section 6.3 Drain fuel service tank ●●●

Open shut-off valve of fuel service tank ●●●

Switch on sealing oil pump ●●●

Switch on fuel feed pump as 6+2 bar sealing oil pressure ●●● has been obtained

Heat separate f uel filter if engine has been stopped on heavy fuel ●●● Section 6.3

Inserire l’impianto di regolazione della viscosità. ●●● Section 6.3

Bleed fuel system ●●●Job 07.03.02

7 Lube oil system Switch on standby oil pump

if used for priming pump ●

Top up lube oil reservoir ●●●

Check level in lube oil reservoir ●●

Clean lube oil filter ●●● 08.10.01

Switch on priming pump and keep min. 0,35 bar pressure ●●● for min. 3 minutes

Section:

Operating the Engine

Page:

Engine:

4-0-07

S/BVM 628

Item Job A B C Reference

8 Cooling water system Top up water level ●

Check water level in header tank ●●●

Bleed water system if necessary ●●

Treat water with additives ●● Section 6.4

Clean separate raw water filter (if provided) ●

Open valves in all water pipework and check for correct valve positions ●●

Switch on water preheater ●●●

Switch on injection valve water preheater ●●● (if provided)

Section 6.3

Switch on injection valve coolant pump ●●●

9 Pneumatic system Check that master and Job 01.11.01

starting valves move freely ●●Job 10.03.01

Drain condensate from dust coll. ●●Job 10.03.02

Drain condensate from pressure reducer station ●●Job 10.06.01

Clean / install running-in screen upstream ●●Job 10.03.91 of master valve

Drain water from air receivers ●●●Job 10.01.01

Check pressure in air receivers ●●●Job 10.01.01

Section:

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Engine:

4-0-08

S/BVM 628

Operating the Engine

Item Job A B C Reference

10 Engine protective system Separate pumps:

check pressures / temperatures in operating media (fuel etc.) ●●●

Test audible and visual alarms ●●●

Section:

Operating the Engine

Page:

Engine:

4-1-01

S/BVM 628

4.2 Running the Engine on Distillate Fuel

Item Procedure A B C Reference

1 Open indicator valves ●●●

2 Turn engine over twice by barring gear, but not later than 1 hour

after prelubricating, otherwise repeat prelubricating ●●

3 Place speed control in lowest possible position ●●Section 3.3.1

4 Keep assistance ready at the

emergency stop drive ●●Job 05.00.01

5 With air receivers closed, move engine control lever

from "Stop" to "Start" position. Slowly open air shut-off valves and

- with indicator valves opened briefly turn engine over. ●●● Close air receivers, move control lever back to "Stop" position and close indicator valves

6 Open air receiver fully ●●●

7 Move local control lever from "Stop" to "Start" position

and - when firing speed is attained move on to "Run" position ●●●Section 3.3.1

8 Should the engine fail to fire at the end of some 3 seconds,

wait for a while and repeat starting attempt. If several such starting attempts are unsuccessful, ●●● Section 7 trace cause of trouble and remedy.

9 Switch off water preheater (if provided)

at temperature specified ●●●Section 3.3.2

10 Where the standby lube oil pump is used for priming,

switch off pump once idling speed is reached or when the starting inhibitor, ●●● if provided, releases

11 Raise engine speed slowly ●●

Section:

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Engine:

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S/BVM 628

Operating the Engine

Item Procedure A B C Reference

12 Run in engine ● Section 4.6

13 Once working temperature is reached, Acceptance

put engine on load ●●● documents

On stationary engines use start and stop button respectively for items 5 and 7.

Section:

Operating the Engine

Page:

Engine:

4-1-03

S/BVM 628

4.2.1 Running the Engine on Blended Fuel (Heavy Fuel)

Item Procedure A B C Reference

1 Open indicator valves ●●●

2 Turn engine over twice by barring gear, but not later than 1 hour

after prelubricating, otherwise repeat prelubricating ●●

3 Place speed control in lowest possible position ●●Section 3.3.1

4 Keep assistance ready at the

emergency device ●●Job 05.00.01

5 With air receivers closed, move engine control lever

from "Stop" to "Start" position. Slowly open air shut-off valves and

- with indicator valves opened briefly turn engine over. ●●● Close air receivers, move control lever back to "Stop" position and close indicator valves

6 Open air receiver fully ●●●

7 Move local control lever from "Stop" to "Start" position

and - when firing speed is attained move on to "Run" position ●●●Section 3.3.1

8 Should the engine fail to fire at the end of some 3 seconds,

wait for a while and repeat starting attempt. If several such starting attempts are unsuccessful, ●●● Section 7 trace cause of trouble and remedy.

