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: ● Speed: ● Date of commissioning: kW / rpm . . 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.
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.
Foreword Medium-sized and large engines 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.
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.
Medium-sized and large engines This page intentionally left blank.
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
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
Table of Contents Inhaltsverzeichnis Indice Table des matières Indice Inhoudsopgave Оглавление 0
0 Table of Contents Inhaltsverzeichnis Indice Table des matières Indice Inhoudsopgave Оглавление
Table of contents 1 Section: 0 Page: 0-0-01 Engine: S/BVM 628 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 1.9 Index of DEUTZ Assembly Groups © 1199 2 Layout and Description of Engine 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.
Section: 0 Page: 0-0-02 Engine: S/BVM 628 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 3.3.2 3.3.3 Design Data Operating Data Setting Data for Saftey Switches 3.4 Weights of Main Engine Components 3.5 Tightening Specification for Heavy - duty Screwed Joints 3.5.1 3.5.2 /3. 3.5.4 Tightening Schedule Tightening Instructions Hydraulic Tool for Annular Nuts 3.
Table of contents Section: 0 Page: 0-0-03 Engine: S/BVM 628 6 Engine Operating Media 7 Trouble - shooting 7.1 7.2 7.3 Summary of Potential Troubles General Trouble Chart 8 Maintenance Schedules, List of Job Cards and Job Cards 8.1 Summary of Maintenance Schedules 8.1.1 8.1.1.1 Initial Maintenance jobs Engines running in countinuos operation, e.g. marine engines, >300 hour / year Engines running in standby operation, e.g. emrgency generating sets, < 300 hours / year 8.1.1.2 8.1.
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Guide to this Manual 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 Operació Указания по пользованию настоящей Указания по пользованию настоящей 1
1 Guide to this Manual 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 Operació Указания по пользованию настоящей Указания по пользованию настоящей
Guide to this Manual 1 Guide to this Manual 1.1 General Section: 1 Page: 1-0-01 Engine: S/BVM 628 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.
Section: 1 Page: 1-0-02 Engine: S/BVM 628 1.2 Guide to this Manual 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.
Guide to this Manual 1.6 Section: 1 Page: 1-0-03 Engine: S/BVM 628 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 Standard tools are those tools which are normally included in a workshop tool box.
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Guide to this Manual 1.9 Section: 1 Page: 1-0-05 Engine: S/BVM 628 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 02.03.03 02.04.01 02.05.01 02.06.01 02 Crankshaft system 10 Camshaft 04.05.01 04.06.01 04 Timing system 10 Camshaft bearing 04.01.01 04 Timing system 58 Charge air cooler 06.04.01 06.04.02 06 Exhaust / Turbocharging system 32 Charge air system 06.02.
Section: 1 Page: 1-0-06 Engine: S/BVM 628 Guide to this Manual Assembly Group Job Card Maintenance Group 08 Exhaust valve 01.01.01 01.05.01 01.05.04 01.05.05 01.07.01 01 Cylinder head 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 07.10.01 07 Fuel system 29 Hydr. governor drive 05.04.01 05 Speed control system 29 Hydr. governor linkage 05.04.
Guide to this Manual Section: 1 Page: 1-0-07 Engine: S/BVM 628 Assembly Group Job Card Maintenance Group 02 Main bearing 02.03.02 02.03.03 02.04.01 02.07.01 02.08.01 02 Crankshaft system 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.
Section: 1 Page: 1-0-08 Engine: S/BVM 628 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 01.03.02 01 Cylinder head 16 Valve seat lubrication 08.14.01 08 Lubricating oil system 08 Valve seat ring 01.07.01 01.03.01 01 Cylinder head 34 Vibration damper 12.01.01 12.01.
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
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 2 Layout and Description of Engine 2.1 01 Cylinder Head Section: 2 Page: 2-0-01 Engine: S/BVM 628 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.
Section: 2 Page: 2-0-02 Engine: S/BV 6/8/9 M 628 2.4 Layout and Description of Engine 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.
Layout and Description of Engine 2.7 Section: 2 Page: 2-0-03 Engine: S/BV 6/8/9 M 628 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.
Section: 2 Page: 2-0-04 Engine: S/BV 6/8/9 M 628 2.10 Layout and Description of Engine 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.
Section: 2 Page: 2-1-01 Engine: S/BV 6/8/9 M 628 Layout and description of engine 2.13 Engine Assemblies and Subassemblies (as for the relevant location, please refer to Section 2.14) Assy Group No.
Section: 2 Page: 2-1-02 Engine: S/BV 6/8/9 M 628 Layout and description of engine Cutaway View of Engine 8 9 10 11 12 13 24 23 22 21 20 19 51452 2 © 7 25 18 6 26 17 5 27 16 4 28 15 3 29 14 2 30 (8-cyl. engine) 1 2.
Specification Data Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens Тенические данные 3
3 Specification Data Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens Тенические данные
Specification Data 3 Specification Data 3.1 Model Designation: S/BV 6/8/9 M 628 S B V 6/8/9 3.2 = = = = Marine (uni-direction) Turbocharged Four stroke cycle 6, 8 or 9 cylinders M 6 28 = = = Section: 3.1 and 3.2 Page: 3-0-01 Engine: S/BV 6/8/9 M 628 Water cooled Generation No. Piston stroke in cm Designations of engine sides, cylinders and rotation direction Viewed towards the drive-side coupling flange of the engine.
Specification Data 3.3 3.3.1 Section: 3.3 Page: 3-1-01 Engine: S/BV 6/8/9M 628 Basic Data Power and speed Bore Stroke Capacity per cylinder Total capacity: 6 cylinder 8 cylinder 9 cylinder see acceptance test sheets 240 mm 280 mm 12,66 litres 75,66 litres 101,28 litres 113,94 litres Compression ratio 13 : 1 Design Data 01 Cylinder Head Safety valve opens at 170 ± 5 bar 02 Crankshaft System Crankshaft main jounal dia. running width of main bearing crankpin dia.
Section: 3.3 Page: 3-1-02 Engine: S/BV 6/8/9M 628 Specification Data Inlet valve opens Inlet valve closes 43,5° KW 23,6° KW p. PMS d. PMS 0,2 mm clearance, engine cold Exhaust valve opens Exhaust valve closes 52,9° KW 38,9° KW p. PMS d.
Specification Data Section: 3.3 Page: 3-1-03 Engine: S/BV 6/8/9 M 628 07 Fuel System Fuel grade Fuel consumption Filter mesh Fuel pressure at inj. pump inlet at rated speed See Section 6 . 3 See acceptance test sheet 7 - 60 µm 3,0 - 4, 5 bar Fuel temperature at inj.
Section: 3.3 Page: 3-1-04 Engine: 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 5 bar - Pressure Oil Sump Inclinations and Capacities Dipstick with 3 marks Dipstick with 3 marks Connections for low-level tank © 51 201 0 α ± = 3° Max. sump inclination (incl. installation angle) α ± = 10° Max. permanent inclination β ± = 22,5° Max.
Specification Data Connection for low-level tank ("dry" sump) Drain A or B for inclinations α ± < Section: 3.3 Page: 3-1-05 Engine: S/BV 6/8/9 M 628 6-cyl. 8-cyl. 9-cyl. 10° 8% 7° > 8° - 10° > 7° - 10° Drain A and B for inclinations α ± Oil Delivery Rate for Valve Seat Lubrication Rated Engine Speed 1/min. 1000 900 800 750 720 6-cyl. Delivery in drops / 4 min 8-cyl. 42 37 34 32 30 9-cyl.
Section: 3.3 Page: 3-1-06 Engine: S/BV 6/8/9 M 628 Specification Data 10 Pneumatic System Air receiver capacity see Classification Societies (min. 125 lit.) Max. starting pressure Min.
Specification Data 3.3.3 Section: 3.3 Page: 3-1-07 Engine: S/BV 6/8/9 M 628 Setting data for monitoring equipment Minimum equipment marine propulsion engines auxiliary marine stationary engines Data in “bar” Pressure monitor (referring to dropping pressure) lube oil pressure: initial alarm main alarm (engine stop) engine speed ≤ 600/min > 600/min – 1,0 – 2,0 Temperature monitor 2,0 1,8 – 2,0 Data in „°C“ circ. cool. water temp circuit I charge air temp., max.
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Specification Data 3.3.4 3.3 Page: 3-1-09 Engine: S/BV M 628 Arrangement of Electrical Equipment Measuring point No. as per separately supplied list of measuring points 1.3.1 1.3.3 1.3.4 1.3.7 1.3.8 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.7 2.3.8 2.3.9 2.4.1 2.4.6 2.4.8 2.4.10 2.4.11 2.6.3 3.3.2 3.3.3 3.3.4 3.3.5 3.3.7 3.3.10 3.4.4 3.6.4 4.3.1 4.3.2 4.3.3 4.6.2 5.4.1 5.4.3 6.3.1 6.4.5 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.6 7.3.9 7.3.
Section: 3.3 Page: 3-1-10 Engine: S/BV 6/8/9 M 628 Measuring point No. as per separately supplied list of measuring points 7.3.14 7.5.8 7.5.9 7.5.10 7.5.12 7.5.14 7.5.15 7.5.16 7.5.17 7.5.20 8.1.1 8.1.2 Specification Data Function / description of the equipment or of the gauge point Tacho-generator monitor Solenoid - emergency shutdown Starting solenoid, 3/2-way valve Pushbutton - delocking emergency stop Speed control monitor Pushbutton - stop Solenoid - emergency shutdown Solenoid - stop Electr.
Specification Data 3.3 Page: 3-1-11 Engine: S/BV 6/8/9 M 628 Exhaust Turbocharger at Driving End 25 437 2 © 3.3.4.
3.
Specification Data 3.3 Page: 3-1-13 Engine: S/BV 6/8/9 M 628 Exhaust Turbocharger at Free End 25 439 2 © 3.3.4.
3.
Specification Data 3.4 Section: 3.4 Page: 3-2-01 Engine: S/BV 6/8/9 M 628 Weight of Engine Components (approx. kg per unit) No. Description 6-cyl. 1 Engine with flywheel 9500 11500 13400 2 Crankcase w/o main bearing cap Crankcase w.main bearing cap 2080 2310 2617 2920 3700 4030 3 Oil tank ...(wet sump) Oil tank ...(dry sump) 365 320 430 380 470 410 4 Cylinder liner 58 58 58 5 Crankshaft w/o balance weights 790 995 1097 6 Balance weights w.
Section: 3.4 Page: 3-2-02 Engine: S/BV 6/8/9 M 628 Specification Data Item Description ca.
Specification Data Item 21 © 1185 Section: 3.4 Page: 3-2-03 Engine: S/BV 6/8/9 M 628 Description 6-cyl. ca. kg 8-cyl. ca. kg 9-cyl ca.
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Specification Data Section: 3.5 Page: 3-3-01 Engine: S/BVM 628 3.5 Tightening Specification for Heavy-Duty Screwed Joints 3.5.1 Table Line No. Constr. group 01 01 02 01 Line No. N. costgroup Joints tightened by hydraulic tool Thread Oil pressure bar Remarks Crankcase / cylinder head M 33 x 2 835 bar Job 01.09.01 Crankcase / bearing cap (vertical) M 33 x 2 1030 bar Section 3.5.2, Job 02.08.
Section: 3.5 Page: 3-3-02 Engine: S/BVM 628 Line No. Constr.
Specification Data Line No.
Section: 3.5 Page: 3-3-04 Engine: S/BVM 628 3.5.2 Specification Data 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.
Specification Data 3.5.3 Section: 3.5 Page: 3-3-05 Engine: S/BVM 628 Tightening Procedure Proceed by applying lube oil or other compound 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).
Section: 3.5 Page: 3-3-06 Engine: 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.
Specification Data 3.6 Designation Section: 3.
Section: 3.6 Page: 3-4-02 Engine: S/BVM 628 Designation Description Specification Data Application Condition Use Remarks Equivalent Product Lubricating Compounds: Deutz S1 Heatresistant Deutz S2 Special compound Deutz S4 Molybdic sulfide Prevention of thread seizure (e.g. exhaust system) „Never Seez“ from P.H.
Specification Data 3.7 Section: 3.7 Page: 3-5-01 Engine: S/BVM 628 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.
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Specification Data 3.8 Section: 3.8 Page: 3-6-01 Engine: S/BVM 628 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.
Section: 3.8 Page: 3-6-02 Engine: S/BVM 628 Specification Data 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 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 4
4 Operating the Engine 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
Operating the Engine 4.1 Section: 4 Page: 4-0-01 Engine: S/BVM 628 Preparations for Operating the Engine on Distillate Fuel (see also sections 7, 8.2, 8.
Section: 4 Page: 4-0-02 Engine: S/BVM 628 Item Job 6 Fuel system Operating the Engine A Reference ● 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 ● ● Drain fuel service tank ● ● ● ● ● ● ● Bleed fuel system Job 07.03.
Operating the Engine Item Job 8 Cooling water system Section: 4 Page: 4-0-03 Engine: S/BVM 628 A Treat water with additives B C ● ● Open valves in all water pipework and check for correct valve pos. Pneumatic system © 0585 Engine protective system ● ● Standby sets: Check that preheating temperature (if provided) ● ● ● Clean separate raw water filter (if provided) ● ● ● Check that master and starting valves move freely ● ● Job 01.11.01 Job 10.03.
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Operating the Engine 4.1.1 Section: 4 Page: 4-0-05 Engine: S/BVM 628 Preparation for Operating the Engine on blended Fuel (heavy Fuel) (see also sections 7, 8.2, 8.3 and "Summarized Instructions" hereto).
Section: 4 Page: 4-0-06 Engine: S/BVM 628 Item Job 6 Fuel system Operating the Engine A B Lube oil system Reference ● Clean fuel service tank 7 C Top up fuel service tank ● ● Clean fuel filter ● ● Job 07.10.01 Test fuel injectors ● ● Job 07.08.
Operating the Engine Item Job 8 Cooling water system Section: 4 Page: 4-0-07 Engine: S/BVM 628 A B Reference ● Top up water level Check water level in header tank C ● ● ● Bleed water system if necessary ● ● Treat water with additives ● ● Clean separate raw water filter (if provided) Section 6.
Section: 4 Page: 4-0-08 Engine: S/BVM 628 Item Job 10 Engine protective system Operating the Engine A B C Separate pumps: check pressures / temperatures in operating media (fuel etc.
Operating the Engine 4.2 Section: 4 Page: 4-1-01 Engine: S/BVM 628 Running the Engine on Distillate Fuel Item Procedure A B C 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.
Section: 4 Page: 4-1-02 Engine: S/BVM 628 Item Procedure 12 Run in engine 13 Once working temperature is reached, put engine on load Operating the Engine A B C ● ● ● Reference Section 4.6 ● Acceptance documents On stationary engines use start and stop button respectively for items 5 and 7.
Operating the Engine 4.2.1 Section: 4 Page: 4-1-03 Engine: S/BVM 628 Running the Engine on Blended Fuel (Heavy Fuel) Item Procedure A B C 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.
Section: 4 Page: 4-1-04 Engine: S/BVM 628 Operating the Engine Item Procedure 11 Run in engine 12 Switch off coolant preheater (upon attaining appropriate temperature) ● ● ● 13 Switch off separate preheated filter ● ● ● 14 Switch off injector preheater (if provided). ● ● ● Once working temperature is reached, put the engine on load ● ● ● 15 A B C ● Reference Section 4.6 Section 3.3.2 Section 3.3.
Operating the Engine 4.3 Section: 4 Page: 4-2-01 Engine: S/BVM 628 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 1 General Reference (Section 8.
Section: 4 Page: 4-2-02 Engine: S/BVM 628 Operating the Engine Item Daily Check and Servicing Jobs 3 Pressures Reference (section 8.
Operating the Engine Item Daily Checks and Servicing Jobs 8 Cooling system Check coolant level in hydraulic governor 9 Pneumatic system Charge air receivers and drain condensate after cool-down © 0285 Section: 4 Page: 4-2-03 Engine: S/BVM 628 Acceptance documents Drain condensate from dust collector 10.03.02 Drain condensate from pressure reducer station 10.06.
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Operating the Engine 4.4 Section: 4 Page: 4-3-01 Engine: S/BVM 628 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 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.
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Operating the Engine Section: 4 Page: 4-3-03 Engine: S/BVM 628 4.4.
Section: 4 Page: 4-3-04 Engine: 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.
Operating the Engine 4.5 Section: 4 Page: 4-4-01 Engine: S/BVM 628 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.
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Operating the Engine 4.6 Section: 4 Page: 4-5-01 Engine: S/BVM 628 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.
Section: 4 Page: 4-5-02 Engine: S/BVM 628 4.6.2 Operating the Engine 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.
Operating the Engine 4.7 Section: 4 Page: 4-6-01 Engine: S/BVM 628 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.).
Section: Page: Engine: This page intentionally left blank Operating the Engine
Operating the Engine Section: 4 Page: 4-7-01 Engine: S/BVM 628 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.
Section: 4 Page: 4-7-02 Engine: S/BV 6/8/9 M 628 4.8.1.2 Operating the Engine 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.
Engine Operating Media 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 5
5 Engine Operating Media 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 Media Systems Section: 5 Page: 5-0-01 Engine: S/BVM 628 5 Engine Media Systems 5.1 Fuel System 5.1.1 5.1.2 5.1.3 Legend for Piping Diagrams Piping Diagram for Distillate Fuel and MDF Blend Piping Diagram for Heavy Fuel 5.2 Lubricating Oil System 5.2.1 5.2.2 5.2.3 5.2.4 Legend for Piping Diagrams Deep ("Wet") Sump High-Level Tank ("Dry Sump") Low-Level Tank ("Dry Sump") 5.3 Cooling Water System 5.3.1 5.3.2 5.3.3 5.3.
Section: Page: Engine Media Systems Engine: This page intentionally left blank © 1185
Section: Engine Media Systems 5.
Section: 5 Page: 5-1-02 Engine: S/BVM 628 Engine Media Systems 5.1 Fuel System 5.1.1 Legend for Piping Diagrams 5.1.1.1 Engine Components F 16.2 Piping panel for pressure monitoring *) K 1 Fuel transfer pump K 9 Fuel feed pump *) K 10 Microfilter K 11 Injection pumps *) K 37 Flow switch for shielded injection lines 5.1.1.
Section: Engine Media Systems Page: Engine: 5.1.2 Piping Diagram for Distillate Fuel 5.1.2.
Section: Page: Engine: 5 5-1-04 Engine Media Systems S/BV 6/8/9 M 628 5.1.2 Piping Diagram for Distillate Fuel 5.1.2.
Section: Engine Media Systems Page: Engine: 5.1.3 Piping Diagram for Blended Fuel (Heavy Fuel) 5.1.3.
Section: Page: Engine: 5 5-1-06 Engine Media Systems S/BV 6/8/9 M 628 5.1.3 Piping Diagram for Blended Fuel (Heavy Fuel) 5.1.3.
Engine Media Systems 5.
Section: 5 Page: 5-2-02 Engine: S/BVM 628 Engine Media Systems 5.2 Lubricating Oil System 5.2.1 Legend for Piping Diagrams 5.2.1.1 Engine Components F 16.2 Piping panel for pressure monitoring S 2 Suction pump S 4 Delivery pump S 7 Oil cooler S 8 Edge filter S 22 Oil centrifuge S 33 Microfilter in full flow S 35 Pressure monitor S 37 Thermometer S 40 Temperature monitor S 57 Level sensor S 62 Check valve S 63 Oil distributor *) 5.2.1.
Engine Media Systems 5.2.2 Oil Sump Lubrication 5.2.2.
