Deutz 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

Table of Contents 0

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

Table of Contents 0

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

Table of Contents

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

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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:

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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.

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