9 Where the standby lube oil pump is used for priming,

switch off pump once idling speed is reached ●●● or when the starting inhibitor, if provided, releases

10 Operate engine at high speed with some 25% power,

raising to some 60% power ●●

Section:

Page:

Engine:

4-1-04

S/BVM 628

Operating the Engine

Item Procedure A B C Reference

11 Run in engine ● Section 4.6

12 Switch off coolant preheater

(upon attaining appropriate temperature) ●●● Section 3.3.2

13 Switch off separate preheated filter ●●●

14 Switch off injector preheater

(if provided). ●●●Section 3.3.2

15 Once working temperature is reached,

put the engine on load ●●●

On stationary engines use start and stop button respectively for items 5 and 7.

Section:

Operating the Engine

Page:

Engine:

4-2-01

S/BVM 628

4.3 Attendance in Service

Record readings right from the start, unless automatically printed where periodically unattended service is provided. See also section 3.3.

Item Daily Checks and Servicing Jobs Reference Reading

(Section 8.3)

1 General Listen to running noise

Check colour of exhaust Section 7

Inspect entire engine for leaks, especially external pipework

Compare engine operating data with acceptance documents

2 Temperatures Lube oil temperature Section max. 65 °C

at engine inlet 3.3.2 max. 75° C Water temperature Section max. 80 °C

a t engine outlet 3.3.2 max. 85 °C

Water temperature differential at engine inlet / outlet 8 - 12 °C

Fuel temperature Section in injection pump 6.3

Charge air temperature Acceptance at engine inlet documents (full load)

Exhaust temperature Acceptance at turbine outlet documents

3 Pressures Lube oil pressure

at filter outlet ≥ 3,5 bar (engine hot, rated speed)

Sealing oil pressure Section in injection pumps 3.3.2

Section:

Page:

Engine:

4-2-02

S/BVM 628

Operating the Engine

Item Daily Check and Servicing Jobs Reference Reading

(section 8.3)

3 Pressures Water pressure ~ 4 bar

at engine inlet

Fuel pressure 3,0 + 1,5 bar at injection pump inlet

Charge air pressure Acceptance documents

Starting air pressure, max / min 30/10 bar

Raw water pressure

4 Speed control system Check oil level 05.03.11

in hydraulic governor

5 Exhaust / Clean turbocharger

turbocharging system air side 06.12.01

Check exhaust mean temperatures Acceptance (differences between cylinders documents are irrelevant for power output). section Check limit temperatures 3.3.2

Check oil level in turbocharger 06.05.01

6 Fuel system Drain water from fuel tank

Check fuel level in service tank

Check flow switch for monitoring shielded injection lines (if provided) 11.01.03

7 Lube oil system Check oil levels

Service wire coil edge-type filter 08.09.01

Check service gauge of oil filter 08.10.01

Inspect valve seat lubrication 08.14.01

Section:

Operating the Engine

Page:

Engine:

4-2-03

S/BVM 628

Item Daily Checks and Servicing Jobs Acceptance Reading

documents

8 Cooling system Check coolant level

in hydraulic governor

9 Pneumatic system Charge air receivers and

drain condensate after cool-down

Drain condensate from dust collector 10.03.02

Drain condensate from pressure reducer station 10.06.01

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Operating the Engine

Section:

Operating the Engine

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4.4 Stoppage / Layoff of Engine Running on Distillate Fuel

A Short period (Engine remains readily available)

B Prolonged Period

C Period exceeding 3 months

Item Job A B C

1 To prevent heat accumulation, let engine idle for 10 minutes

or so before shutting down from prolonged full-load service. ●● ● Where separate oil and coolant pumps are provided, keep them going for 10 minutes following engine shutdown.