Section: 5 Page: 5-2-04 Engine: S/BVM 628 Engine Media Systems This page intentionally left blank ©␣ 0883
Engine Media Systems 5.2.2 Oil Sump Lubrication 5.2.2.1 Built-on Oil Cooler Section: 5 Page: 5-2-05 Engine: S/BVM 628 5.2.2.1.
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Engine Media Systems 5.2.2 Oil Sump Lubrication 5.2.2.1 Separate Oil Cooler Section: 5 Page: 5-2-07 Engine: S/BVM 628 5.2.2.1.
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Engine Media Systems 5.2.3 High-Level Tank ("Dry Sump") 5.2.3.
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Engine Media Systems 5.2.3 High-Level Tank ("Dry Sump") 5.2.3.1 Built-on Oil Cooler Section: 5 Page: 5-2-11 Engine: S/BVM 628 5.2.3.1.
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Engine Media Systems 5.2.4 Low-Level Tank ("Dry Sump") 5.2.4.
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Engine Media Systems 5.2.4 Low-Level Tank ("Dry Sump") 5.2.4.1 Built-on Oil Cooler Section: 5 Page: 5-2-15 Engine: S/BVM 628 5.2.4.1.
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Engine Media Systems 5.2.4 Low-Level Tank ("Dry Sump") 5.2.4.2 Separate Oil Cooler Section: 5 Page: 5-2-17 Engine: S/BVM 628 5.2.4.2.
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Engine Media Systems 5.
Section: 5 Page: 5-3-02 Engine: S/BVM 628 Engine Media Systems 5.3 Cooling Water System 5.3.1 Legend for Piping Diagrams 5.3.1.1 Engine Components A 4 Turbocharger F. 16.2 Piping panel for pressure monitoring L 2 Charge air cooler R 5 Raw water pump S 7 Oil cooler U 1 Water collecting pipe U 2 Water pump U 6 Water distributing pipe U 9 Pressure gauge U 15 Temperature monitor U 16 Bleeder (automatic) U 22 Pressure monitor U 34 CHeck valve U 43 Thermometer *) 5.3.1.
Engine Media Systems 5.3.2 Single-Circuit Cooling System 5.3.2.1 Built-On Oil Cooler before Single-Stage Air Cooler Section: 5 Page: 5-3-03 Engine: S/BV 6/8/9 M 628 5.3.2.1.
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Engine Media Systems 5.3.2 Single-Circuit Cooling System 5.3.2.1 Built-On Oil Cooler before Single-Stage Charge Air Cooler Section: 5 Page: 5-3-05 Engine: S/BV 6/8/9 M 628 5.3.2.1.
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Engine Media Systems 5.3.3 Single-Circuit Cooling System 5.3.3.1 Built-On Oil Cooler before Single-Stage Charge Air Cooler Section: 5 Page: 5-3-07 Engine: S/BV 6/8/9 M 628 5.3.3.1.
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Engine Media Systems 5.3.3 Double-Circuit Cooling System 5.3.3.1 Built-On Oil Cooler before Single-Stage Charge Air Cooler Section: 5 Page: 5-3-09 Engine: S/BV 6/8/9 M 628 5.3.3.1.
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Engine Media Systems Section: 5 Page: 5-3-11 Engine: S/BV 6/8/9 M 628 5.3.3 Double-Circuit Cooling System 5.3.3.2 Built-On Oil Cooler behind Two-Stage Charge Air Cooler, with Disconnection of L.T. Circuit 5.3.3.2.1 Two Built-On Coolant Pumps © 51 384 0 * © 0686 On SBVM only H 222 resp. H 237 On BVM optionally H 222 resp.
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Engine Media Systems Section: 5 Page: 5-3-13 Engine: S/BV 6/8/9 M 628 5.3.3 Double-Circuit Cooling System 5.3.3.2 Built-On Oil Cooler behind Two-Stage Charge Air Cooler, with Disconnection of L.T. Circuit 5.3.3.2.1 Separate Coolant Pumps © 51 385 0 * © 0686 On SBVM only H 222 resp. H 237 On BVM optionally H 222 resp.
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Engine Media Systems Section: 5 Page: 5-3-15 Engine: S/BV 6/8/9 M 628 5.3.4 Double-Circuit Cooling System 5.3.4.1 Two-Stage Charge Air Cooler, without Disconnection of L.T. Circuit, Separate Oil Cooler 5.3.4.1.1 Two Built-On Coolant Pumps © 51 386 0 * © 0686 On SBVM only H 222 resp. H 237 On BVM optionally H 222 resp.
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Engine Media Systems Section: 5 Page: 5-3-17 Engine: S/BV 6/8/9 M 628 5.3.4 Triple-Circuit Cooling System 5.3.4.1 Two-Stage Charge Air Cooler, without Disconnection of L.T. Circuit, Separate Oil Cooler 5.3.4.1.2 Separate Coolant Pumps © 51 387 0 * © 0686 On SBVM only H 222 resp. H 237 On BVM optionally H 222 resp.
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Engine Media Systems Section: 5 Page: 5-3-19 Engine: S/BV 6/8/9 M 628 5.3.4 Triple-Circuit Cooling System 5.3.4.2 Two-Stage Charge Air Cooler, without Disconnection of L.T. Circuit, Separate Oil Cooler 5.3.4.2.1 Two Built-On Coolant Pumps © 51 388 0 * © 0686 On SBVM only H 222 resp. H 237 On BVM optionally H 222 resp.
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Engine Media Systems Section: 5 Page: 5-3-21 Engine: S/BV 6/8/9 M 628 5.3.4 Triple-Circuit Cooling System 5.3.4.2 Two-Stage Charge Air Cooler, without Disconnection of L.T. Circuit, Separate Oil Cooler 5.3.4.2.2 Separate Coolant Pumps © 51 389 0 * © 0686 On SBVM only H 222 resp. H 237 On BVM optionally H 222 resp.
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Engine Media Systems 5.
Section: 5 Page: 5-4-02 Engine: S/BVM 628 5.4 Pneumatic System 5.4.1 Legend for Piping Diagrams 5.4.1.1 Engine Components D 6 Starting air master valve D 8 Starting pilot air distributor D 54 Quick-release valve F 1 Engine control unit F 5 Governor F 16.1 Piping panel for pneumatic system F 16.2 Piping panel for pressure monitoring F 34 Booster S 56 Crankcase oil mist detector K 11 Injection pump *) 5.4.1.
Engine Media Systems 5.4 Pneumatic System 5.4.
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Engine Media Systems 5.
Section: 5 Page: 5-5-02 Engine: S/BVM 628 5.5 Sealing-Oil System 5.5.1 Legend for Piping Diagrams 5.5.1.1 Engine mounted components F K S S S 5.5.1.2 16.
Engine Media Systems 5.5 Sealing-Oil System 5.5.2 Fuel Conveyer Pump mounted on the Engine Section: 5 Page: 5-5-03 Engine: S/BV 6/8/9 M 628 © 51 391 0 5.5.
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Engine Media Systems 5.
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Engine Media Systems 5.
Section: 5 Page: 5-6-04 Engine: S/BV 6/8/9 M 628 This page intentionally left blank Engine Media Systems
Engine Media Systems Section: 5 Page: 5-7-01 Engine: S/BV M 628 5.7 Symbols Used in Piping Diagrams (Definitions to DIN 30600) 5.7.1 Piping Item . DIN No. Ser. No. Description Symbol 30600 No. Remarks 1.01 2481 4.01 Principal Media Cooling water, lube oil, fuel oil, compressed air 1.02 2481 4.01 Direction of flow Arrow above or incorporated 1.03 2481 4.01 Raw water 2481 Control line 1.04 1.05 1.06 1.07 1.08 1.09 Insulated pipe 1.10 1.11 2481 4.25 2429 1.
Section: 5 Page: 5-7-02 Engine: S/BVM 628 Item DIN No. Ser. No. Description Engine Media Systems Symbol 30600 No. Remarks 1.13 1.14 1.15 2429 4.1.1.5 Flexible joint Hose 1.16 2481 4.32 DRain tundish 582 1.17 2481 4.36 Pipe cross section reduction / expansion piece 580 1.18 2481 Outlet to atmosphere Rain cap 583 1.19 5.7.2 Shut-off Fittings 2.01 2481 5.05 Shut-off valve through-way valve 588 2 . 02 2481 5.07 Angle valve 590 2 . 03 2481 Three-way valve 591 2.
Engine Media Systems Description S ymbol Section: 5 Page: 5-7-03 Engine: S/BVM 628 Item DIN No. Ser. No. 30600 No. 2.07 2481 Angled non-return valve 605 2.08 2481 Pressure reducing through-way valve 594 5.17 2.09 2481 Angled pressure reducing valve 595 2.10 2481 5.15 Floating-ball valve 578 2.11 2481 Gate valve 586 2.12 2481 5.25 Through-way 599 2.13 2481 5.26 Angled cock 600 2.14 2481 Three-way change-over cock 601 2.15 2418 Four-way change-over cock 602 2.
Section: 5 Page: 5-7-04 Engine: S/BVM 628 Description Engine Media Systems Item DIN No. Ser. No. Symbol 2.19 2481 5.31 2.20 2429 3.2.2.1 2.21 2481 5.34 Drive by hand 2.22 2481 5.36 Drive by solenoid 2.23 2481 5.36 Drive by motor 2.24 2481 5.37 Drive by f luid e.g. hydraulic or pneumatic 2.25 2481 5.40 Drive by weight Quick.closing valve 2.26 2481 5.42 Relief valve spring-loaded Angular design 2.02 2.28 2481 5.
Engine Media Systems Description 5 Page: 5-7-05 Engine: S/BVM 628 Item DIN No. Ser. No. 2.31 2481 5.65 Flow limiter using restrictor plate (single orifice) 612 2.32 2481 5.67 Flow inspection 611 2.34 24300 page 3 2.3 5.7.3 Accessories Symbol Section: 30600 No. Remarks Two-way valve 3.01 2481 5.72 Silencer 615 3.02 2481 5.79 2429 5.2 Condensate trap 629 3.03 2421 5.1 Separator 3.04 2429 5.3 Strainer 3. 05 2429 Filter, single- element 3.06 Filter, twin-element 3.
Section: 5 Page: 5-7-06 Engine: S/BVM 628 Item DIN No. Ser. No. Description 3.09 Breather valve 3.10 Preheater for engine coolant Engine Media Systems Symbol 30600 No. Remarks Energy also 9.05 M 3.11 Preheater for engine coolant and lube oil I: engine coolant II: lube oil A I M I Energy also 9.05 B II C A : from oil reservoir B : to engine C : to oil reservoir M II 3.12 Viscometer B A : heavy oil inlet B : heavy oil outlet T M Energy also 9.05 A B 3.
Engine Media Systems Item DIN No. Ser. No. Description Symbol Section: 5 Page: 5-7-07 Engine: S/BVM 628 30600 No. Remarks 3.18 3.19 3.20 3.21 5.7.4 4.01 5.7.5 Heavy Exchangers 2481 Surface heat exchanger with media crossing Containers 5.01 2431 10.02 Tank 5.02 2481 10.
Section: 5 Page: 5-7-08 Engine: S/BVM 628 Item DIN No. Ser. No. Description Engine Media Systems Symbol 30600 No. Remarks 732 A = charging pipe B = discharging pipe E =drain e.g. turbo charger 5.03 5.04 43609 3.2.2.2 Air receiver with valve head B A E 5.7.6 Machinery 5.7.6.1 Driving Machines 6.01 2481 11.01 Turbine 632 6.02 2481 11.11 Diesel engine 633 6 . 03 2481 11.14 Electric motor M 635 6.04 6.05 5.7.6.2 Driven Machines 6.06 2481 11.47 Electric generator 6.
Engine Media Systems Item DIN No. Ser. No. 6. 09 2481 6.10 Description Gear-type pump Symbol Section: 5 Page: 5-7-09 Engine: S/BVM 628 30600 No. Remarks 702 Hand-operated pump 6.11 2481 11.33 Rotary compressor 715 e.g. fan 6.12 2481 11.34 Reciprocating compressor 716 e.g. compressor 6.13 2481 11.37 Turbo compressor 724 e.g. turbocharger 6.14 6.15 6.16 5.7.7 Water Heat Exchangers 7.01 2481 14.01 7.02 7.03 7.
Section: 5 Page: 5-7-10 Engine: S/BVM 628 Item DIN No. Ser. No. Description Engine Media Systems Symbol 30600 No. Remarks Gauge Gauge shown alternately with or w/o circle 5.7.8 Measuring and Control 8.01 2481 15.01 Flow 687 Code letter F 8.02 2481 Level 776 Code letter L 8.03 2481 15.04 Pressure 681 Code letter P 8.04 2481 15.03 Temperature 688 Code letter T 8.05 Service gauge 8.06 8.07 Thermostat (flow divider) B A : from engine B : to pump C : to cooler C A 8.
Engine Media Systems Page: 5-7-11 Engine: S/BVM 628 DIN No. Ser. No. 9.02 2481 16.02 Pneumatic energy 274 9.03 2481 16.06 Electric energy 278 9.04 2481 16.07 Hydraulic energy 279 9.05 2431 16.03 Heat energy 275 9.06 2481 16.04 Stream energy 276 9.08 Symbol 5 Item 9.07 Description Section: 30600 No.
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Engine Operating Media Treatment 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 6
6 Engine Operating Media Treatment 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
Operating Media 6 Section: 6 Page: 6-0-1 Engine: S/BVM 628 Operating Media For information on the operating media used in your engine please refer to our technical circulars which are consistently kept up-to-date. Technical circulars currently in force are the following : 6.1 TR 0199-99-2082 concerning lube oils for ABB turbochargers 6.2 TR 0199-2090 concerning motor oils 6.3 TR 0199-2089 concerning fuels 6.4 TR 0199-2091 concerning cooling water 6.
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Operating Media 6.1 6.1 Page: 6-1-01 Engine: S/BVM 628 Instructions for use of lube oils for ABB turbocharger see TR 0199-99-2082 enclosed.
Section: 6.
Operating Media 6.2 Instructions for Use of Motor Oils see TR 0199-2090 enclosed © 1199 Section: 6.
Section: 6.
Operating Media 6.3 Instructions for Use of Fuels see TR 0199-2089 enclosed. © 0690 Section: 6.
Section: 6.
Operating Media 6.4 Instructions for Colling Water see TR 0199-2091 enclosed © 0691 Section: 6.
Section: 6.
Operating Media 6.5 Instructions for Engine Preservation see TR 0199-99-2116 enclosed. © 1199 Section: 6.
Section: 6.
Trouble-shooting 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 7
7 Trouble-shooting 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
Trouble-shooting 7 Trouble-shooting 7.
Section: 7 Page: 7-0-02 Engine: S/BVM 628 7.2 Trouble-shooting General Should trouble arise during engine starting or running, be sure to stop the engine immediately and to restart the engine only after the fault has been remedied. The following trouble chart is not exclusive. When opening crankcase, be sure to observe safety precautions (job 02.00.01). 7.
Trouble-shooting Trouble Engine fails to fire or stalls 7 Page: 7-0-03 Engine: S/BVM 628 Potential cause Remedy Section / Job Card Oil pressure switch defective or out of adjustment, so slenoid valve preventing engine start Adjust switch or replace 11.01.02 Safety feature in starting air pipe defective Recondition safety device 01.12.01 No fuel supply Open fuel cock, switch on fuel feed pump and fill up service tank. If necessary, clean piping and filter and bleed. 07.10.01 07.03.
Section: 7 Page: 7-0-04 Engine: S/BVM 628 Trouble Trouble-shooting Potential Cause Remedy Section / Job Card Free the fuel low pressure system, the injection pumps, piping and valves. Section 6.3 Insufficient engine fluid Switch on the coolant pre-heating device to preheat. Section 4.1.1 Faulty injection pump operation Check injection pump, replace defective pump element, if necessary. 01.07.01 07.02.01 Test injectors Engine fails to develop full power 07.08.
Trouble-shooting Trouble Engine knocks © 1283 Section: 7 Page: 7-0-05 Engine: S/BVM 628 Potential Cause Remedy Section / Job Card Fuel feed pump defective Replace pump 07.11.01 Low charge air pressure Clean pressure charger, air cleaner and cooler; eliminate air and exhaust gas losses 06.12.01 06.03.11 06.04.02 Air in injection system Bleed system 07.03.
Section: 7 Page: 7-0-06 Engine: S/BVM 628 Trouble Power / speed falling off Sluggish governor action Trouble-shooting Potential Cause Remedy Section / Job Card Engine overloaded Reduce load Faulty injector operation Test injectors 07.08.01 Low charge air pressure Clean pressure charger, air cleaner and cooler; eliminate air and exhaust gas losses 06.12.01 06.03.11 06.04.02 Turbocharger defective Overhaul charger 06.06.01 Foundation bolts loose Tighten bolts 03.07.
Trouble-shooting Section: 7 Page: 7-0-07 Engine: S/BVM 628 Trouble Potential Cause Remedy Section / Job Card Excessive engine speed Governor linkage binding or maladjusted Free linkage or readjust 05.04.14 07.01.01 Control lever unable to stop engine Injection pump on/off control maladjusted or worn Stop fuel supply and hence engine, and readjust on/off control 05.00.01 Deficient oil pressure Low oil level in tank Top up oil 08.02.
Section: 7 Page: 7-0-08 Engine: S/BVM 628 Trouble-shooting Trouble Potential Cause Remedy Heavy emission of oil mist from crankcase Piston rings seized or defective. Combustion gas is penetrating the crankcase and then visibly emerging at the crank chamber exhaust.
Trouble-shooting Section: 7 Page: 7-0-09 Engine: S/BVM 628 Trouble Potential Cause Remedy Section / Job Card High charge air pressure Charge air cooler dirty Clean cooler 06.04.02 High intake air temperature Reduce load (over 45°C temperature rise = 2% reduction in power). Raw water flow insufficient Check flow; clean filter, if necessary.
Section: 7 Page: 7-0-10 Engine: S/BVM 628 Trouble-shooting The following table specifies the possible causes and remedies for three operating troubles - black, blue and white exhaust. Trouble Potential Cause Remedy Section / Job Card Poor Combustion: Black Exhaust Incomplete Combustion Inspect injectors 07.08.01 Low charge air pressure Clean intake air cleaner, turbocharger, charge air cooler. Check air piping gaskets,replace if necessary 06.03.11 06.12.01 06.04.
Trouble-shooting Section: 7 Page: 7-0-11 Engine: S/BVM 628 Trouble Potential Cause Remedy Section / Job Card B. Blue Exhaust (lube oil in exhaust) Oil control rings sticking or worn Renew rings 02.10.01 Feed from oil reservoir insufficient Check oil level Heavy liner scoring Service liners 03.02.01 Fuel fails to fire Check heavy fuel temperature and injection timing Section 6.3 Injectors defective Recondition injectors 07.08.
Section: 7 Page: 7-0-12 Engine: S/BVM 628 Trouble Trouble-shooting Potential Cause Remedy No propulsion air Check air supply Open cover of measuring unit, e.g. due to cleaning Close cover Dirty air cleaner Clean or replace Detector leaky Inspect cover gaskets between measuring unit and mounting plate as well as bellows Section / Job Card 11.05.
Maintenance Schedules and List of Job Cards 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 8
8 Maintenance Schedules and List of Job Cards 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
Maintenance Schedules and Job Cards Section: 8 Page: 8-0-01 Engine: S/BVM 628 8 Maintenance Schedules, List of Job Cards and Job Cards 8.1 Summary of Maintenance Schedules All fittings, shutoff and control devices of the operating media piping systems as well as of the compressed air piping system not listed in these schedules shall be maintained according to manufacturer’s specifications. 8.1.1 8.1.1.1 8.1.1.2 Initial maintenance jobs - Engines running in continuous operation, e.g.
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Maintenance Schedules Section: 8 Page: 8-1-01 Engine: S/BVM 628 8.1.1 Initial Maitenance Jobs Job ... RH after commissioning 8.1.1.1 Engines running in continuous operation, e.g. marine engines, > 300 hours / year Job Card No.
Section: 8 Page: 8-1-02 Engine: S/BVM 628 Job.. RH after commisioning 8.1.1.2 Maintenance Schedules Engines running in continuous operation, e.g. marine engines, > 300 hours / year Job Card No.
Maintenance Schedule Section: 8 Page: 8-1-03 Engine: S/BVM 628 8.1.2 Daily maintenance jobs, see Section 4.3 8.1.3 Periodic maintenance jobs for engines running in continuous operation, e.g. marine engines > 300 hours / year. All fittings, shutoff and control devices of operating media systems as well as of compressed air piping system shall be maintained according to manufacturer’s specifications. Ser. No. Periodic Maintenance Jobs Job Card No.
Section: 8 Page: 8-1-04 Engine: S/BVM 628 Ser No. Periodic Maintenance Jobs 6 7 8 9 10 11 Maintenance Schedule Job Card No. See Footnotes Interval: every 3000 engine running hours Jobs as under ser. Nos. 1 to 5 Inspecting combustion chamber Servicing cylinder head Checking crankweb deflection / gauging axial clearance Inspecting foundation bolts Changing oil of hydr.
Maintenance Schedule Ser.. No. Periodic Maintenance Jobs 12 Interval: every 15000 engine running hours Jobs as under ser. Nos. 1 to 6 Inspecting main bearing Inspection of injection pump at DEUTZ SERVICE Replacing viscous-type torsional vibration damper 13 Interval: every 18000 engine running hours Jobs as under ser. Nos. 1 to 8 and 10 Inspecting main bearing Inspection of injection pump at DEUTZ SERVICE 14 Interval: every 24000 engine running hours Jobs as under ser. Nos.
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Maintenance Schedules Section: 8 Page: 8-1-07 Engine: S/BVM 628 8.1.4 Periodic maintenance jobs for engines running < 300 hours / year, which are exclusively or for the greater part of time in standby mode (DEUTZ minimum requirement). In addition, there exist numerous national and international standards which may also be applied if they do not restrict the specifications given here.
Section: 8 Page: 8-1-08 Engine: S/BVM 628 Maintenance Schedules Ser. No.: Interval: Job: 5 Interval: every year Jobs as under ser. Nos. 1 to 4 Checking: Inlet and exhaust valve clearances Inspecting: Inner crankcase Inspecting: Engine mounting (foundation) Inspecting: Control governor control linkage x1 Cleaning: Air cleaner (w.
Maintenance Schedules Ser. No.: Interval: Job: 8 Interval: Inspecting: Servicing: Section: 8 Page: 8-1-09 Engine: S/BVM 628 Engine ready for operation ? after 7 - 8 years Main bearings (2 pcs) Visual inspection of cams and rollers Visual inspection of gear train Turbocharger Replacing temperature monitors Replacing thermocouples (exhaust pyrometer unit) Renew flexible lines, -compensators, rubber tubes no Job Card or Section No.: 02.04.01 04.02.01 04.08.01 06.06.01 11.01.01 11.01.
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List of Job Cards 8.2 Section: 8 Page: 8-2-01 Engine: S/BVM 628 List of Job Cards The Job Cards cover the following work: Inspection Assy. Group Job Card No. Servicing Job (see also Maintenance Schedule here to for) Repairing Mounting © 0185 01.00.00 CYLINDER HEAD 11 01.01.01 Inlet / Exhaust Valve Clearance Checking 11 01.02.02 Rocker Arm Removal / Refitment 11 01.02.03 Rocker Arm Bearing Inspection/Repairing ● 08 01.03.01 Valve Rotator / Inspecting ● 08 01.03.
Section: 8 Page: 8-2-02 Engine: S/BVM 628 Assy. Group Job Card No. List of Job Cards Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting 02.00.00 CRANKSHAFT SYSTEM 05 02.00.01 Crankshaft System Precautions 05 02.01.01 Crankshaft System Inspection ● 05 02.02.01 Crankweb Deflection Gauging ● 06 02.03.02 Bearing Shell Spread Gauging ● 06 02.03.03 Bearing Clearance Gauging ● 06 02.04.
List of Job Cards Assy. Group Job Card No. Section: 8 Page: 8-2-03 Engine: S/BVM 628 Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting © 0983 03.00.00 ENGINE FRAME 01 03.01.01 Crankcase Relief Valve Inspection/Servicing 04 03.02.01 Cylinder Liner Servicing ● 04 03.02.03 Cylinder Liner Servicing/Reconditioning ● 04 03.03.01 Cylinder Liner Inspection/Gauging 04 03.04.01 Cylinder Liner Removal ● 04 03.
Section: 8 Page: 8-2-04 Engine: S/BVM 628 Assy. Group Job Card No. List of Job Cards Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting 05.00.00 SPEED CONTROL SYSTEM 27 05.00.01 Speed Control System Safety Precautions 27 05.03.11 Hydraulic Governor Servicing (Oil Change) 27 05.03.12 Hydraulic Governor Setting 27 05.03.13 Electr. Governor Speed Pick-up Rem./Ref. 27 05.03.14 Hydr. and electr. Governor Serv.
List of Job Cards Assy. Group Job Card No. Section: 8 Page: 8-2-05 Engine: S/BVM 628 Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting © 0885 06.00.00 EXHAUST / TURBOCHARGING SYSTEM 41 06.01.01 Exhaust Manifold Inspection ● 41 06.01.03 Exhaust Elbow ● 87 06.02.01 Charge Air System Inspection ● 87 06.03.11 Intake Air Cleaner Servicing 58 06.04.02 Charge Air Cooler Water Side Servicing 58 06.04.
Section: 8 Page: 8-2-06 Engine: S/BVM 628 Assy. Group Job Card No. List of Job Cards Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting 07.00.00 FUEL SYSTEM 17 07.00.01 Instructions - Fuel System 17 07.01.01 Inj. Pump Element Locking Contr. Rod Insp. 17 07.02.01 Injection Pump Element Removal/Refitment 17 07.02.02 Idle Stroke Setting 17 07.02.03 Injection Pump Control Rod Rem./Refitm. 17 07.02.
List of Job Cards Assy Group Job Card No. Section: 8 Page: 8-2-07 Engine: S/BVM 628 Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting 08.00.00 LUBRICATING OIL SYSTEM 16 08.00.01 Instructions - lubricating oil System 15 08.01.01 Oil Sampling ● 15 08.02.01 Oil System Inspection ● 15 08.02.02 Oil Change ● 14 08.04.01 Oil Pump Servicing ● 15 08.09.01 Oil Edge Filter Servicing/Reconditioning ● 15 08.
Section: 8 Page: 8-2-08 Engine: S/BVM 628 Assy. Group Job Card No. List of Job Cards Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting 09.00.00 COOLING WATER SYSTEM 37 09.00.00 Cooling Water System Draining 37 09.07.01 Coolant Circulation Pump Water and Oil Seals 37 9.07.02 Coolant Circulation Pump 10.00.00 PNEUMATIC SYSTEM 32 10.01.01 Pneumatic System 30 10.02.
List of Job Cards Assy. Group Job Card No. Section: 8 Page: 8-2-09 Engine: S/BVM 628 Job The Job Cards cover the (see also Maintenance Schedule heretofore) following work: Inspection Servicing Repairing Mounting © 1087 11.00.00 ENGINE PROTECTIVE SYSTEM 48 11.01.01 Temperature Switches (Oil, Water, Air) ● 48 11.01.02 Pressure Switches (Oil, Water, Air) ● 48 11.01.03 Flow Switch ● 48 11.01.04 Rem./Refitm. Exhaust Gas Thermocouples 48 11.01.05 Exhaust Gas Thermocouples ● 48 11.
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Job Cards Arbeitskarten Schede di lavoro Cartes de travail Fichas de trabajo Werkkaarten PабоЧие ка ты JC AK SL CT FT WK AK
JC Job Cards AK SL CT FT WK AK Arbeitskarten Schede di lavoro Cartes de travail Fichas de trabajo Werkkaarten PабоЧие ка ты
Job Card No.: 01.01.01 Valve Clearance Checking Engine: Filing No.: S/BVM 628 0178-11-10 1065 Checking Tools: Check inlet and exhaust valve clearance and adjust as necessary. Inspect upper valve drive. - Standard tools, Feeler gauge Excessive clearance causes the valves to open jerkily, so the cams may be damaged; insufficient clearance results in failure of the valves to close completely, so they will be destroyed by the gases streaming out. Job: Open indicator valves of all cylinders.
Job Card No.: Valve Clearance Checking Engine: Filing No.
Job Card No.: Rocker Arm Removal / Refitment 01.02.02 Engine: Filing No.: S/BVM 628 0178-11-10 1066 Job: Job Cards: Observe safety precautions. Open indicator valves. Turn camshaft so in tappet roller of the lower valve drive rests on the cam base circle and the rocker arm is unloaded. Unscrew bolts (5) to remove cover (1). - Removing: Exhaust Rocker with Fulcrum Unscrew bolts (2) with washers (14) and raise rocker (3) with fulcrum (4). Withdraw fulcrum from rocker. - 01.01.01 02.00.
Job Card No.: Rocker Arm Removal / Refitment Engine: Filing No..: This page intentionally left blank.
Job Card No.: Rocker Arm Inspection / Reconditioning 01.02.03 Engine: S/BVM 628 0178-11-10 1067 Filing No.: Inspection Tools: Check running clearance and replace bushes if required. - Standard tools, Feeler gauge (or caliper gauge), Brass arbor Job Card: Job: Remove arm (Job 01.02.02). Clean all components. Check radial clearance between bush (2) and fulcrum (3) by feeler gauge. Note that the bush bottom zone will present most wear. Note that the bush bottom zone will present the most wear.
Job Card No.: Rocker Arm Inspection / Reconditioning Engine: Filing No.
Job Card No.: Valve Rotator Inspection 01.03.01 Engine: Filing No.: 0178-11-10 1797 S/BVM 628 Inspection Tools: Every 250 hours check while engine is running that exhaust valves rotators move freely. - Standard tools, Lamp, Clock Job: Unscrew plug (1) and O-seal (2) from rocker chamber cover (3). Check with lamp that rotator (4) moves freely: at 700/min engine speed check time needed for a full revolution by watching cam (5).
Job Card No.: Valve Rotator Inspection Engine: Filing No.
Job Card No.: Valve Rotator Reconditioning 01.03.02 Engine: Filing No.: S/BVM 628 0178-08-10 1382 Reconditioning Job Cards: If, upon inspection of valve rotator (Job 01.03.01), the rotator is found to be malfunctioning, renew same. - 01.01.01 01.02.02 01.03.01 01.05.05 Tools: - Standard tools Job: Remove rocker arm (Job Card 01.02.02) and replace rotator (Job Card 01.05.05). Refitment is made in the reverse order. Check valve clearance (Job Card 01.01.01).
Job Card No.: Valve Rotator Reconditioning Engine: Filing No.
Job Card No.: Cylinder Head Removal 01.04.01 Page 1 of 3 Engine: Filing No.: 0178-08-10 1798 S/BV 6/8/9M 628 Job Cards: - 01.08.01 01.09.01 02.00.01 02.16.02 09.00.01 Tools: - Standard tools, Puller screw, Hydraulic tool for annular nuts (Section 1.8), Head removing device (Section 1.8) , Wooden support © 51 394 0 Fig. 1 Job: Observe safety precautions (Job Card 02.00.01). Drain cooling water. Remove rocker chamber cover (4) - fig 1 - and turn engine so that inlet and exhaust valves are closed.
Job Card No.: 01.04.01 Cylinder Head Removal Page 2 of 3 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-08-10 1798 Releasing Annular Nut (15) - Fig. 4 Assemble hydraulic tool (10) with hoses and pump and fill with hydraulic oil. Clean thread of stud (14) with gas oil acc. to Job Card 02.16.02. Screw stud (12) in place. Position bushes (11) (two pairs - fig. 5) with yoke (7) and tool (19). Make sure that no bush is in contact with an adjacent cylinder. Fit washers (9) and screw together with hex.
Job Card No.: Cylinder Head Removal 01.04.01 Page 3 of 3 Engine: Filing No.: 0178-08-10 1798 S/BV 6/8/9 M 628 To avoid jamming *) - fig 4 - of nut (15) by stud (12), be sure not to screw nut (15) against the stud. Unload pressure and disconnect hose. Unscrew hex. nuts (8) and remove tools (10) with bushes (11). Unscrew stud (12) and annular nuts (15). Unscrew hexagon nuts (8) and remove tools (10) with bushes (11). Unscrew stud (12) and annular nuts (15).
Job Card No.: Cylinder Head Removal Engine: Filing No.
Job Card No.: Inlet Valve Removal / Refitment Filing No.: 01.05.01 Engine: 0178-08-10 1580 S/BVM 628 Job Cards: - 01.01.01 01.04.01 01.05.05 01.07.01 Tools: - Standard toolsi, Valve removing / refitting device (Section 1.8) Job: Removing the Valve After removing the cylinder head (see Job Card 01.05.01), remove clamping cone (7) by using removing device (see Job Card 01.05.05). Take down spring cap (6), springs (4) and (5), and spring cap (9). Withdraw valve downwards. Renew O-seal (10).
Job Card No.: Inlet Valve Removal / Refitment Engine: Filing No.
Job Card No.: Exhaust Valve Removal / Refitment 01.05.01 Engine: Filing No.: S/BVM 628 0178-08-10 2067 Job Cards: - 01.01.01 01.04.01 01.05.05 01.07.01 Tools: - Standard tools Valve removing / refitting device (Section 1.8) Job: Removing the Valve After removing the cylinder head (see job 01.05.01), remove clamping cone (7) by using removing device (see job card 01.05.05). Take down rotor (2), compression springs (4) and (5), and spring cap (3). Withdraw exhaust valve downwards. Renew O-seal (10).
Job Card No.: Exhaust Valve Removal / Refitment Engine: Filing No.
Job Card No.: Inlet and Exhaust Valves Inspection (by Endoscope) 01.05.04 Page1 of 2 Engine: Filing No.: S/BVM 628 0178-08-10 1660 Inspection Job Card: The use of an endoscope enables both valves (plus cylinder wall) to be inspected without removing the head. - The endoscope with transformer for 110/220 volts a.c., as well as the valve pliers, can be obtained from the Deutz head office. 07. 07.
Job Card No.: 01.05.04 Inlet and Exhaust Valves Inspection (by Endoscope) Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-08-10 1660 Inspecting the Valves Turn endoscope until valve seat is in full view. Location of stem (6), seat (7) and plate (8): see "X". (Note that endoscope view appears as mirrored image and upside down). Vary light intensity with the regulator on the transformer as required. If you are irritated by a dazzling effect, adjust endoscope level.
Job Card No.: Valve Spring Removal / Refitment 01.05.05 Engine: Filing No.: S/BVM 628 0178-08-10 1073 When working on cylinder head in fitted condition, the piston must be in TDC. Job Card: - 01.05.01 Tools: - Valve removing device Job: Removing the Springs Push up sleeve (4) and spread with suitable screwdriver. Place removing device on spring cap and let both dogs engage in groove of valve stem. Press sleeve down until removing device is safely secured to valve stem.
Job Card No.: Valve Spring Removal / Refitment Engine: Filing No.
Job Card No.: Valve Guide Clearance Checking / Reconditioning 01.06.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-08-10 1799 Checking Job Cards: When reconditioning valves (Job Card 01.07.01), check the valve stem guide clearance. - 01.05.01 01.07.01 Tools: - Standard tools, Caliper gauge, Brass arbor Job: Pull valve out of guide bush (1) / (2). Clean both. Measure bore of guide bushes (1) and (2) within a range of up to about 10 mm from the bottom end.
Job Card No.: 01.06.01 Valve Guide Clearance Checking / Reconditioning Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-08-10 1799 Refitment of guides is done after undercooling (shrinking) in liquid nitrogen (boiling temperature: -195,8°C) down to between -170°C and -195°C. To ensure that the guides are cooled deep into their cores, check that the nitrogen has stopped boiling (see also Section 3.7). Make also sure that all shrink-fit surfaces are perfectly clean (metallically bright).
Job Card No.: Valve Seat Ring and Valve Cone 01.07.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-08-297 6506 Checking and Reconditioning Inlet and Exhaust Valve Cones and Valve Seat Rings Before re-using the valves, these are to be checked and reconditioned, if necessary, as described in the following: Faulty condition of the engine, inadequate preheating and treatment of fuel and cooling water, and non-permissible lugging operation (speed drop with control lever at fuel stop), etc.
Job Card No.: 01.07.01 Valve Seat Ring and Valve Cone Page 2 of 2 Engine: S/BVM 628 0178-08-297 6506 Filing No.: 245 Exhaust valve 205 Inlet valve 285 Exhaust valve 215 Inlet valve befor reworking © 50 659 0 - in the areas X and Y no interruption of the (shiny) chrome layer - between the zones X and Y (Fig on Page 2) - no corrosion pittings deeper than 0,2 mm, - stem diameter at no point < 15,5 mm. Out-of truth (deviation) of the cleaned disc edge relative to stem not exceeding 0,2 mm.
Job Card No.: Cylinder Head 01.08.01 Engine: Filing No.: S/BVM 628 0178-08-10 1982 Servicing Job Cards: The cylinder servicing intervals may differ very considerably since they are governed by engine application and load, as well as by fuel and lube oil qualities. To arrive at a rational servicing interval, we suggest that the following method be adopted. - 01.04.01 01.05.04 01.09.01 Inspection When using an endoscope all cylinder heads are to be inspected as per Job Card 01.05.04.
Job Card No.: Cylinder Head Engine: Filing No.
Job Card No.: Cylinder Head Refitment 01.09.01 Page 1 of 3 Engine: Filing No.: S/BV 6/8/9 M 628 0178-08-10 1801 Cylinder Head Refitment Job Cards: - 01.01.01 02.16.02 06.02.01 Tools: - Standard tools hoist puller screws special tools (Section 1.8), - Hyrdaulic clamping tool - Cylinder head lifting device Spare Parts: - 0-seals for plug-in pieces Cylinder head gasket if necessary Job: Preparation ● Clean all joint faces thoroughly.
Job Card No.: 01.09.01 Cylinder Head Refitment Page 2 of 3 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-08-10 1801 Tightening Annular Nuts (Fig. 3) Apply oil to studs (14). Check that annular nuts (15) turn easily over the entire stud length. Screw nuts in place and tighten by hand. Check by feeler gauge that nuts are squarely seated. Fit hydraulic tool and pump as in job card 01.04.01 (Releasing Nuts) and build up pressure (Section 3.5, item 1).
Job Card No.: Cylinder Head Refitment 01.09.01 Page 3 of 3 Engine: Filing No.: 0178-08-10 1801 S/BV 6/8/9 M 628 Fit puller screw (19) in exhaust manifold (20) - Fig. 5 - and press off manifold from head until gasket (21) can be fitted in the gap. Screw in two bolts (22), so gasket cannot fall out. Unscrew bolts (19) and securely tighten remaining bolts (22). Connect air and fuel piping. Set valve clearance (Job Card 01.01.01). Bring indicator cock in normal position and tighten bolts.