2 Stop engine ●● ● 3 Close shut-off valve of air receiver ●● 4 Close shut-off valves of fuel service tank ●● 5 Close shut-off valves before and after water colle ●●

6 When frost is imminent, switch on water preheater,

unless an anti-freeze has been added, or drain all water from engine and attachments (see Job Card 09.00.01) ●

7 Drain all water from engine and attachments

(see Job Card 09.00.01) ●

8 Drain all lubricating oil from engine and attachments

(except speed governor) ●

9 Preserve engine (section 6.5) ●

10 While the engine is out of service, switch on standby lube oil pump

once a week, open indicator valves and turn engine over. (This applies only in the case of vibration of the shut-down engine, e.g. due to other engines in service) ●

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Section:

Operating the Engine

Page:

Engine:

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4.4.1 Stoppage / Layoff of Engine Running on Heavy Fuel or MDF Blend

A Short Period (Engine remains readily available)

B Prolonged Period

C Period exceeding 3 months

Item Job A B C

1 When operating with blended fuel < 380 mm2 /s (cSt) / 50 °C ,

we recommend running the engine for at least 1 hour with distillate fuel before shutdown ●●

When operating with blended fuel > 380 mm2 /s (cSt) / 50° C , the engine must be run for at least 1 hour with distillate fuel before shut-down - longer than 72 hours - until the fuel system is completely filled with distillate fuel.

2 To prevent heat accumulation, let engine idle for 5 minutes

or so before shutting it down from prolonged full-load service. Where separate oil and coolant pumps are provided, keep them going for 5 minutes following shut-down. ●● ●

3 Stop engine ●● ●

4 Switch off viscosity control, injector coolant pump,

fuel feed pump and fuel plunger sealing oil pump ●● 5 Close shut-off valve of air receiver ●● 6 Close shut-off valve of fuel service tank ●● 7 Close shut-off valves before and after water cooler ●●

8 When frost is imminent, switch on water preheater,

unless an anti-freeze has been added,

or drain all water from engine and attachments

(see Job 09.00.01) ●

9 Drain all water from engine and attachments

(see Job 09.00.01) ●

Section:

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Engine:

4-3-04

S/BVM 628

Operating the Engine

Item Job A B C

10 Drain lube oil completely from engine, accassories,

pipings and fittings (but not from speed governor). ●

11 Preserve engine (section 6.5) ●

12 When engine is out of service, switch on standby lube oil pump

once a week, open indicator valves and turn engine over. (This applies only in the case of vibration of the shut-down engine, e.g. due to other engines in service) ●

Section:

Operating the Engine

4.5 Taking Combustion Indicator Diagrams

Be sure closely to observe the instructions issued by the indicator manufacturer, or readings are liable to be incorrect. The instrument recommended by us is the Mahaik torsionspring indicator, type S, plunger 1/2, with the following springs:

Max. combustion pressure Spring

100 bar F 100 bar No. 50

120 bar F 120 bar No. 60

140 bar F 140 bar No. 70

160 bar F 160 bar No. 80

Page:

Engine:

4-4-01

S/BVM 628

Pressures see acceptance records.

Taking Indicator Diagrams

Thoroughly blow through the indicator valves to prevent any carbon particles entering the gauge. Then screw indicator firmly in its place.

Put indicator paper on the recording drum and draw the zero line.

Open indicator valve and slowly turn drum from recording the combustion pressures

For recording the compression pressure, cut out injection pump (Job Card 07.01.01) and check that control rod of the injection pump does not abut at its load limit.

The following data should be entered upon the diagram:

Date, spring scale, cylinder No., corresponding exhaust temperature, control rod position, speed and charge air pressure.

Assessing the Readings

Compare readings with the values given in the Acceptance Record.

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Operating the Engine

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4.6 Run-in Instructions

Engines which leave the manufacturer's works have been run in; thus run-in at site is not necessary.

Following servicing work on main and big-end bearings, pistons, piston rings and cylinder liners the engine must be run in again.

The following run-in programs apply to the different drive types:

4.6.1 Drive type "Fixed-pitch propeller and comparable drives"

(Engine load is mainly dependent on speed, n = variable)

● Start engine, sections 4.1 and 4.2, and run at low speed for 5 minutes.

● Stop engine, section 4.4.

● Check bearings and crankshaft.

If the engine has warmed up noticeably, the cause must be locked for immediately and remedied.

● Start engine again and r un at low speed for 30 minutes.

● Stop engine again.

● Check bearings and crankshaft.

If the engine has warmed up noticeably, the cause must be locked for immediately and remedied.

● Start engine again and increase speed gradually according to the following table.