Job Card No.: Cylinder Head Refitment Engine: Filing No.
Job Card No.: Starting Valve Inspection 01.11.01 Engine: Filing No.: 0178-31-10 1606 S/BVM 628 Inspection Check valve for free movement and freedom from leaks. Job Cards: - 01.11.02 02.00.01 Tools: - Standard tools If the starting air pipe gets hot at the cylinder head when the engine is running, this suggeststhat the associated starting valve is leaky. Job: Observe safety precautions (job 02.00.01). Checking Valve Stem and Guide Piston from Free Movement Unscrew banjo bolt (58) - Fig.
Job Card No.: Starting Valve Inspection Engine: Filing No.
GEREKİRSE OKU Starting Valve Servicing Job Card No.: 01.11.02 Page 1 of 2 Engine: Filing No.: 0178-31-10 1869 S/BVM 628 Servicing When servicing the cylinder head (Job Card 01.08.01) , the starting valve is also due for removal and servicing. Job Card: - 01.04.01 Tools: - Valve seat miller (Section 1.8.1), Socket spanner (Section1.8.), Standard tools, Grinding-in paste Job: Place cylinder head on a wooden support. Unscrew hex. bolt (10) - Fig. 1 - with lockwasher (11), and remove cover (8).
Job Card No.: 01.11.02 Starting Valve Servicing Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-31-10 1869 Installation of the starting valve in the cylinder head is carried out in reverse order. Renew 0-ring (9) and, if necessary, packing rings (4). Tighten hex. nut (6) with socket spanner, while holding the starting valve (1) with a screwdriver in the slot of the valve disc. Counterlock hex. nut (7) with socket and hex. nut (6) by means of the socket spanner. Mount circlip (12).
Safety Valve Servicing Job Card No.: 01.12.01 Engine: Filing No.: 0178-31-10 1080 S/BVM 628 Servicing When servicing the cylinder head or when a safety valve has become leaky, remove valve, dismantle and, if necessary, regrind. Tools: - Standard tools, Fine grinding compound Aid: - Asbestos cord, Deutz S1 compound (Section 3.6), Never try to remove a leak by increasing zhe valve spring loading. Job: © 51 246 0 GEREKİRSE OKU Stop engine.
Job Card No.: Safety Valve Servicing Engine: Filing No.
Job Card No.: Valve Seat Ring Removal / Refitment 01.13.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-08-10 1854 In accordance with the engine equipment specificatio - depending on the type of fuel stated when the engine is ordered - the cylinder heads can be provided with cooled or uncooled exhaust valve-seat rings. Inlet valve-seat rings are always uncooled. Job Cards: - 01.05.01 01.07.01 Tools: - Standard tools, Puller tool for fitting and removing valve-seat rings (Section1.8).
Job Card No.: 01.13.01 Valve Seat Ring Removal / Refitment Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-08-10 1854 Removing the Cooled Valve-Seat Ring - Fig . 2 Place puller bush (5) through the exhaust passage onto the valve-seat ring. From the combustion chamber side, screw hex. bolt (4), together with washer (2), bearing (3) and puller support (1), into the puller bush. Pull out the valve-seat ring by tightening the hex. bolt. Clean receiving bore in the cylinder head without damaging it.
Valve Seat Ring Removal / Refitment Job Card No.: 01.13.01 Page 3 of 3 Engine: Filing No.: 0178-08-10 1854 Fitting the Cooled Valve-Seat Ring - fig. 4 Apply Deutz DW 57 to the entire seat ring receiving bore in cylinder head and to sealing surfaces of the valve-seat ring. Check that coolant passage between cylinder head and valve-seat ring is not blokked. Push seat ring into cylinder head. Mount threaded spindle (1), together with hex. nut (6), washer (5), bearing (4) and bush (3).
Job Card No.: Valve Seat Ring Removal / Refitment Engine: Filing No.
Crankshaft System Overhaul Safety Precautions Job Card No.: 02.00.01 Engine: Filing No.: 0178-01-10 1081 S/BVM 628 Prior to Work ● ● ● ● ● Stop engine. Close shut-off valve on air receivers. Bleed air piping to engine. Open indicator valves. Wait 10 minutes before removing crankcase doors and some further minutes, allowing crankcase oil mist to dissipate, before starting work. Remove cover (3) along with oil dipstick (1) and guide tube (2).
Job Card No.: Crankshaft System Overhaul Safety Precautions Engine: Filing No.
Job Card No.: Crankshaft System Inspection 02.01.01 Engine: Filing No.: S/BVM 628 0178-05-10 1082 Inspection Job Cards: Inspect system at regular intervals. - Job: 02.00.01 02.15.01 04.02.01 Observe safety precautions (Job Card 02.00.01). Tools: Open indicator valves. 10 minutes after stopping of engine and interruption of oil circulation remove crankcase doors. Touch main and big-end bearings with your hands and check that they have abn even temperature. - Tuning bar (Section. 1.
Job Card No.: Crankshaft System Inspection Engine: Filing No.
Job Card No.: Crankweb Deflection Gauging 02.02.01 Page 1 of 3 Engine: Filing No.: S/BV 6/8/9 M 628 03120364-0178 Inspection Job Card: - In addition to regular gaugings, check deflection whenever this seems necessary. 02.00.
Job Card No.: 02.02.01 Crankweb Deflection Gauging Page 2 of 3 Engine: S/BV 6/8/9 M 628 Filing No.: 03120364-0178 Job: Introduce gauge into marks punched into webs (not beween balance weights) and rotate several times in this position. Set gauge to 25/100 of scale in measuring positions (1) or (2). Meßstellungen Measuring positions When using a mirror, check readings especially carefully. For taking readings, turn crankshaft counterclockwise, without touching the gauge.
Job Card No.: Crankweb Deflection Gauging 02.02.01 Page 3 of 3 Engine: S/BV 6/8/9 M 628 03120364-0178 Filing No.: Typical Gauging Sheet Engine Model: Engine Serial No.: Engine hot Engine stopped for Engine preheated Measuring position hours °C Water temp Crankpin position °C Cyl. temp. Reading in Throw of Cylinder No.: Line A/B 1 1 Lowest 2 First auxiliary 3 First horizontal 4 Highest 5 Second horizontal 6 Second auxiliary Vertical deflection ( ∆ „a“) Pos. 1 min. 4 or Pos.
Job Card No.: Crankweb Deflection Gauging Engine: Filing No.
Job Card No.: Bearing Shell Spread Gauging 02.03.02 Engine: Filing No.: S/BV M 628 0178-06-10 1603 Gauging Main and big-end bearing shells to be fitted must have sufficient positive spread, so they will have preload in their receiving bores. Tools: - Caliper gauge All new shells have apositive spread unless they have been improperly handled, for instance in transit. İLGİNÇ BİR BİLGİ...
Job Card No.: Bearing Shell Spread Gauging Engine: Filing No.
Job Card No.: Bearing Clearance Gauging 02.03.03 Engine: S/BVM 628 0178-06-10 1085 Filing No.: Gauging Tools: Check running clearance in all cases of doubt. - Normally, the running clearance need not be checked, since only new and genuine Deutz bearings may be fitted in new bores and the bolts tightened according to specification. Dial gauge with magnetic support, Feeler gauge, Square timber of about 2000 mm length Job Card: - 02.00.
Job Card No.: Bearing Clearance Gauging Engine: Filing No.
Job Card No.: Bearing Shell Inspection 02.04.01 Engine: Filing No.: 0178-01-10 1852 S/BVM 628 Inspection Job Cards: Inspection of big-end bearings is required whenever removing pistons. If the wear pattern is unsatisfactory of if deep scoring and/or embedments of foreign particles are discovered. - Inspect one main bearing also, in accordance with the Maintenance Schedule, and, if in bad shape, the rest als. The first bearing to be inspected should be the central one. 02.03.02 02.03.03 02.05.
Job Card No.: Bearing Shell Inspection Engine: Filing No.
Job Card No.: Big-end Bearing Removal 02.05.01 Engine: Filing No.: S/BVM 628 0178-06-10 1087 Job Cards: - 02.00.01 02.06.01 Tools: - Standard tools, Possibly square timber, Socket spanner (Section 1.8) Job: Bearing Removal with Piston Removal Observe Safety Precautions given on Job Card 02.00.01. On S/BV12/16M 628 engines use a ben tsokket spanner to loosen the big-end bolts on cylinder A1.
Job Card No.: Big-end Bearing Removal Engine: Filing No.
Job Card No.: Big-end Bearing Refitment 02.06.01 Page 1 of 2 Engine: Filing No.: S/BV 6/8/9 M 628 0178-06-10 1088 Inspect shells for wear pattern and renew, if required (job 02.04.01). Used shells, caps and bolts must always be refitted in their original location. Shells, caps, connecting rods and pistons carry mating Nos. (cylinder No.). Inspect condition of crankpin. It should not be out-of-round for more than 0,1 mm. Job Cards: - 02.03.03 02.14.01 02.15.
Job Card No.: 02.06.01 Big-end Bearing Refitment Page 2 of 2 Engine: S/BV 6/8/9 M 628 0178-06-10 1088 Filing No.: Bearing Refitment with the Piston not Removed In the case of piston and big-end bearing not being removed, lift and support big-end bearing with square timber, insert bearing shell (1) as described under "Bearing Refitment with Piston Removed", and slowly turn crankpin into head. Remove square timber. Clean cap (5) and shell (4) and apply oil to shell inside.
Job Card No.: Main Bearing Removal 02.07.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-01-10 1836 To begin with, make sure that cylinder No. markings are provided on bearing cap fronts and face the engine's driving end. Provide marks if missing.. Remove only every second bearing at a time, to prevent crankshaft sagging. Support flywheel when removing the bearing next to it. Job Cards: - 02.00.01 02.16.02 02.04.01 Tools: - Standard tools, Driving pin (Section 1.8), Hydr.
Job Card No.: 02.07.01 Main Bearing Removal Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-01-10 1836 Back bolt (10) through one turn. Connect hydr. pump with hoses and operate pump to obtain the pressure specified (Section 3.5, item 2). Introduce pin (13) Fig. 3 - through aperture in bush (8). If annular nut (4) still resists turning, slowly raise oil pressure (10 to 20 bar). Check by mirror when pumping that the marking groove (Fig. 2) i n the piston will not project beyond the cylinder.
Job Card No.: Main Bearing Removal 02.07.01 Page 3 of 3 Engine: Filing No.: 0178-01-10 1836 S/BVM 628 Removing the Shells Take out lower bearing shell and make sure that its lug is provided with a marking on the back. NIf upper shell (14) cannot be pushed out by hand, insert driver pin (15) into oil passage 'X' of crankshaft (1) and carefully turn crankshaft in the arrowed direction (Fig. 5) until the flat of pin (15) contacts the joint of upper shell (14).
Job Card No.: Main Bearing Removal Engine: Filing No.
Job Card No.: Main Bearing Refitment 02.08.01 Page 1 of 3 Engine: Filing No.: 0178-01-10 1837 S/BVM 628 Job Cards: - 02.03.02 02.03.03 Tools: - Standard tools, Driving pin (Section 1.8), Hydr. tool assembly (Section 1.8), H.P. pump with pressure gauge (Section 1.8), H.P. hoses and distributor (Section 1.8), Lever (Section 1.8), Deutz S2 compound (Section 3.6) Inspect bearing shells and renew as necessary (job 02.04.01). Used shells must be refitted in their original location.
Job Card No.: 02.08.01 Main Bearing Refitment Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-01-10 1837 Slowly turn crankshaft as arrowed until top shell (14) - Fig. 1 - is equidistant from cap joints. Be sure not to damage the shell lug. Remove driving pin (15) - Fig 2 - and put bottom shell (5) - Fig. 1 - (mark facing driving end) into cap (17). Apply motor oil to threads of studs (2), and check that nuts (4) turn easily over the entire thread length.
Job Card No.: Main Bearing Refitment 02.08.01 Page 3 of 3 Engine: Filing No.: S/BVM 628 0178-01-10 1837 Where studs (2) must be renewed, apply Deutz DW 60 compound to length of threads of new studs, screw into crankcase as far as they will go and tighten through 130 Nm (13 kpm). Refit oil sump (if removed) after application of Deutz DW 48 compound as a continuous "bead" (Fig. 5) of 2 - 3 mm width (not more) on the joint face. Bead © 51 263 0 Fig.
Job Card No.: Main Bearing Refitment Engine: Filing No.
Job Card No.: Piston Removal 02.09.01 Engine: Filing No.: 0178-06-10 1091 S/BVM 628 Job Cards: - 01.04.01 02.05.01 03.02.01 Tools: - Standard tools Piston removing / refitting device (Section 1.8) 2 liner retainers (Section 1.8), Tap M 10 Hoist Job: Remove cylinder head (job 01.04.01) and big-end bearing cap (Job Card 02.05.01). Place both liner retainers (7) - Fig. 1 - on two opposite studs and tighten annular nut (6) moderately. Firmly screw thrust pad (11) on liner.
Job Card No.: Piston Removal Engine: Filing No.
Job Card No.: Piston 02.10.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-07-297 5843 Inspection Tools: - The piston servicing intervals with regard to "Scheduled Maintenance" are very different, depending on engine application and loading. The following procedure has been established so that efficient servicing intervals can be determined. Job: Standard tools Job Cards: - 01.05.04 01.08.01 02.04.01 02.09.01 02.10.02 02.10.04 02.12.01 03.02.01 06.02.
Job Card No.: 02.10.01 Piston Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-07-297 5843 Servicing: Tools: - Piston ring pliers (Section 1.8) All rings of adrawn piston must be renewed. Only in exceptional cases and after thorough inspection piston rings having run less than 1000 hours may be refitted. Aid: - Ground piston ring (100 mm long) Fine emery cloth, No. 250 Carborundum Spare parts: - Set of piston ring Job Card: - 02.10.02 Job: ● Remove piston rings with piston ring pliers (1).
Job Card No.: Piston 02.10.01 Page 3 of 3 Engine: Filing No.: S/BVM 628 0178-07-297 5843 Ring Pack 1. Rectangular ring 2. Taper-faced compression ring 3. Bevelled-edge oil control ring After removal of piston control big-end bearingr, see Job Card 02.04.01. © 51 265 0 Fig.
Job Card No.: Piston Engine: Filing No.
Piston ring grooves Job Card No.: 02.10.02 Engine: Filing No.: 0178-07-10 1093 S/BVM 628 Checking Piston Ring Grooves Following each piston removal renew piston rings and gauge axial clearance "S" between new piston ring and bottom flank or ring groove at 8 points offset by 45°, Fig. 1. Tools: - Feeler gauge Job Cards: - 02.10.01 02.11.01 © 50 618 1 Fig. 1 Measuring points for gauging axial clearances Job: ● Fit new piston rings as per job 02.10.01.
Job Card No.: Piston ring grooves Engine: Filing No.
Job Card No.: Piston 02.10.04 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-07-297 5844 Reconditioning Job Cards: Normally, dismantling of the piston is not necessary. If, however, dismantling is indispensable because of the gauging results, this work may only be carried out by DEUTZ AG or an authorzed workshop. - 03.20.02 02.10.02 Auxiliaries: - Job: Lubricant DEUTZ S2 (Section 3.6) Tools: Removal ● Inspect piston as per Job Card 02.10.01. ● Inspect piston rings grooves as per Job Card 02.
Job Card No.: 02.10.04 Piston Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-07-297 5844 ● Screw nuts (4) onto studs (6). - Tighten nuts crosswise with 35 Nm. Release nuts. STighten nuts crosswise with 15 Nm. Tighten nuts further through 60° - 90°. Check: - Tighten nuts with 35 Nm, while doing this the nuts must not continue to turn. Otherwise determine and remedy cause; contact surfaces may be dirty or damaged, etc. © 50 627 0 Fig.
Piston Ring Grooves Job Card No.: 02.11.01 Engine: Filing No.: 0178-07-297 5838 S/BVM 628 Reconditioning If it becomes obvious during an inspection of the piston ring grooves that the piston needs to be reconditioned, this can only be done by chromium-plating carried out by DEUTZ AG or by an authorized workshop.
Job Card No.: Piston Ring Grooves Engine: Filing No.
Piston Pin Removal / Refitment Job Card No.: 02.12.01 Engine: Filing No.: 0178-07-10 1656 S/BVM 628 Job Cards: - 02.09.01 02.13.01 02.14.01 Tools: - Circlip pliers Hoist Remove piston (job 02.09.01). Before removing piston pin, check that respective cylinder No. is marked at piston, shank, and big-end bearing cap (points I, II, and III in adjacent Fig.). Provide marks, if missing. Following pin removal, gauge small-end bush and pin (job 02.13.01).
Job Card No.: Piston Pin Removal / Refitment Engine: Filing No.
Piston Pin, Piston Pin Bush, Piston Pin Bore Gauging / Reconditioning Job Card No.: 02.13.01 Page 1 of 2 Engine: S/BVM 628 0178-07-10 1096 Filing No.: Gauging Tools: Measure the bearing clearance. - Job: Remove pin (job 02.12.01). Put rod (3) upright. Introduce cleaned pin (1) into cleaned bush until pin projection "a" is equal at both bush ends. Feeler gauge, Inside micrometer, Outside micrometer, Removing/Refitting device for big-end bush (Section 1.8.
Job Card No.: 02.13.01 Piston Pin, Piston Pin Bush, Piston Pin Bore Gauging / Reconditioning Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-07-10 1096 Remove rings from piston (job 02.10.01). Install piston (job 02.14.01), however, without piston rings. Introduce a feeler gauge between piston and liner and check that clearance endwise and crosswise to the engine are identical. If there is no equal clearance or if the unparallelism exceeds the specification, replace rod.
Job Card No.: Piston Refitment 02.14.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-07-10 1339 To begin with check, maintain and measure rings as under Job Cards 02.10.01 and 02.10.02. Inspect liner (Job Card 03.02.01). Matching of rings to grooves: see Job Card 02.10.01. If piston/rod assembly was dismantled, see Job Card 02.12.01. Job Cards: - 01.09.01 02.06.01 02.10.01 02.10.02 02.12.01 02.15.01 03.02.01 Tools: - Suspension device (Section 1.8), Ring compressor (Section 1.
Job Card No.: 02.14.01 Piston Refitment Page 1 of 2 Engine: S/BVM 628 Filing No.: This page intentionally left blank.
Job Card No.: Piston Coolant Nozzle Inspection 02.15.01 Engine: Filing No.: S/BVM 628 0178-16-10 1980 Inspection To ensure proper piston cooling, check that the coolant jet centrally enters the inlet hole of the piston. Make sure, therefore, the coolant nozzle is properly located. Tools: - Pocket lamp, Mirror (Section 1.8), Check pin (Section 1.8), Aligning tool (Section 1.8). Job: Inspecting the Check Pin Make sure the bottom end of pin (2) is free from defects and the whole pin is straight.
Job Card No.: Piston Coolant Nozzle Inspection Engine: Filing No.
Job Card No.: Hydraulic Tool for Annular Nuts Servicing 02.16.02 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-49-10 1100 Servicing Job Cards: (Filling and Bleeding) - Although satisfactory operation of this equipment requires complete freedom from air in piping etc., specific bleeding is normally not required since the automatic couplings keep oil in and air out. 1 2 3 4 5 6 Pump Oil reservoir Filler plug Hand lever Retaining spring Hand wheel for shut-off valve 7 8 9 10 11 12 01.04.01 01.
Job Card No.: 02.16.02 Hydraulic Tool for Annular Nuts Servicing Page 2 of 3 Engine: S/BVM 628 0178-49-10 1100 Filing No.: Design and Function Pump (1) builds up oil pressure which reaches rams (11) through hoses (8). Overpressure is avoided by a relief valve. Gauge (7) is used for setting the oil pressure required for the spec ific screwed joint. Hand wheel (6) is turned to let off pressure afterwards. Safety hose couplings (10) and (12) are used in combination with H.P.
Hydraulic Tool for Annular Nuts Servicing Job Card No.: 02.16.02 Page 3 of 3 Engine: Filing No.: 0178-49-10 1100 S/BVM 628 If trouble arises, for instance with the build-up or drop of hydraulic pressure, proceed as follows: with pump (1) in vertical position (hose connection down), work lever (4) quickly up and down, while opening and closing shut-off wheel (6). Inspect ball valve in the support of gauge (7) and, if necessary, recondition.
Job Card No.: Hydraulic Tool for Annular Nuts Servicing Engine: Filing No.
Job Card No.: Flexible Coupling (Vulkan-type with Flange) 02.17.01 Page 1 of 2 Engine: Coupling size: S/BV 6/8/9 M 628 0178-52-10 1608 Filing No.: EZ 121 S / EZ 135 S EZ 142 S / EZ 166 S Tools: - The coupling can be radially removed without affecting engine and driven machine. Standard tools, Hoist, Puller bolts. Job: Removing the Coupling Attach coupling to hoist. Mark flanged jacket (4) Fig. 1 - relative to flywheel (6), and coupling flange (9) relative to flanged hub (10). Slacken hex.
Job Card No.: 02.17.01 Flexible Coupling (Vulkan-type with Flange) Page 2 of 2 Engine: S/BV 6/8/9 M 628 Filing No.: Refitting and Coupling Refitment is done in reverse order: after installing the coupling, restore connection between flywheel (6) and jacket (4). Tighten bolts (7) as specified (Section 3.5, Item 42 for couplings EZ 121 S / EZ 135 S, and Item 43 for couplings EZ 142 S / EZ 166 S). Finally, attach flange (9) - Fig. 2 - to hub (10) and secure external element fastenings. © 51 275 0 Fig.
Job Card No.: Flexible Coupling (Vulkan-type w/o Flange) 02.17.01 Engine: Filing No.: Coupling Size: S/BVM 628 0178-52-10 1610 EZ 121 S, EZ 135 S, EZ 142 S, EZ 166 S, EZ 171 S, EZ 195 S, EZ 201 S Tools: - Standard tools, Puller bolts. Elements can be radially removed without affecting engine and driven machine. Job: Replacing Elements Release hex.
Job Card No.: Flexible Coupling (Vulkan-type w/o Flange) Engine: Filing No.
Job Card No.: Crankcase Relief Valve 03.01.01 Engine: Filing No.: S/BVM 628 0178-01-10 1101 Inspection Tools: Inspect gaskets of crankcase doors and test relief valves. - Standard tools Following removal of doors (1) with valves (4) inspect liner seals between water jackets and crankcase interior. Prime lubricating circuit and check that all bearings are supplied with oil. Clean oil sump from any sludge. Job: Unscrew hex. bolts (3) and remove door (1) with relief valve (4).
Job Card No.: Crankcase Relief Valve Engine: Filing No.
Job Card No.: Cylinder Liner Servicing 03.02.01 Engine: Filing No.: S/BVM 628 0178-04-10 1102 Servicing Job Cards: At every piston inspection, check also liner running surface and cylinder head gsket seat. - Renew heavily scored liners. Remove any slight scores or high spots with emery cloth. Remove any shoulder marks. The nitrided cylinder liners need not to be extra re-roughened. 02.09.01 03.03.01 03.06.
Job Card No.: Cylinder Liner Servicing Engine: Filing No.
Job Card No.: Cylinder Liner 03.02.03 Engine: Filing No.: S/BVM 628 0178-04-10 1853 Servicing Job Cards: Remove all cylinder liners, check and recondition or renew as necessary. - Any necessary reconditioning of the cylinder liners and possibly of the crankcase must be carried out by DEUTZ Service. 03.02.01 03.03.01 03.04.01 03.05.01 03.06.01 09.00.01 Tools: - Standard tools Job: ● Drain off cooling water (Job Card 09.00.01). ● Remove cylinder liner (Job Card 03.04.01) and clean.
Job Card No.: Cylinder Liner Engine: Filing No.
Job Card No.: Cylinder Liner 03.03.01 Engine: S/BVM 628 0178-04-10 2068 Filing No.: Inspection / Gauging Check (TDC) piston reversing mark. If it exceeds some 0,2 mm, gauge liner. Following installation of a new liner, a check for roundness will be sufficient. Tools: - Stadia (fabricated locally), Block gauge To begin with, carefully clean liner and stadia and cover up the crankcase interior below the liner. Job: Set micrometer to nominal liner diameter. Suspend stadia (1) in liner (2).
Job Card No.: Cylinder Liner Engine: Filing No.
Job Card No.: Cylinder lining Removal 03.04.01 Engine: Filing No.: S/BVM 628 0178-04-10 1104 Cylinder lining removal Job Cards: Remove the cylinder lining once the max. admissible degree of wear or required repair has been reached. - Prior to removing the cylinder lining, take the standard measurement See job card 03.03.01 01.04.01 03.02.01 03.03.01 09.00.01 Tools: - Removal and refitment tool (section 1.8).
Job Card No.: Cylinder lining Removal Engine: Filing No.
Job Card No.: Cylinder liner Refitment 03.05.01 Engine: Filing No.: S/BV 6/8/9 M 628 0178-04-10 1105 Gauge new liner after installation max. ovality 0,15 mm. When refitting used liners, inspect reversing marks of upper piston rings (see job 03.02.01). Job Cards: - 03.02.01 03.03.01 03.06.01 Tools: - Standard tools, Lubrificant Deutz F5 (Section 3.6), Liner removing / refitting device (Section 1.
Job Card No.: Cylinder liner Refitment Engine: Filing No.
Honing Cylinder Liner Job Card No.: 03.06.01 Engine: Filing No.: 0178-04-10 2063 S/BVM 628 Honing Cylinder Liner A liner must be honed, - upon installation of new piston rings or new piston, - if running surface has become partially or totally bright, i.e. honing grooves are no longer visible, - if grooves are too deep. The honing may only be carried out by DEUTZ AG workshops which are especially equipped to do that job.
Job Card No.: Honing Cylinder Liner Engine: Filing No.
Job Card No. Foundation Bolts Inspection 03.07.01 0178-46-10 1173 S/BVM 628 Engine: Filing No.: Inspection Job Card: - The effects of heat and internal stressing may effect the foundation, so make sure that engine foundation bolts are tight (even where piping renders the access difficult). 02.02.01 Tools: - Standard tools Inspection is especially important during the initial 50 running hours of the engine.
Job Card No.: Foundation Bolts Inspection Engine: Filing No.
Job Card No.: Crankshaft System - Reconditioning of Resiliently Mounted Engines 03.08.01 Engine: Filing No.: S/BVM 628 0178-46-10 1604 Reconditioning Tools: Resiliently mounted engines call for the least possible imbalance of the crankshaft system. - When disassembling the crankshaft system of resilienly mounted engines, make sure that pistons, connecting rods and bearings are marked with the relevant cylinder No.
Job Card No.: Crankshaft System - Reconditioning of Resiliently Mounted Engines Engine: Filing No.
Job Card No.: Camshaft Bearings 04.01.01 Page 1 of 2 Engine: 0178-10-10 1824 Filing No.: S/BVM 628 Inspection / Gauging Job Cards: Measure clearance of accessible bearings. If wear is discovered, examine other bearings also. To do this, remove injection pumps (Job Card 07.04.01). - 02.00.01 04.05.01 04.06.01 07.04.01 Tools: Replacement of bearing bushes requires camshaft removal (Job Card 04.05.01).
Job Card No.: 04.01.01 Camshaft Bearings Page 2 of 2 Engine: S/BVM 628 0178-10-10 1824 Filing No.: Oil bores must coincide ! Detail „X“ © 51 279 0 Detail "X" Install camshaft (Job Card 04.06.01). Refit cover (1), tightening as per Section 3.5, item 28. Finally, mount injection pump (Job Card 07.04.01).
Job Card No.: Lower Valve Drive 04.02.01 Page 1 of 3 Engine: Filing No.: 0178-11-10 1346 Inspection S/BVM 628 Job Cards: - Inspect accessible tappet rollers and cams. If wear is found, inspect other tappet rollers and cams. To do this, remove injection pumps (Job Card 07.04.01 ). 01.04.01 01.09.01 07.04.01 Tools: - Job: Remove accessible covers (10) - Fig. 1 -. Turn engine and check for perfect running of the rollers and that the cams have a perfectly smooth surface.
Job Card No.: 04.02.01 Lower Valve Drive Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-11-10 1346 turned by 90° © 50 116 1 Fig. 2 Job: Removing the Drive Remove cylinder head (Job Card 01.04.01). Take out pushrods (25) - Fig. 2 - and remove bolts (16) together with spring lock-washers (17). Raise tappet guide (30) by means of a screwdriver inserted into the pocket provided in the flange of the tappet guide. Remove washer and compression spring (if provided).
Lower Valve Drive Job Card No.: 04.02.01 Page 3 of 3 Engine: Filing No.: 0178-11-10 1346 S/BVM 628 Removing Tappet Roller After removing the complete tappet (29), the roller can be removed. The best way to do this is to use a prism, on which the tappet is placed to press out the roller pin (32) - Fig. 3 -. If no prism is to hand, the tappet can be placed on a hard-wood block (33) or on an aluminium plate provided with a suitable large hole for free passage of the roller pin when being pressed out.
Job Card No.: Lower Valve Drive Engine: Filing No.
Job Card No.: Lower Valve Drive 04.02.01 Page 1 of 3 Engine: Filing No.: 0178-11-10 1992 Inspection S/BVM 628 Job Cards: - Inspect accessible tappet rollers and cams. If wear is found, inspect the other tappet rollers and cams. To do this, remove injection pumps (job 07.04.01). 01.04.01 01.09.01 07.04.01 Tools: - Standard tools Lamp Prism Hard-wood block or aluminium plate Job Remove accessible covers (10) - Fig. 1 -.
Job Card No.: 04.02.01 Lower Valve Drive Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-11-10 1992 turned by 90° © 50 040 1 Fig. 2 Job: Removing the Drive Remove cylinder head (Job Card 01.04.01). Take out pushrods (25) - Fig. 2 - and remove bolts (16) together with spring lock-washers (17). Raise tappet guide (30) by means of a screwdriver inserted into the pocket provided in the flange of the tappet guide. Remove circlip (23).
Lower Valve Drive Job Card No.: 04.02.01 Page 3 of 3 Engine: Filing No.: 0178-11-10 1992 S/BVM 628 Removing Tappet Roller After removing the complete tappet (29), the roller can be removed. The best way to do this is to use a prism, on which the tappet is placed to press out the roller pin (32) - Fig. 3 -. If no prism is to hand, the tappet can be placed on a hard-wood block (33) or on an aluminium plate provided with a suitable large hole for free passage of the roller pin when being pressed out.
Job Card No.: Lower Valve Drive Engine: Filing No.
Job Card No.: Timing Gear Train Removal / Refitment 04.04.01 Page 1 of 4 Engine: Filing No.: 0178-09-10 1601 Observe safety precautions (see job 05.00.01). Do not allow any components to fall into the crankcase. S/BV 6/8/9 M 628 Tools: - Standard tools, Removing device for pivot pins (42), (44) and (14), Deutz DW 60 compound (see section 3.6). Job Cards: Job: Remove covers (24), (30) and (36). - 04.05.01, 04.06.01, 04.06.02, 04.08.01, 05.00.01, 07.04.01, 07.06.01, 10.02.
Job Card No.: 04.04.01 Timing Gear Train Removal / Refitment Page 2 of 4 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-09-10 1601 Removing Idler Gear (26) Turn flywheel until its aperture coincides with bolt (39). Unscrew bolts (41) and take down retainer plate (40). Unscrew bolt (39). Using removing device (see section 1.8). Withdraw fulcrum (42) from the centering, while retaining gear (26) and was her (45). Then withdraw fulcrum (42) completely. Remove gear (26) and washer (45) sideways.
Timing Gear Train Removal / Refitment Job Card No.: 04.04.01 Page 3 of 4 Engine: Filing No.: 0178-09-10 1601 S/BV 6/8/9 M 628 Removing Injection Pump Drive Gear (8) Remove oil pump with cover and piping (job 07.06.01). Remove screws (9). While retaining gear (8), pull out part (10). Take out gear sideways. Clean all components. Inspect gear (8) for wear and bearing bush for score marks. Removing Camshaft Gear (5). Take off cover (104) and gasket (52). For further procedure, see job 04.05.01.
Job Card No.: 04.04.01 Timing Gear Train Removal / Refitment Page 4 of 4 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-09-10 1601 Refitting Idler Gear (35) - Fig. 3 Turn flywheel until its aperture coincides with bearing hole in timing chest. Apply thin film of oil to fulcrum (44) and bearing bush in gear (35). Apply grease to washer (46) and stick in recess of gear (35). Raise gear (35) in chest and install fulcrum (44) with O-seal (50).
Job Card No.: Engine Timing 04.05.01 Page 1 of 3 Engine: Filing No.: 0178-10-10 2069 S/BV 6/8/9 M 628 Camshaft Removal Removal is required when replacing camshaft bearings or repairing the camshaft. If in confined spaces the complete camshaft unit cannot be removed from the crankcase towards driving end ("KS") or free end ("KGS"), it is separated in the middle, at the flanged connection. Job Cards: - 01.02.02 04.02.01 07.04.01 10.02.
Job Card No.: 04.05.01 Engine Timing Page 2 of 3 Engine: S/BV 6/8/9 M 628 ● ● ● ● ● ● ● ● ● Filing No.: 0178-10-10 2069 Unscrew waisted hex. bolt (5). Take off starting cam (4). Remove dowel pin (6). Remove locking wires of cheese-head bolts (3) and turn out bolts Take off gear (1). Remove dowel pin (2). Screw guide arbor with its short grub screw end into camshaft at engine driving end. Carefully pull out camshaft while turning it. Carfully place camshaft on two wooden supports. © 50 528 1 Fig.
Job Card No.: Engine Timing 04.05.01 Page 3 of 3 Engine: Filing No.: 0178-10-10 2069 S/BV 6/8/9 M 628 Camshaft Removal in Confined Spaces ● Remove camshaft, as described above, towards driving or free end of engine, until flanged connection moves beyond bearing zone when pulling our pushing out camshaft; then connection may be detached. Secure first half-camshaft against falling down. ● ● ● ● Remove locking wire (2). Turn out cheese-head bolts (1). Remove dowel pin (3).
Job Card No.: Engine Timing Engine: Filing No.
Job Card No.: Engine Timing 04.06.01 Page 1 of 4 Engine: Filing No.: 0178-10-10 2070 S/BV 6/8/9 M 628 Camshaft Refitment Job Cards: - 01.01.01 01.02.02 04.02.01 04.06.02 04.08.01 07.04.01 10.02.01 Tools: - - Standard tools Special tool (Section 1.8) - Torque wrench - Socket insert Special tool (Section 1.8.1) - Guide arbor © 50 524 2 Fig.
Job Card No.: 04.06.01 Engine Timing Page 2 of 4 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-10-10 2070 ● Rotate gear (1) until ”R” mark or resp. notch (3) on gear coincides with mark on timing chest - at inspection hole centreline. ● Mesh gear with idler gear. © 50 521 2 Fig. 4 Camshaft drive gear marking ● ● ● ● ● Screw in hex. bolt (11) with new locking plate (12). Tighten hex. bolt (11) an secure locking plate (12). Refit cover (14) with new gasket (8). Screw in hex. bolts (9) and tighten.
Job Card No.: Engine Timing 04.06.01 Page 3 of 4 Engine: Filing No.: 0178-10-10 2070 S/BV 6/8/9 M 628 ● Screw guide arbour with its long grub screw end into camshaft at engine driving end. ● Carefully introduce camshaft through bearing bushes with guide arbour. ● Rotate camshaft with gear until ”R” mark or resp. notch (3) on gear (1) coincides with mark on timing chest sealing surface. ● Mesh gear with idler gear. ● Screw off guide arbour. © 50 521 2 Fig.
Job Card No.: 04.06.01 Engine Timing Page 4 of 4 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-10-10 2070 Refitment in confined spaces The joint faces of the half-camshafts must be absolutely clean and free from oil and grease. ● Introduce first half-shaft with guide arbour and dowel pin (3) into crankcase. ● Introduce second half-shaft and tighten with cheese head bolts (1) according to specification, section 3.5, line 27. ● Lock cheese head bolts with locking wire (2).
Job Card No..: Valve Timing Checking 04.06.02 Engine: Filing No.: 0178-10-10 1113 S/BVM 628 Checking Tools: Check inlet/exhaust valve timing. - Standard tools Tape rule A timing check is required following camshaft fitment (Job Card 04.06.01) and when inspecting or working on the timing gears. Job: Check valve clearance (Job Card 01.01.01). Turn crankshaft in the normal running direction until the valve drive of No.
Job Card No.: Valve Timing Checking Engine: Filing No.
Job Card No.: Timing Gear Train Inspection / Gauging 04.08.01 Page 1 of 2 Engine: F iling No.: 0178-09-10 1114 Inspection / Gauging Inspect and measure backlash of gears in main timing gear train (engine’s driving end) and pump drive (engine’s free end). S/BV 6/8/9 M 628 Tools: - Standard tools Dial gauge with magnetic holder While gear fulcrums are connected to the engine’s main lube circuit, the gears themselves are lubricated by oil jet.
Job Card No.: 04.08.01 Timing Gear Train Inspection / Gauging Page 2 of 2 Engine: S/BV 6/8/9 M 628 0178-09-10 1114 Filing No.
Job Card No.: Flywheel Removal / Refitment 04.09.01 Engine: Filing No.: 0178-05-10 1924 Flywheel removal is required for replacement of the crankshaft gear. S/BVM 628 Tools: - Standard tools Hoist Eye screw Job Card - 05.00.01 Job Observe safety precautions (job 05.00.01). Mark position of drive shaft relative to adapter flange or flexible coupling, and of flywheel to crankshaft. Removing the Flywheel Fit eye screw (4) and hold flywheel (1) by hoist.
Job Card No.: Flywheel Removal / Refitment Engine: Filing No.: This page intentionally left blank.
Crankshaft Gear Removal / Refitment Job Card No.: 04.11.01 Engine: Filing No.: 0178-15-10 1602 S/BVM 628 Tools: - Standard tools - Wrench with insert for socket-head screws (Section 1.8), - 2 hex. bolts M 8x80 - Deutz DW 57 compound Job Card: - 04.16.01 Job: Removing the gear Remove coupling flange (job 04.16.01). Unscrew hex. bolts (2) and remove deflector (1). Now remove all socket-head srews (3). In two opposing bores for bolts (2), screw in the two hex.
Job Card No.: Crankshaft Gear Removal / Refitment Engine: Filing No.: This page intentionally left blank.
Job Card No.: Water Pump Idler Gear Removal / Refitment 04.13.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-14-10 1118 To begin with, remove water pump (job 09.07.02). Tools: - Standard tools Deutz DW49 compound (Section 1. 8) Job Cards: - 04.08.01 09.07.02 Job Removing the gear Disconnect oil pipe to gear. Unscrew nuts (2) and carefully withdraw fulcrum holder (6) with fulcrum (10). Retain gear (8) and washer (9) by hand. Take out components through timing chest aperture (11) of pump.