Run-in time Engine speed in %

in minutes of rated speed

60 35 30 45 60 55 15 35 45 70 15 55 45 80 With propeller drives, this part of the 15 65 program must not be run with the 45 90 vessel tied on! 15 70 45 95

● Check engine operating data and compare with those of repair / acceptance test record. In case of

major deviations cause must be locked for and remedied.

During the following 24 hours engine should not be run with control rod set to fuel stop and reduced speed, nor with overload, in order to intensify run-in effect.

Section:

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Operating the Engine

4.6.2 Drive type "C.P. propeller with shaft generator, electric generators and comparable drives"

(Engine load adjustable independent of speed, n = constant)

● Start engine, sections 4.1 and 4.2, and run at low speed for 5 minutes.

● Stop engine, section 4.4.

● Check bearings and crankshaft.

If the engine has warmed up noticeably, the cause must be locked for immediately and remedied.

● Start engine again and r un at low speed for 30 minutes.

● Stop engine again.

● Check bearings and crankshaft.

If the engine has warmed up noticeably, the cause must be locked for immediately and remedied

● Start engine again and increase speed gradually according to the following table.

Run-in time Engine speed in % Engine power in %

in minutes of rated speed of rated power

60 30 - 50 bis 5 30 50 5 - 10 60 100 bis 20 15 30 - 50 bis 5 45 100 30 - 40 15 100 bis 25 With propeller drives, 45 100 50 - 60 this part of the program 15 100 20 - 30 must not be run with 45 100 80 - 90 the vessel tied on! 15 100 30 - 40 45 100 80 - 90

● Check engine operating data and compare with those of repair / acceptance test record. In case of

major deviations cause must be locked for and remedied.

During the following 24 hours engine should not be run with control rod set to fuel stop and reduced speed, nor with overload, in order to intensify run-in effect.

Section:

BRAKE MEAN EFFECTIVE PRESSURE

Operating the Engine

4.7 Running the Engine with Defective Turbocharger

If blades of the turbocharger rotor are warped or broken (indicated primarily by turbocharger vibration or abnormal noise) or if bearings have run hot, it will be recommendable to take the turbocharger out of service (BBC instruct.). In this case it will be necessary to reduce engine speed / power substantially to make sure that the exhaust temperatures at full load as stated in the acceptance test sheet will not be exceeded. The remaining b.m.e.p will be 4,5 bar only.

This applies both to engines with a single turbocharger and engines with several turbochargers where not all rotors have been inactivated.

The following table of maximum obtainable speeds / loads as a function of the b.m.e.p. of the rated power (Acceptance documents) fixed-pitch propeller.

Max. Obtainable Speeds / Outputs with Inactivated Turbocharger

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S/BVM 628

B.m.e.p. of rated power Obtainable speed in % Obtainable power in % (Accepted documents) of rated speed of rated power

bar approx. approx.

11 64 26

14 56,5 18

16 53 15

18 50 12,5

20 47,5 11,5

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Operating the Engine

Section:

Operating the Engine

4.8 Emergency Operation

4.8.1 Engine Operation by Use of the Emergency Operation Device

In case of failure of the engine operating device (control console or remote control), the engine can be started and shut down by hand.

The specifications as per sections

4.1 to 4.4. are to be observed here. To avoid faulty switchings, the lever at the pressure reducing unit (control console or remote control) is to be put in the position shown in Fig.1.

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S/BVM 628

4.8.1.1 Starting the Engine

Pull out locking device at knurled nut (1) - Fig. 2 -, and pull lever down. If the engine does not start after approx. 3 seconds, repeat starting procedure. If the engine fails to start after repeated starting attempts, determine the cause and remedy.

Fig. 1

Fig. 2

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S/BV 6/8/9 M 628

4.8.1.2 Speed Setting

The speed is to be set in accordance with the manufacturer's instructions.

4.8.2 Engine Shutdown

The engine is shut down by pressing the shutdown button, see the instructions of the governor manufacturer.

Furthermore, the engine can be shut down by using an open-end spanner (5) at the lever of the governor shaft (6) which is to be turned in the direction of the driving end. This method can be applied, provided that the governor linkage is set correctly (see Fig. 3).