Job Card No.: 04.13.01 Water Pump Idler Gear Removal / Refitment Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-14-10 1118 Refitting the Gear Clean gear and inspect for wear. If defective, replace gear (8),fulcrum (10), washer (9), bush (11) . Replace 0seals (4) and (7) in any case. Gear refitment is made in the reverse order, paying attention to correct location of eccentric (Fig. 1). Check gearlash (Job Card 04.08.01). © 51 293 0 Fig.
Job Card No.: Pump Chest Removal / Refitment 04.14.01 Page 1 of 3 Engine: Filing No.: 0178-14-10 1119 Prior to pump chest removal, remove oil pump(s) (job 08.04.01), water pump(s) (job 09.07.02), vibration damper (jobs 12.01.01. and 12.01.02) and piping. S/BVM 628 Tools: - Standard tools Deutz DW48 compound (Section 1.8) Hoist Crowbar Job Cards: - 08.04.01 09.07.02 12.01.01 12.01.02 04.08.01 Job Removing the Chest Unscrew nuts (5) and take down oil deflector (4).
Job Card No.: 04.14.01 Pump Chest Removal / Refitment Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-14-10 1119 © 51 296 0 © 51 295 0 Fig. 2 Fig. 3 © 51 298 0 © 51 297 0 Fig. 4 Fig. 5 Locate chest (3) with dowel bushes (9). Install both tubes (8) and screw in all bolts (1) and (6) with washers (9) plus bolts (10). Fit oil deflector. Fit pumps, vibration damper and piping (see pertaining job cards). Gauge backlash (job 04.08.01). View Z Section J - K © 51 299 0 Fig.
Job Card No.: Pump Chest Removal / Refitment 04.14.01 Page 3 of 3 Engine: 0178-14-10 1119 Filing No.: S/BVM 628 © 51 430 0 Fig. 7 Section N - O View Section P - Q View © 51 300 0 Fig. 8 © 1283 © 51 301 0 Fig.
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Job Card No.: Crankshaft Coupling Flange Removal / Refitment 04.16.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-05-10 1502 This job should preferably be entrusted to Deutz servicemen. Tools: - Standard tools Hydraulic flange spreader assy. (Section 1.8.1). Job Cards: - 04.09.01 04.16.02 Job: Removing the Flange (see also page 3) Normal Procedure Remove flywheel (Job Card 04.09.01). Screw stud (4) into crankshaft jounal. Fit crossbearer (2) and screw nut (3) in place on stud (4).
Job Card No.: 04.16.01 Crankshaft Coupling Flange Removal / Refitment Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-05-10 1502 Refitting the Flange (see also page 3) Unscrew plug (11) from flange (12). Check that oil passages and groove of flange and joint faces between flange, taper sleeve (8) and crankshaft (13) are perfectly clean, but use only detergents that cause no corrosion. Also check that joint between crankshaft (13) and taper sleeve (8) is completely dry.
Crankshaft Coupling Flange Removal / Refitment Job Card No.: 04.16.01 Page 3 of 3 Engine: S/BVM 628 0178-05-10 1502 Filing No.: Removing the Flange Refitting the Flange Section a - B Removal in steps of approx. 5 mm Removing the Flange Normal Procedure Exceptional Procedure © 51 304 0 Fig.
Job Card No.: Crankshaft Coupling Flange Removal / Refitment Engine: Filing No.: This page intentionally left blank.
Job Card No.: Coupling Flange Oil Pump Filling 04.16.02 Engine: Filing No.: 0178-49-10 1501 Filling S/BVM 628 Tools: - Container for hydraulic fluid The hydraulic fluid should be SAE 30 motor oil only. To avoid corrosion, no other fluid is permissible. Especially not an aggressive one.. Job: Unscrew reservoir (10) from pump and dip nipple (12) into a fluid container. Pull piston (11) to fill reservoir (10). Hold nipple (12) up and slightly press valve ball (13) in order to bleed any air present.
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Speed Control System Safety Precautions (Barber-Colman Electronic Governor Plus 8) Job Card No.: 05.02.01 Engine: Filing No.: 0178-27-10 1590 BVM 628 If work is to be carried out on a speed governor, engine control unit, governing linkage and injection pump, strictly observe the following safety precautions. Prior to Work Stop engine. Close shut-off valve (2) on air receivers (1). Bleed air supply line (3) to starting air master valve (4). Following Work Open shut-off valves (2) on air receivers (1).
Job Card No.: Speed Control System Safety Precautions (Barber-Colman Electronic Governor Plus 8) Engine: Filing No.
Speed Control System Safety Precautions (Woodward UG 8 D/L Hydraulic Governor) Job Card No.: 05.01.01 Engine: Filing No.: 0178-27-10 1985 S/BVM 628 If work is to be carried out on a speed governor, engine control unit, governing linkage and injection pump, strictly observe the following safety precautions. Prior to Work Stop engine. Close shut-off valve (2) on air receivers (1). Bleed air supply line (3) to starting air master valve (4). Following Work Open shut-off valves (2) on air receivers (1).
Job Card No.: Speed Control System Safety Precautions (Woodward UG 8 D/L Hydraulic Governor) Engine: Filing No.
Speed Control System Safety Precautions Regulateurs Europa Ltd. Hydraulic Governor Job Card No.: 05.00.01 Engine: Filing No.: 0178-27-10 1987 S/BVM 628 If work is to be carried out on a speed governor, engine control unit, governing linkage and injection pump, strictly observe the following safety precautions. Prior to Work Stop engine. Close shut-off valve (2) on air receivers (1). Bleed air supply line (3) to starting air master valve (4).
Job Card No.: Speed Control System Safety Precautions Regulateurs Europa Ltd. Hydraulic Governor Engine: Filing No.
Job Card No.: Regulateurs Europa Ltd. Hydraulic Governor Servicing 05.03.11 Engine: Filing No.: S/BVM 628 0178-27-10 1122 Servicing Tools: (Oil Change) Contaminated oil will lead to governor trouble. - Standard tools Job Card: Be sure to use fresh oil only as specified by governor manufacturers which will guarantee proper, satisfactory operation and long service life of governor. - 05.03.12 The old oil is drained in hot condition.
Job Card No.: Regulateurs Europa Ltd. Hydraulic Governor Servicing Engine: Filing No.
Woodward UG 8 D/L Hydraulic Governor Servicing (Oil Change) Job Card No.: 05.03.11 Engine: Filing No.: S/BVM 628 0178-27-10 1988 Servicing Tools: (Oil Change) Contaminated oil will lead to governor trouble. - Be sure to use fresh oil only as specified by governor manufacturers which will guarantee proper, satisfactory operation and long service life of governor. Standard tools Job Card: - 05.03.12 The old oil is drained in hot condition.
Job Card No.: Woodward UG 8 D/L Hydraulic Governor Servicing (Oil Change) Engine: Filing No.
Woodward UG 8 D/L Hydraulic Governor Setting Job Card No.: 05.03.12 Engine: Filing No.: S/BVM 628 0178-27-10 1587 Inspection Tools: Occasionally or after a governor oil change (job card 05.03.11) the compensation (needle valve) may need adjustment. - Standard tools Job Card: - 05.03.11 When sudden load changes result in heavy over- or underspeeding and sluggish return to the preset speed, this suggests wrong compensation setting.
Job Card No.: Woodward UG 8 D/L Hydraulic Governor Setting Engine: Filing No.
Regulateurs Europa Ltd. Hydraulic Governor Setting Job Card No.: 05.03.12 Engine: Filing No.: S/BVM 628 0178-27-10 1989 Setting Tools: Occasionally or after a governor oil change (job card 05.03.11) the compensation (needle valve) may need adjustment. - Standard tools Job Card: - 05.03.11 When sudden load changes result in heavy over- or underspeeding and sluggish return to the preset speed, this suggests wrong compensation setting.
Job Card No.: Regulateurs Europa Ltd. Hydraulic Governor Setting Engine: Filing No.
Setting the Magnetic Frequency Generator Job Card No.: 05.03.13 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-27-10 1591 Setting the magnetic frequency generator Tools: - The magnetic frequency generator (Fig. 1) is attached to the gearbox at the height of the intermediate wheel in relation to the speed control drive, Fig. 2.
Job Card No.: 05.03.13 Setting the Magnetic Frequency Generator Page 2 of 2 Engine: S/BVM 628 0178-27-10 1591 Filing No.: BV 6/8/9 M 628 BV 12/16 M 628 © 51 307 0 Fig.
Regulateurs Europa Ltd. Hydraulic Governor Servicing / Reconditioning Job Card No.: 05.03.14 Engine: Filing No.: 0178-27-10 1124 S/BVM 628 Servicing / Reconditioning Any servicing or reconditioning work on the "Europa" governor should be carried out strictly in accordance with the manufacturers' instructions or preferably by the manufacturers themselves. Before removing governor from engine, mark connections.
Job Card No.: Regulateurs Europa Ltd. Hydraulic Governor Servicing / Reconditioning Engine: Filing No.
Woodward UG 8 D/L Hydraulic Governor Servicing / Reconditioning Job Card No.: 05.03.14 Engine: Filing No.: 0178-27-10 1589 S/BVM 628 Servicing / Reconditioning IAny servicing or reconditioning work on the "Europa" governor should be carried out strictly in accordance with the manufacturers' instructions or preferably by the manufacturers themselves. Before removing governor from engine, mark connections.
Job Card No.: Woodward UG 8 D/L Hydraulic Governor Servicing / Reconditioning Engine: Filing No.
Barber-Colman Plus 8 Electronic Governor Servicing / Reconditioning Job Card No.: 05.03.14 Engine: Filing No.: 0178-27-10 1592 S/BVM 628 Servicing / Reconditioning Any servicing or reconditioning work on the "Europa" governor should be carried out strictly in accordance with the manufacturers' instructions or preferably by the manufacturers themselves. Before removing governor from engine, mark connections.
Job Card No.: Barber-Colman Plus 8 Electronic Governor Servicing / Reconditioning Engine: Filing No.
Job Card No.: Hydraulic Governor Drive Inspection 05.04.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-27-10 1612 Inspection / Gauging Unscrew governor fastening parts from governor drive. Dismantle drive and inspect for wear. Before dismantling drive, make sure it turns freely. In addition, gauge backlash between bevel gears. Excessive backlash may be eliminated by shim (9 or 20). IShould the bearings be worn, it will be recommendable to install new bearings and bevel gears.
Job Card No.: 05.04.01 Hydraulic Governor Drive Inspection Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-27-10 1612 For further dimantling of bearing (39), drive shaft of gear (17) out of ball bearings (21) and (36). Drive bearing (21) out of bearing (29) and take out bush (18). Remove outer circlip (30) also . Unscrew bolts (11) and withdraw fulcrum (12) with gear (6). Remove shims(9), which are likewise required for correct backlash of bevel gears (6) and (17). Pull fulcrum (12) out of gear (6).
Job Card No.: Hydraulic Governor Drive Inspection 05.04.01 Page 3 of 3 Engine: Filing No.: S/BVM 628 0178-27-10 1612 Refitting the Drive Place gasket (19) on casing (2). Push casing with driving parts into timing chest and secure by bolts (16) and (34). Ba cklash between gear (27) and idler gear: see job 04.08.01 . Fit gasket (31) and install governor with toothed shaft into drive shaft (6) , taking note of the dowel pin (78). Screw in bolts (8) and tighten. Fit governing linkage (Job Card 05.04.14).
Job Card No.: Hydraulic Governor Drive Inspection Engine: Filing No.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 1 of 11 Engine: Filing No.: 0178-29-10 1806 S/BV 6/8 M 628 Servicing / Setting Tools: For removing the injection pumps, it is necessary to remove the linkage between the pumps and to detach the linkage between pump and governor. After the pumps have been refitted , the linkage has to be checked and adjusted as necessary.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 2 of 11 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1806 Unscrew chees-head screws (60) - Fig. 2 -. Remove gaskets (64). Push covers (59) and bellows (29) towards the middle of links (55). Then undo cheese-head screws (62) and scrap. Remove flat irons (63). Slacken eccentrics (61) and carefully lift links out of the injection pumps. © 24 924 1 Fig. 2 After undoing the fastening screw A5 (Fig.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 3 of 11 Engine: 0178-29-10 1806 Filing No.: S/BV 6/8 M 628 Midpos. When Removing Governor Unscrew fastening bolt (*) - Fig. 3), remove link C3 and take down governor. © 24 925 1 Fig. 3 Refitting the Linkage For following operations, see also Fig. 1. Checking Linkage Settings 1. Before refitting links C1and C3, check pertaining distance dimensions. They must be as follows: © 0593 Link C1 = 310 mm, see Fig.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 4 of 11 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1806 Synchronizing the Injection Pumps 2. Detach link C1 at point A5 (*) - Fig. 4 -. © 24 926 1 Fig. 4 3. Fully screw in stop screw (*) at point A 13 - Fig. 5 -. Record screw setting (**) where linkage is adjusted repeatedly. © 24 927 1 Fig. 5 4. Release screw (*) - Fig. 6 - to remove lever on starting fuel allowance stop, point A17. © 24 928 1 Fig.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 5 of 11 Engine: Filing No.: 0178-29-10 1806 S/BV 6/8 M 628 © 24 929 1 Fig. 7 5. Use tools (*) - Fig. 7 - to pull control rods of all injection pumps against the gauges (**) contacting check stops (***) at points A18 and A19. Leave tools (*) mounted for the time being. 6.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 6 of 11 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1806 © 24 973 3 Fig. 8 Then, at the right-hand end of the link (*) (point A24), adjust the length of the link by means of the eccentric (**) so that the control rods contact the check stops without pressure, with the gauges inserted (see Fig. 7). Insert new cheese-head screws according to tightening specification, see "Specification Data", Section 3.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 7 of 11 Engine: Filing No.: 0178-29-10 1806 S/BV 6/8 M 628 Then adjust distance between stop piston ("Stop" position) at point A15 (Fig. 10) and shock absorber. Lock grooved nut (*). © 24 932 1 Fig. 10 8. Refit the tools (see under 5.) , then check whether, at operating position of the springloaded cylinder A15 (Fig.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 8 of 11 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1806 Governor link 9. Turn governor output shaft to graduation 5 (midposition) - Fig. 12 -, then fasten lever C11 (*) on output shaft in roughly vertical position. Governor output shaft © 24 934 1 Fig. 12 10. Turn governor to graduation (10) - Fig. 13 - and secure link C1 to point A5 (*).
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 9 of 11 Engine: Filing No.: 11. S/BV 6/8 M 628 0178-29-10 1806 Adjust linkage at points C8 (*) or C10 (**) Fig. 14 - so as to obtain the settings scheduled in table below. Then tighten all locknuts. Graduation Governor Injection Pump 2 0 0 - 2,5 to - 5 9 approx. 14 Section A - B © 24 937 1 Fig.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 10 of11 Engine: S/BV 6/8 M 628 12. Filing No.: 0178-29-10 1806 Set stop screw A13 so that load indicator on injection pump points to graduation (14) - Fig. 15. © 24 938 1 Fig. 15 13. Check that linkage abuts at stop screw (*) Fig. 16 - when pushed to maximum load (point A13). Upon completion of the setting, lead-seal the engine output (**). © 24 939 1 Fig. 16 14.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 11 of 11 Engine: Filing No.: 15. 0178-29-10 1806 S/BV 6/8 M 628 Setting the starting fuel limit: While the engine is running at 11 bar b.m.e.p., pressurize air cylinder of fuel limit and adjust refitted lever so that there is contact at point (**) - Fig. 17 - . Tighten screw (*), depressurize air cylinder. After finally completing the settings, refit the covers at points A21 and A24 - Fig.
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Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 1 of 11 Engine: Filing No.: 0178-29-10 1807 S/BV 9 M 628 Servicing / Setting Tools: For removing the injection pumps, it is necessary to remove the linkage between the pumps and to detach the linkage between pump and governor. After the pumps have been refitted , the linkage has to be checked and adjusted as necessary.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 2 of 11 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1807 Unscrew cheese-head screws (60) - Fig. 2 -. Remove gaskets (64). Push covers (59) and bellows (29) towards the middle of links (55). Then undo cheese-head screws (62) and scrap. Remove flat irons (63). Slacken eccentrics (61) and carefully lift links out of the injection pumps. © 24 924 1 Fig. 2 After undoing the fastening screw A5 (Fig.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 3 of 11 Engine: 0178-29-10 1807 Filing No.: S/BV 9 M 628 Midpos. When Removing Governor Unscrew fastening bolt (*) - Fig. 3 -, remove link C3 and take down governor. © 24 925 1 Fig. 3 Refitting the Linkage For following operations, see also Fig. 1. Checking Linkage Settings 1. Before refitting links C1and C3, check pertaining distance dimensions. They must be as follows: © 0583 Link C1 = 310 mm, see Fig.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 4 of 11 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1807 Synchronizing the Injection Pumps 2. Detach link C1 at point A5 (*) - Fig. 4 -. © 24 926 1 Fig. 4 3. Fully screw in stop screw (*) at point A 13 - Fig. 5 -. Record screw setting (**) where linkage is adjusted repeatedly. © 24 927 1 Fig. 5 4. Release screw (*) - Fig. 6 - to remove lever on starting fuel allowance stop, point A17. © 24 928 1 Fig.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 5 of 11 Engine: Filing No.: 0178-29-10 1807 S/BV 9 M 628 © 24 929 1 Fig. 7 5. Use tools (*) - Fig. 7 - to pull control rods of all injection pumps against the gauges (**) contacting check stops (***) at points A18, A19 and A20. Leave tools (*) mounted for the time being. 6.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 6 of 11 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1807 © 24 930 3 Fig. 8 Then, at the right-hand end of the link (*) (point A24), adjust the length of the link by means of the eccentric (**) so that the control rods contact the check stops without pressure, with the gauges inserted (see Fig. 7). Insert new cheese-head screws according to tightening specification, see "Specification Data", Section 3.5, line 60.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 7 of 11 Engine: Filing No.: 0178-29-10 1807 S/BV 9 M 628 Then adjust distance between stop piston ("Stop" position) at point A15 (Fig. 10) and shock absorber. Lock grooved nut (*). © 24 932 1 Fig. 10 8. Refit the tools (see under 5.) , then check whether, at operating position of the springloaded cylinder A15 (Fig.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 8 of 11 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1807 Governor link 9. Turn governor output shaft to graduation 5 (midposition) - Fig. 12 -, then fasten lever C11 (*) on output shaft in roughly vertical position. Governor output shaft © 24 934 1 Fig. 12 10. Turn governor to graduation (10) - Fig. 13 - and secure link C1 to point A5 (*).
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 8 of 11 Engine: Filing No.: 11. S/BV 9 M 628 0178-29-10 1807 Adjust linkage at points C8 (*) or C10 (**) - Fig. 14 - so as to obtain the settings scheduled in table below. Then tighten all locknuts. Graduation Governor Injection Pump 2 0 0 - 2,5 to - 5 9 approx. 14 Section A - B © 24 937 1 Fig.
Job Card No.: 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Page 10 of 11 Engine: S/BV 9 M 628 12. Filing No.: 0178-29-10 1807 Set stop screw A13 so that load indicator on injection pump points to graduation (14) - Fig. 15. © 24 938 1 Fig. 15 13. Check that linkage abuts at stop screw (*) Fig. 16 - when pushed to maximum load (point A13). Upon completion of the setting, lead-seal the engine output (**). © 24 939 1 Fig. 16 14.
Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 11 of 11 Engine: Filing No.: 15. 0178-29-10 1807 S/BV 9 M 628 Setting the starting fuel limit: While the engine is running at 11 bar b.m.e.p., pressurize air cylinder of fuel limit and adjust refitted lever so that there is contact at point (**) - Fig. 17 - . Tighten screw (*), depressurize air cylinder. After finally completing the settings, refit the covers at points A22, A25, A23 and A26 - Fig.
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Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 1 of 12 Engine: Filing No.: 0178-29-10 1808 S/BV 6/8 M 628 Servicing / Setting Tools: For removing the injection pumps, it is necessary to remove the linkage between the pumps and to detach the linkage between pump and governor. After the pumps have been refitted , the linkage has to be checked and adjusted as necessary.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 2 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1808 Unscrew chees-head screws (60) - Fig. 2 -. Remove gaskets (64). Push covers (59) and bellows (29) towards the middle of links (55). Then undo cheese-head screws (62) and scrap. Remove flat irons (63). Slacken eccentrics (61) and carefully lift links out of the injection pumps. © 24 924 1 Fig. 2 After undoing the fastening screw A5 (Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 3 of 12 Engine: 0178-29-10 1808 Filing No.: S/BV 6/8 M 628 Midpos. When Removing Governor Unscrew fastening bolt (*) - Fig. 3), remove link C3 and take down governor. © 24 925 1 Fig. 3 Refitting the Linkage For following operations, see also Fig. 1. Checking Linkage Settings 1. Before refitting links C1and C3, check pertaining distance dimensions. They must be as follows: © 0583 Link C1 = 310 mm, see Fig.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 4 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1808 Synchronizing the Injection Pumps 2. Detach link C1 at point A5 (*) - Fig. 4 -. © 24 926 1 Fig. 4 3. Fully screw in stop screw (*) at point A 13 - Fig. 5 -. Record screw setting (**) where linkage is adjusted repeatedly. © 24 927 1 Fig. 5 4. Release screw (*) - Fig. 6 - to remove lever on starting fuel allowance stop, point A17. © 24 928 1 Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 5 of 12 Engine: Filing No.: 0178-29-10 1808 S/BV 6/8 M 628 © 24 929 1 Fig. 7 5. Use tools (*) - Fig. 7 - to pull control rods of all injection pumps against the gauges (**) contacting check stops (***) at points A18 and A19. Leave tools (*) mounted for the time being. 6.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 6 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1808 © 24 973 3 Fig. 8 Then, at the right-hand end of the link (*) (point A24), adjust the length of the link by means of the eccentric (**) so that the control rods contact the check stops without pressure, with the gauges inserted (see Fig. 7). Insert new cheese-head screws according to tightening specification, see "Specification Data", Section 3.5, line 60.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 7 of 12 Engine: Filing No.: 0178-29-10 1808 S/BV 6/8 M 628 Then adjust distance between stop piston ("Stop" position) at point A15 (Fig. 10) and shock absorber. Lock grooved nut (*). © 24 932 1 Fig. 10 8. Refit the tools (see under 5.) , then check whether, at operating position of the springloaded cylinder A15 (Fig.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 8 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1808 Governor link 9. Governor UG8D (Fig. 12) Turn knob of LOAD LIMIT to scale graduation 10 and output shaft to midposition (arrow). © 24 954 1 Fig. 12 Governor UG8L (Fig. 13) Turn output shaft to mid-position 5 © 24 955 1 Fig. 13 Thereafter proceed on both models as follows: Secure lever C11 (*) - Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 9 of 12 Engine: Filing No.: 0178-29-10 1808 S/BV 6/8 M 628 © 24 950 1 Fig. 15 10. Turn governor to graduation (10) - Fig. 15 - and secure link C1(Fig. 16) to point A5 (*). Adjust length of link (**) at point C5 to ensure freedom from internal stressing. Remove tool from all injection pumps (see Fig. 7). © 24 959 1 Fig.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 10 of 12 Engine: S/BV 6/8 M 628 11. Filing No.: 0178-29-10 1808 Adjust linkage at points C8 (*) or C10 (**) - Fig. 17 - so as to obtain the settings scheduled in table at right. Then tighten all locknuts. Graduation Governor Injection Pump 2 0 0 - 2,5 to - 5 9 approx. 14 Section A - B © 24 937 1 Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 11 of 12 Engine: 0178-29-10 1808 Filing No.: 12. S/BV 6/8 M 628 Set stop screw A13 so that load indicator on injection pump points to graduation (14) - Fig. 18. © 24 938 1 Fig. 18 13. Check that linkage abuts at stop screw (*) Fig. 19 - when pushed to maximum load (point A13). Upon completion of the setting, lead-seal the engine output (**). © 24 939 1 Fig. 19 14.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 12 of 12 Engine: S/BV 6/8 M 628 15. Filing No.: 0178-29-10 1808 Setting the starting fuel limit: While the engine is running at 11 bar b.m.e.p., pressurize air cylinder of fuel limit and adjust refitted lever so that there is contact at point (**) - Fig. 20 - . Tighten screw (*), depressurize air cylinder. After finally completing the settings, refit the covers at points A21 and A24 - Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 1 of 12 Engine: Filing No.: 0178-29-10 1809 S/BV 9 M 628 Servicing / Setting Tools: For removing the injection pumps, it is necessary to remove the linkage between the pumps and to detach the linkage between pump and governor. After the pumps have been refitted , the linkage has to be checked and adjusted as necessary.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 2 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1809 Unscrew cheese-head screws (60) - Fig. 2 -. Remove gaskets (64). Push covers (59) and bellows (29) towards the middle of links (55). Then undo cheese-head screws (62) and scrap. Remove flat irons (63). Slacken eccentrics (61) and carefully lift links out of the injection pumps. © 24 924 1 Fig. 2 After undoing the fastening screw A5 (Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 3 of 12 Engine: 0178-29-10 1809 Filing No.: S/BV 9 M 628 Midpos. When Removing Governor Unscrew fastening bolt (*) - Fig. 3 -, remove link C3 and take down governor. © 24 925 1 Fig. 3 Refitting the Linkage For following operations, see also Fig. 1. Checking Linkage Settings 1. Before refitting links C1and C3, check pertaining distance dimensions. They must be as follows: © 0583 Link C1 = 310 mm, see Fig.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 4 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1809 Synchronizing the Injection Pumps 2. Detach link C1 at point A5 (*) - Fig. 4 -. © 24 926 1 Fig. 4 3. Fully screw in stop screw (*) at point A 13 - Fig. 5 -. Record screw setting (**) where linkage is adjusted repeatedly. © 24 927 1 Fig. 5 4. Release screw (*) - Fig. 6 - to remove lever on starting fuel allowance stop, point A17. © 24 928 1 Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 5 of 12 Engine: Filing No.: 0178-29-10 1809 S/BV 9 M 628 © 24 929 1 Fig. 7 5. Use tools (*) - Fig. 7 - to pull control rods of all injection pumps against the gauges (**) contacting check stops (***) at points A18, A19 and A20. Leave tools (*) mounted for the time being. 6.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 6 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1809 © 24 930 3 Fig. 8 Then, at the right-hand ends of the links (*) (point A25, A26), adjust the length of the link by means of the eccentric (**) so that the control rods contact the check stops without pressure, with the gauges inserted (see Fig. 7). Insert new cheese-head screws according to tightening specification, see "Specification Data", Section 3.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 7 of 12 Engine: Filing No.: 0178-29-10 1809 S/BV 9 M 628 Then adjust distance between stop piston ("Stop" position) at point A15 (Fig. 10) and shock absorber. Lock grooved nut (*). © 24 932 1 Fig. 10 8. Refit the tools (see under 5.) , then check whether, at operating position of the springloaded cylinder A15 (Fig.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 8 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1809 Governor link 9. Governor UG8D (Fig. 12) Turn knob of LOAD LIMIT to scale graduation 10 and output shaft to mid-position 5 (arrow). © 24 954 1 Fig. 12 Governor UG8L (Fig. 13) Turn output shaft to mid-position 5. © 24 955 1 Fig. 13 Thereafter proceed on both models as follows: Secure lever C11 (*) - Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 9 of 12 Engine: Filing No.: 0178-29-10 1809 S/BV 9 M 628 © 24 950 1 Fig. 15 10. Turn governor to scale graduation 10 - Fig. 15 - and secure link C1(Fig. 16) to point A5 (*). Adjust length of link (**) at point C5 to ensure freedom from internal stressing. Remove tool from all injection pumps (see Fig. 7). © 24 959 1 Fig.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 10 of 12 Engine: S/BV 9 M 628 11. Filing No.: 0178-29-10 1809 Adjust linkage at points C8 (*) or C10 (**) - Fig. 17 - so as to obtain the settings scheduled in table at right. Then tighten all locknuts. Graduation Governor Injection Pump 2 0 0 - 2,5 to - 5 9 approx. 14 Section A - B © 24 937 1 Fig.
Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Job Card No.: 05.04.14 Page 11 of 12 Engine: 0178-29-10 1809 Filing No.: 12. S/BV 9 M 628 Set stop screw A13 so that load indicator on injection pump (Fig. 18) points to graduation 14. © 24 938 1 Fig. 18 13. Check that linkage abuts at top screw (*) - Fig. 19 - when pushed to maximum load (point A13). Upon completion of the setting, lead-seal the engine output (**). © 24 939 1 Fig. 19 14.
Job Card No.: 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting Page 12 of 12 Engine: S/BV 9 M 628 15. Filing No.: 0178-29-10 1809 Setting the starting fuel limit: While the engine is running at 11 bar b.m.e.p., pressurize air cylinder of fuel limit and adjust refitted lever so that there is contact at point (**) - Fig. 20 - . Tighten screw (*), depressurize air cylinder. After finally completing the settings, refit the covers at points A22, A25, A23 and A26 - Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 1 of 12 Engine: Filing No.: 0178-29-10 1810 S/BV 6/8 M 628 Servicing / Setting Tools: For removing the injection pumps, it is necessary to remove the linkage between the pumps and to detach the linkage between pump and governor. After the pumps have been refitted , the linkage has to be checked and adjusted as necessary.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 2 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1810 Unscrew chees-head screws (60) - Fig. 2 -. Remove gaskets (64). Push covers (59) and bellows (29) towards the middle of link (55). Then undo cheese-head screws (62) and scrap. Remove flat irons (63). Slacken eccentrics (61) and carefully lift links out of the injection pumps. © 24 924 1 Fig. 2 After undoing the fastening screw A5 (Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 3 of 12 Engine: 0178-29-10 1810 Filing No.: S/BV 6/8 M 628 Midpos. When Removing Governor Unscrew fastening bolt (*) - Fig. 3 -, remove link C3 and take down governor. © 24 925 1 Fig. 3 Refitting the Linkage For following operations, see also Fig. 1. Checking Linkage Settings 1. Before refitting links C1and C3, check pertaining distance dimensions. They must be as follows: © 1283 Link C1 = 310 mm, see Fig.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 4 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1810 Synchronizing the Injection Pumps 2. Detach link C1 at point A5 (*) - Fig. 4 -. © 24 926 1 Fig. 4 3. Fully screw in stop screw (*) at point A 13 - Fig. 5 -. Record screw setting (**) where linkage is adjusted repeatedly. © 24 927 1 Fig. 5 4. Release screw (*) - Fig. 6 - to remove lever on starting fuel allowance stop, point A17. © 24 928 1 Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 5 of 12 Engine: Filing No.: 0178-29-10 1810 S/BV 6/8 M 628 © 24 929 1 Fig. 7 5. Use tools (*) - Fig. 7 - to pull control rods of all injection pumps against the gauges (**) contacting check stops (***) at points A18 and A19. Leave tools (*) mounted for the time being. 6.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 6 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1810 © 24 973 3 Fig. 8 Then, at the right-hand end of the link (*) (point A24), adjust the length of the link by means of the eccentric (**) so that the control rods contact the check stops without pressure, with the gauges inserted (see Fig. 7). Insert new cheese-head screws (***) and tighten according to specification, see "Specification Data", Section 3.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 7 of 12 Engine: Filing No.: 0178-29-10 1810 S/BV 6/8 M 628 Then adjust distance between stop piston ("Stop" position) at point A15 (Fig. 10) and shock absorber. Lock grooved nut (*). © 24 932 1 Fig. 10 8. Refit the tools (see under 5.) , then check whether, at operating position of the springloaded cylinder A15 (Fig.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 8 of 12 Engine: S/BV 6/8 M 628 Filing No.: 0178-29-10 1810 Actuator Link 9. Secure lever C11 (*) (Fig. 12) to actuator so that the lever is roughly vertical when the actuator shaft (Fig. 13) is in mid-position. (Shaft rotation is max. 45°.) Governor output shaft © 24 958 1 Fig. 12 Mark vertical lever position on external free shaft end (**) Governor se rea Inc l fue Middle position © 24 949 1 Fig.
Job Card No.: Barber-Colman plus 8 Electronic Governor Linkage Setting 05.04.14 Page 9 of 12 Engine: Filing No.: With governing linkage removed, the actuator shaft will always be in "Stop"position. Turn shaft to maximum fuel (Fig. 14). x. f u el Governor ma 10. S/BV 6/8 M 628 0178-29-10 1810 © 24 953 1 Fig. 14 Then secure linkage C1 (Fig. 15) to point A5 (*) and adjust length of link at point C5 (**) to ensure freedom from internal stressing. Remove tools from all injection pumps (see Fig. 7).
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 10 of 12 Engine: S/BV 6/8 M 628 11. Filing No.: 0178-29-10 1810 Adjust linkage at points C8 (*) or C10 (**) - Fig. 17 - so as to obtain the settings scheduled in table below. Then tighten all locknuts. Graduation Actuator 9° from Stop Injection Pump 0 Stop limit position - 2,5 to - 5 34° from Stop approx. 14 Section A - B © 24 937 1 Fig. 16 Typical setting Governor Injection Pump © 24 951 1 Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 11 of 12 Engine: Filing No.: 12. 0178-29-10 1810 S/BV 6/8 M 628 Set stop screw A13 so that load indicator on injection pump points to graduation (14) - Fig. 17. © 24 938 1 13. Check that linkage abuts at stop screw (*) Fig. 18 - when pushed to maximum load (point A13). Upon completion of the setting, lead-seal the engine output (**). © 24 939 1 Fig.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 12 of 12 Engine: S/BV 6/8 M 628 14. Filing No.: 0178-29-10 1810 After the engine has been put back to service and final load setting has been made, check that the governor scale gives the following readings: No load Full load = = 9° rotation 34° rotation measured from Stop position Failing this, adjust linkage (points C8 or C10 under 11.). 15.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 1 of 12 Engine: Filing No.: 0178-29-10 1811 S/BV 9 M 628 Servicing / Setting Tools: For removing the injection pumps, it is necessary to remove the linkage between the pumps and to detach the linkage between pump and governor. After the pumps have been refitted , the linkage has to be checked and adjusted as necessary.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 2 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1811 Unscrew chees-head screws (60) - Fig. 2 -. Remove gaskets (64). Push covers (59) and bellows (29) towards the middle of link (55). Then undo cheese-head screws (62) and scrap. Remove flat irons (63). Slacken eccentrics (61) and carefully lift links out of the injection pumps. © 24 924 1 Fig. 2 After undoing the fastening screw A5 (Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 3 of 12 Engine: 0178-29-10 1811 Filing No.: S/BV 9 M 628 Midpos. When Removing Governor Unscrew fastening bolt (*) - Fig. 3 -, remove link C3 and take down governor. © 24 925 1 Fig. 3 Refitting the Linkage For following operations, see also Fig. 1. Checking Linkage Settings 1. Before refitting links C1and C3, check pertaining distance dimensions. They must be as follows: © 1283 Link C1 = 310 mm, see Fig.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 4 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1811 Synchronizing the Injection Pumps 2. Detach link C1 at point A5 (*) - Fig. 4 -. © 24 926 1 Fig. 4 3. Fully screw in stop screw (*) at point A 13 - Fig. 5 -. Record screw setting (**) where linkage is adjusted repeatedly. © 24 927 1 Fig. 5 4. Release screw (*) - Fig. 6 - to remove lever on starting fuel allowance stop, point A17. © 24 928 1 Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 5 of 12 Engine: Filing No.: 0178-29-10 1811 S/BV 9 M 628 © 24 929 1 Fig. 7 5. Use tools (*) - Fig. 7 - to pull control rods of all injection pumps against the gauges (**) contacting check stops (***) at points A18, A19 and A20. Leave tools (*) mounted for the time being. 6.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 6 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1811 © 24 930 3 Fig. 8 Then, at the right-hand end of the link (*) (points A25, A26), adjust the length of the link by means of the eccentric (**) so that the control rods contact the check stops without pressure, with the gauges inserted (see Fig. 7). Insert new cheese-head screws (***) and tighten according to specification, see "Specification Data", Section 3.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 7 of 12 Engine: Filing No.: 0178-29-10 1811 S/BV 9 M 628 Then adjust distance between stop piston ("Stop" position) at point A15 (Fig. 10) and shock absorber. Lock grooved nut (*). © 24 932 1 Fig. 10 8. Refit the tools (see under 5.) , then check whether, at operating position of the springloaded cylinder A15 (Fig.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 8 of 12 Engine: S/BV 9 M 628 Filing No.: 0178-29-10 1811 Actuator Link 9. Secure lever C11 (*) (Fig. 12) to actuator so that the lever is roughly vertical when the actuator shaft (Fig. 13) is in mid-position. (Shaft rotation is max. 45°.) Governor output shaft © 24 958 1 Fig. 12 Mark vertical lever position on external free shaft end (**) Governor se rea Inc l fue Middle position © 24 949 1 Fig.
Job Card No.: Barber-Colman plus 8 Electronic Governor Linkage Setting 05.04.14 Page 9 of 12 Engine: Filing No.: S/BV 9 M 628 With governing linkage removed, the actuator shaft will always be in "Stop"position. Turn shaft to maximum fuel (Fig. 14). x. f u el Governor ma 10. 0178-29-10 1811 © 24 953 1 Fig. 14 Then secure linkage C1 (Fig. 15) to point A5 (*) and adjust length of link at point C5 (**) to ensure freedom from internal stressing. Remove tools from all injection pumps (see Fig. 7).
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 10 of 12 Engine: S/BV 9 M 628 11. Filing No.: 0178-29-10 1811 Adjust linkage at points C8 (*) or C10 (**) - Fig. 17 - so as to obtain the settings scheduled in table at right. Then tighten all locknuts. Graduation Actuator 9° from Stop Injection Pump 0 Stop limit position - 2,5 to - 5 34° from Stop approx. 14 Section A - B © 24 937 1 Fig.
Barber-Colman plus 8 Electronic Governor Linkage Setting Job Card No.: 05.04.14 Page 11 of 12 Engine: Filing No.: 12. 0178-29-10 1811 S/BV 9 M 628 Set stop screw A13 so that load indicator on injection pump points to graduation (14) - Fig. 17. © 24 938 1 Fig. 17 13. Check that linkage abuts at stop screw (*) Fig. 18 - when pushed to maximum load (point A13). Upon completion of the setting, lead-seal the engine output (**). © 24 939 1 Fig.
Job Card No.: 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting Page 12 of 12 Engine: S/BV 9 M 628 14. Filing No.: 0178-29-10 1811 After the engine has been put back to service and final load setting has been made, check that the governor scale gives the following readings: No load Full load = = 9° rotation 34° rotation measured from Stop position Failing this, adjust linkage (points C8 or C10 under 11.). 15.
Job Card No.: Control Linkage 05.04.15 Page 1 of 5 Engine: Filing No.:: 0178-29-10 2004 Inspection S/BV 6/8/9 M 628 Tools: Check function of the telescopic pieces; check link bearings for wear. - Proper condition of the link bearings and of the telescopic pieces is essential for problemfree operation of the engines. This calls for regular inspection and servicing of the telescopes - by greasing - and of the link bearings by checking the degree of wear.