Operating the Engine

Fig. 3

Engine Operating Media

Пояснения к системаи эксплуатацион-ных мате иалов длв двигателей

5 Engine Operating Media

Пояснения к системаи эксплуатацион-ных мате иалов длв двигателей

Section:

Engine Media Systems

5 Engine Media Systems

5.1 Fuel System

5.1.1 Legend for Piping Diagrams

5.1.2 Piping Diagram for Distillate Fuel and MDF Blend

5.1.3 Piping Diagram for Heavy Fuel

5.2 Lubricating Oil System

5.2.1 Legend for Piping Diagrams

5.2.2 Deep ("Wet") Sump

5.2.3 High-Level Tank ("Dry Sump")

5.2.4 Low-Level Tank ("Dry Sump")

5.3 Cooling Water System

5.3.1 Legend for Piping Diagrams

5.3.2 Single-Circuit System

5.3.3 Double-Circuit System

5.3.4 Triple-Circuit System

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S/BVM 628

5.4 Pneumatic System

5.4.1 Legend for Piping Diagrams

5.4.2 Starting / Control / Pilot Air

5.5 Sealing Oil System

5.5.1 Legend for Piping Diagrams

5.5.2 Fuel Conveyer Pump mounted on the Engine

5.5.3 Fuel Conveyer Pump not mounted on the Engine

5.6 Injection Nozzle Cooling

5.7 Legend for Symbols Used in Piping Diagrams (acc. to DIN)

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Engine Media Systems

Section:

5.1 Fuel System

Engine Media Systems

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5-1-01

S/BVM 628

Deutz Engine S-BV6-8-9M628 Operation Manual Deutz Engine S-BV6-8-9M628 Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Operation Manual

S/BV6/8/9M628

0297 7945 en

Foreword

Medium-sized and large engines General

Table of contents

1 Guide to this Manual

1.1 General

1.2 Trouble-shooting

1.3 Planned Maintenance

1.4 Ordering of Spare Parts

1.5 Specification Data

1.6 Job Card No.

1.7 Standard Tools

1.8 Special Tools

1.9 Index of DEUTZ Assembly Groups as Incorporated in System 333 - Job Cards, Maintenance Groups

2 Layout and Description of Engine

2.1 01 Cylinder Head

2.2 02 Crankshaft System

2.3 03 Engine Frame

2.4 04 Timing System

2.5 05 Speed Control System

2.6 06 Exhaust / Turbocharging System

2.7 07 Fuel System (see also 5.1)

2.8 08 Lubricating Oil System (see also 5.2)

2.9 09 Cooling Water System (see also 5.3)

2.10 10 Pneumatic System (see also 5.4)

2.11 11 Engine Protective System

2.12 12 Engine Auxiliaries

2.13 Engine Assemblies and Subassemblies (as for the relevant location, please refer

3 Specification Data

3.1 Model Designation: S/BV 6/8/9 M 628

3.2 Designations of engine sides, cylinders and rotation direction

3.3 Basic Data

3.3.1 Design Data

3.3.2 Operating Data

3.3.3 Setting data for monitoring equipment

3.3.4 Arrangement of Electrical Equipment

3.3.4.1 Exhaust Turbocharger at Driving End

3.3.4.2 Exhaust Turbocharger at Free End

3.4 Weight of Engine Components

3.5 Tightening Specification for Heavy-Duty Screwed Joints

3.5.1 Table

3.5.2 Legend for Items 2 and 3

3.5.3 Tightening Procedure

3.5.4 Information on the Hydraulic Tool for Annular Nuts

3.6 Sealing, Locking, Lubrication and Heat Conductor Compounds

3.7 Use of Liquid Nitrogen

3.8 Dye Checking of Metal Surfaces

Operating the Engine

4.1 Preparations for Operating the Engine on Distillate Fuel

4.1.1 Preparation for Operating the Engine on blended Fuel (heavy Fuel)

4.2 Running the Engine on Distillate Fuel

4.2.1 Running the Engine on Blended Fuel (Heavy Fuel)

4.3 Attendance in Service

4.4 Stoppage / Layoff of Engine Running on Distillate Fuel

4.4.1 Stoppage / Layoff of Engine Running on Heavy Fuel or MDF Blend

4.5 Taking Combustion Indicator Diagrams

4.6 Run-in Instructions

4.6.1 Drive type "Fixed-pitch propeller and comparable drives"

4.6.2 Drive type "C.P. propeller with shaft generator, electric generators and comparable drives"

4.7 Running the Engine with Defective Turbocharger

4.8 Emergency Operation

4.8.1 Engine Operation by Use of the Emergency Operation Device

4.8.1.1 Starting the Engine

4.8.1.2 Speed Setting

4.8.2 Engine Shutdown

5 Engine Media Systems