Job Card No.: 05.04.15 Control Linkage Page 2 of 5 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-29-10 2004 Inspecting Telescopic Piece C1(Fig. 1) Undo fitted hex. bolt (*) - Fig. 2 -. At the other end of the link, release locking plate and screw out fitted hex. bolt. Take link rod out of forked lever, compress by hand, and release. The resistance thereby occurring should result solely from the compression spring inside the telescopic piece (1) - Fig. 1 -.
Control Linkage Job Card No.: 05.04.15 Page 3 of 5 Engine: Filing No.:: 0178-29-10 2004 S/BV 6/8/9 M 628 Loosen hex. nuts (13) and (15) - Fig. 4 - and turn out link heads (10) and (16). Parts (10) and (13) have left-hand threads. Clean all parts in diesel fuel. Fit new heads and reassemble link rods in the reverse order. Check and set linkage as per job card 05.04.14. Remount as described under "Inspecting Telescopic Pieces". Lead-seal hex. nuts (13) and (15). © 50 072 1 Fig.
Job Card No.: 05.04.15 Control Linkage Page 4 of 5 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-29-10 2004 Renewing Link Bearings of Bearing Block (2) Fig. 1 Release link rods C1 and C3 - Fig. 6 - at the levers (5), as described under ”Renewing Link Heads”. Unlock hex. bolts (7) and remove. Take off levers (5) and Woodruff keys (6). Remove Allen-head screws (43), take off bearing block. Carefully drive out shaft (44) with brass drift and remove link bearings (3).
Control Linkage Job Card No.: 05.04.15 Page 5 of 5 Engine: Filing No.:: 0178-29-10 2004 S/BV 6/8/9 M 628 © 50 073 1 Fig. 7 Reconditioning of the telescopic pieces Reconditioning Telescopic Pieces Dismantle link rod C1 - Fig. 1 - as described under ”Inspecting Telescopic Piece”. Loosen hex. nuts (15) - Fig. 7 - and remove link heads (16) and (10), the latter together with turnbuckle (14). Carefully screw off union nut (4), which is under pressure of compression spring (9) inside the telescope.
Job Card No.: Control Linkage Engine: Filing No.: This page intentionally left blank.
Job Card No.: Exhaust Manifold 06.01.01 Page 1 of 3 Engine: Filing No.: S/BV 6 M 628 0178-41-10 1998 Tools: Inspection - When the cylinder head is due for servicing (job 01.08.01), inspect the manifold for leaks and contamination inside, see also job card 06.01.03. If heavy deposits of soot are inside, remove and clean manifold. - Standard tools Lubricating compound "Deutz S1" (Section 3.6) Brush Job Cards: - 01.08.01 06.01.03 Job: Check manifold for leaks.
Job Card No.: 06.01.01 Exhaust Manifold Page 2 of 3 Engine: S/BV 6 M 628 0178-41-10 1998 Filing No.: Turbocharger Turbocharger © 50 119 1 "KGS" = Free end "KS" = Driving end Compensator Laid length b 88 +1 -4 c 88 +1 -6 Fig.
Exhaust Manifold Job Card No.: 06.01.01 Page 3 of 3 Engine: Filing No.: 0178-41-10 1998 S/BV 6 M 628 © 50 043 0 Fig. 4 Mount fillers at the end of the exhaust manifold sections as per Fig. 4. The marking groove is always situated opposite to the exhaust inlet of the upper cross pipe of the Tshaped exhaust bend, as shown. Boltings of the exhaust gas system which are subject to thermal stress loads have to be coated with protective lubricating compound ”Deutz S1” to facilitate later dismantling.
Job Card No.: Exhaust Manifold Engine: Filing No.
Job Card No.: Exhaust Manifold 06.01.01 Page 1 of 3 Engine: Filing No.: 0178-41-10 1986 S/BV 8 M 628 Tools: Inspection - When the cylinder head is due for servicing (job 01.08.01), inspect the manifold for leaks and contamination inside, see also job 06.01.03. If heavy deposits of soot are inside, remove and clean manifold. - Standard tools Lubrificating compound „Deutz S1“ (Section 3.6) Brush Job Cards: - Job: Check manifold for leaks.
Job Card No.: 06.01.01 Exhaust Manifold Page 2 of 3 Engine: S/BV 8 M 628 0178-41-10 1986 Filing No.: View X Turbocharger Turbocharger © 50 035 1 Fig. 2 "KGS" = Free end "KS" = Driving end Compensator Laid length a 88 +1 b 88 +1 -4 c 68 +1 -6 g 68 +1 -2 Fig.
Exhaust Manifold Job Card No.: 06.01.01 Page 3 of 3 Engine: Filing No.: 0178-41-10 1986 S/BV 8 M 628 © 50 043 1 Fig. 4 Mount fillers at the ends of the exhaust manifold sections as per Fig. 4. The marking groove is always situated opposite to the exhaust inlet of the upper cross pipe of the Tshaped exhaust bend, as shown. Boltings of the exhaust gas system which are subject to thermal stress loads have to be coated with protective lubricating compound ”Deutz S1” to facilitate later dismantling.
Job Card No.: 06.01.01 Exhaust Manifold Page 4 of 3 Engine: S/BV 8 M 628 Filing No.
Job Card No.: Exhaust Manifold 06.01.01 Page 1 of 3 Engine: Filing No.: 0178-41-10 1999 S/BV 9 M 628 Tools: Inspection - When the cylinder head is due for servicing (Job Card 01.08.01), inspect the manifold for leaks and contamination inside, see also Job Card 06.01.03. If heavy deposits of soot are inside, remove and clean manifold. Standard tools „Deutz S1“ compound (Section 3.6) Brush Job Cards: - 01.08.01 06.01.03 Job: Check manifold for leaks.
Job Card No.: 06.01.01 Exhaust Manifold Page 2 of 3 Engine: S/BV 9 M 628 0178-41-10 1999 Filing No.: View X Turbocharger Turbocharger © 25 600 1 Fig. 2 Compensator Laid length a 88 +1 b 88 +1 -4 c 68 +1 -6 g 68 +1 -2 Fig.
Exhaust Manifold Job Card No.: 06.01.01 Page 3 of 3 Engine: Filing No.: 0178-41-10 1999 S/BV 9 M 628 © 50 043 1 Fig. 3 Mount fillers at the ends of the exhaust manifold sections as per Fig. 4. The marking groove is always situated opposite to the exhaust inlet of the upper cross pipe of the Tshaped exhaust bend, as shown. Bolting subjected to thermal stressing are to be treated with Deutz S1 compound to facilitate dismantling work.
Job Card No.: 06.01.01 Exhaust Manifold Page 4 of 3 Engine: S/BV 9 M 628 Filing No.
Job Card No.: Exhaust Elbow 06.01.03 Engine: Filing No.: S/BVM 628 0178-41-297 6504 Inspection Tools: Check exhaust elbow inside for corrosion damage. - - Flashlight Special tool - Ultrasonic tester (see Section 1.8.1) Initially after 24000 running hours Thereafter every 12000 running hours Job ● Illuminate elbow inside using flashlight. If corrosion damage (1) is visible inside of elbow, measure wall thickness with an ultrasonic tester. DEUTZ Service will be at your disposal for such purpose.
Job Card No.: Exhaust Elbow Engine: Filing No.
Charge Air System Job Card No.: 06.02.01 Engine: Filing No.: 0178-87-10 1133 S/BV 6/8/9 M 628 Inspection When a piston is overhauled, inspect charge air piping inside and clean as necessary. Tools: - Standard tools „Deutz F5“ (Section 3.6) If the water detector in the charge air pipe gives an alarm check charge air cooler (2) for leaks. © 50 402 0 Fig. 1 Job: Remove covers (3) and (4). For removal of the latter loosen bolts (5) and tilt cover. Inspect pipe inside.
Job Card No.: Charge Air System 06.02.01 Engine: S/BV 6/8/9 M 628 Filing No.
Job Card No.: Intake Air Cleaner (Plastics) 06.03.11 Servicing Engine: Filing No.: S/BVM 628 178-87-10 1134 Servicing Tools: - This job card refers only to ”Fibroid-elastov 30” filtering mats produced by Delbag. The cleaner consists of two or three segments. Detergents: - If removal of a filtering mat from one of the segments during engine service causes the air pressure to rise, service entire air cleaner.
Job Card No.: Intake Air Cleaner (Plastics) Servicing Engine: Filing No.
Job Card No.: Charge Air Cooler Removal / Refitment 06.04.01 Engine: Filing No.: 0178-58-10 1136 S/BV 6/8/9 M 628 Job: Tools: Removing the Cooler Close shut-off valves in water feed and discharge piping. Open drain cock. Disconnect water piping. Retain charge air pipe (1) plus control unit and support to prevent turning sideways. Retain cooler (2) by hoist. Unscrew (6) bolts (7) and remove pipe (5). Unscrew bolts (9) and remove cooler (2).
Job Card No.: Charge Air Cooler Removal / Refitment Engine: Filing No.
Job Card No.: Charge Air Cooler 06.04.02 Page 1 of 2 Engine: Filing No.: S/BV 6/8/9 M 628 0178-58-10 6509 Tools: Cleaning Charge Air Cooler Air Side Engine-Mounted - At the intervals given in the maintenance chart of the Operation Manual, or when the differential pressure at full load has risen through 100 %, the cooler air side is due for cleaning.
Job Card No.: 06.04.02 Charge Air Cooler Page 2 of 2 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-58-10 6509 ● Connect hose, 30 mm dia. (1), to pipe elbow ”water inlet end”. Connect other hose end to delivery side of liquid pump (7). Connect hose pipe with suction strainer (6) to suction side of liquid pump. ● Connect hose, 30 mm dia. (4), to pipe elbow ”water outlet end”. ● Install shut-off valve (3) between ”water out- let” and end of hose. ● Connect bleed hose, 8 mm dia. (2), to pipe.
Job Card No.: Charge Air Cooler 06.04.02 Engine: F iling No.: S/BVM 628 0178-58-10 6510 Cleaning Charge Air Cooler Air Side Cooler Removed Tools: - Standard tools Aids: At the intervals given in the maintenance chart of the Operation Manual, or when the differential pressure at full load has risen through 100%, the cooler air side is due for cleaning. - Vessel for charge air cooler Cleaning brush of natural or sythetic bristles Detergent, e.g.
Job Card No.: Charge Air Cooler Engine: Filing No.
Turbocharger Servicing Job Card No.: 06.05.01 Engine: Filing No.: 0178-43-10 1936 S/BVM 628 Servicing ● For lube oil type, viscosity, oil changing intervals, see Section 6.1 and ABB operating instructions. ● For lube oil quantity and oil changing procedure, see ABB operating instructions. Drain lube oil into a container using a hair sieve, or if unavailable, using a clean, non-linting cloth.
Job Card No.: Turbocharger Servicing Engine: Filing No.
Job Card No.: Turbocharger Servicing 06.06.01 Engine: Filing No.: S/BVM 628 0178-43-10 1923 Servicing and Reconditioning Job Card: - ● Observe safety precautions (job 05.00.01). ● Perform service work on scavenging nozzles (job 06.13.02). ● Carry out work according to ABB instructions or have carried out by ABB Service. © 0884 05.00.
Job Card No.: Turbocharger Servicing Engine: Filing No.
Job Card No.: Turbocharger Servicing 06.12.01 Engine: Filing No.: S/BVM 628 0178-43-10 1937 Servicing Detergent: Cleaning of the charger at full load. - Clean fresh water VTR 201/214, 0,3 ltrs. VTR 251/254, 0,5 ltrs. To prevent a loss in power due to contamination of the charger unit, clean charger during operation - at full load or at least 60% load by injecting clean water into the charger. In this process the water does not serve as a solvent.
Job Card No.: Turbocharger Servicing Engine: Filing No.
Job Card No.: Turbocharger Turbine 06.13.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-43-10 2008 Servicing Cleaning the turbine during running of the engine on blended or heavy fuel. Periodic scavenging of the turbine with fresh water prevents the formation of heavy carbon deposits on the turbine blading, and hence excessive engine exhaust temperature, plus increased turbocharger bearing loads due to unbalance. Special attention is therefore to be given to the following servicing instructions.
Job Card No.: 06.13.01 Turbocharger Turbine Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-43-10 2008 Be sure to disconnect hose (3) after each scavenging operation, so that water cannot run into the exhaust piping during non-scavenging periods. 8. When no more water or steam comes out of drain pipe (4), close same with cap nut (5). 9. Raise engine load slowly and, where possible, run engine for at least 10 minutes under load in order to prevent possible corrosion.
Job Card No.: Scavenging Nozzles 06.13.02 Engine: Filing No.: S/BVM 628 0178-43-10 1921 Servicing Tools: Remove and service the scavenging nozzles (1) (Fig. 1) on turbine side of the exhaust turbocharger. - Standard tools Fine grinding paste Deutz S1compound (Section 3.6) Job Disconnect water piping from nozzles. Scavenging Nozzle (Fig. 1) Unscrew scavenging nozzle from turbocharger. After taking down hand wheel (1), unscrew hex.
Job Card No.: Scavenging Nozzles Engine: Filing No.
Job Card No.: Turbocharger Scavenging Nozzles 06.13.03 Engine: Filing No.: S/BVM 628 0178-43-10 2009 Tools: Check - Prior to commissioning new engines, and following extensive work on the fresh-water system, it is necessary to measure the quantity of scavenging water at the scavenging nozzles of each turbocharger, correcting as required. Standard tools Measuring vessel Either one or two scavenging nozzles may be provided. Job Undo feed pipe (6) - Fig.
Job Card No.: Turbocharger Scavenging Nozzles Engine: Filing No.
Precautions when Working on Fuel System Job Card No.: 07.00.01 Engine: Filing No.: 0178-17-10 2050 S/BVM 628 When working on the fuel system, the following safety and environment protection precautions are to be observed: ● Pay particular attention to cleanliness. ● Do not open any pressurized components, e.g. injection lines, etc. ● When carrying out injector tests, do not allow the hands to come into contact with the fuel jet.
Job Card No.: Precautions when Working on Fuel System Engine: Filing No.
Job Card No.: Injection Pump Locking Control Rod Inspection 07.01.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-17-10 1947 Inspection Job Card: Check injection pump control rod for movement. - 05.00.01 Located in the injection pump top are the individual plug-in elements, the plungers of which are driven by the injection pump camshaft via roller follower tappets. Positive plunger/tappet contact is ensured by a spring. The control rod 310 - Fig.
Job Card No.: 07.01.01 Injection Pump Locking Control Rod Inspection Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-17-10 1947 Locking out Pump Element (actuate lock) ● Engine Running - Press knurled nut (9) - Fig. 2 - against spring pressure until pin (2) is positioned under roller tappet bush (3). - Turn knurled nut until the arrow points up wards. The lock is now engaged and holds the roller tappet bush in TDC position. ● Engine Stationary - One person must turn the engine by hand.
Job Card No.: Injection Pump Element Removal / Refitment 07.02.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-17-10 1953 Should it become necessary to renew a pump element, a basic setting for the idle stroke and for constant delivery has to be carried out prior to installation. Observe strict cleanliness. Use non-fraying rags for cleaning. Job Cards: - 05.00.01 07.00.01 07.02.02 07.02.04 07.02.05 07.03.01 Tools: - Standard tools Assembly device (Section 1.
Job Card No.: 07.02.01 Injection Pump Element Removal / Refitment Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-17-10 1953 Removing the Element Removal is initially as described under ”Removing the Delivery Valve”. Then turn engine by hand until the plunger of the relevant pump element is in topmost position, i.e. with the tappet roller resting on the cam peak. Take out screws (303) - Fig. 2 - together with washers (348). Remove plate (298), locking strip (299) and bridge (301). © 25 544 1 Fig.
Injection Pump Element Removal / Refitment Job Card No.: 07.02.01 Page 3 of 3 Engine: Filing No.: 0178-17-10 1953 S/BVM 628 Then complete assembly device with bush (7) - Fig. 5 - and fit element seal into position. Place on bush so that locking strip (299) - Fig. 2 - can engage in the cut-out during reassembly. Secure bridge (301) - Fig. 2 -, locking strip (299) and plate (298) by means of screws (303) complete with washers (348).
Job Card No.: Injection Pump Element Removal / Refitment Engine: Filing No.
Job Card No.: Idle Stroke Setting 07.02.02 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-17-10 1955 Job Card: Setting Prior to installing a pump element, it is necessary to carry out a basic setting of the idle stroke. 07.02.01 Tools - Standard tools Depth gauge Job Turn engine by barring gear until the relevant tappet roller rests on the cam base circle. To facilitate gauging, insert a bush (b) - Fig. 1. Using depth gauge, measure dimension (a) and calculate dimension (t).
Job Card No.: 07.02.02 Idle Stroke Setting Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-17-10 1955 The depth dimension (t) of 156 mm - Fig. 1 - is now obtained by means of shim plates (12) of various thicknesses. This results in an idle stroke (X) - Fig. 3 - of 3,5 ± 0,1 mm. © 25 549 1 Fig. 2 Max. tolerance +/- 0.5 mm for later firing pressure correction, in view of limited free distance between spring cap (41) and pump element (293). Changing the thickness of the shim plate pack by 0.
Job Card No.: Injection Pump Control Rod Removal / Refitment 07.02.03 Page 1 of 4 Engine: Filing No.: 0178-17-10 2054 Removal and reinstallation of the plungers require removal of the control rod. This can be done with the fuel injection pump mounted, otherwise remove injection pump as described on Job Card 07.04.01. S/BV 6/8 M 628 Tools: - Standard tools Deutz DW 59 locking compound (Section 3.6) Job Cards: - 07.02.06 05.04.14 Job: Removing Control Rod of Pump No. 1 - Fig.
Job Card No.: 07.02.03 Injection Pump Control Rod Removal / Refitment Page 2 of 4 Engine: S/BV 6/8 M 628 Filing No.: 0178-17-10 2054 Slacken hex. bolts (57) and lever (313) at the RH and LH sides of the control rod. Unscrew hex. bolts (62) and take down washer (61). Withdraw bush(es) (391) and bush (59), if any. Check pertaining shaft seal (60) and renew, if necessary. Pull out shaft(s) (390) complete with circlip (55), tube (326), washers (227, 228).
Injection Pump Control Rod Removal / Refitment Job Card No.: 07.02.03 Page 3 of 4 Engine: Filing No.: 0178-17-10 2054 S/BV 6/8 M 628 Refitting Control Rod of Pump No. 1 The installation of the control rod is carried out in the reverse order to removal. Introduce the rod into the pump case, seeing to it that the adjusting pins (21) engage in the forks (3) - Fig. 3-. © 25 345 1 Fig. 3 When fitting the shafts, set clearance to 0,2 +02 mm Fig. 4 - with shims (227, 228). Lead-seal hex.
Job Card No.: 07.02.03 Injection Pump Control Rod Removal / Refitment Page 4 of 4 Engine: S/BV 6/8 M 628 Filing No.: 0178-17-10 2054 Removing Control Rod of Pump No. 2 - Fig. 1 Remove connection rod (55) (job 05.04.14). Unscrew plug screw (64) - Fig. 2 - with sealing ring (206). Loosen and remove the cheese head screw (343) - Fig. 5 - underneath in the pump housing. Remove cover (277) and gasket (276). Take off the hex.
Job Card No.: Injection Pump Control Rod Removal / Refitment 07.02.03 Page 1 of 4 Engine: Filing No.: 0178-17-10 2055 Removal and reinstallation of the plungers require removal of the control rod. This can be done with the fuel injection pump mounted, otherwise remove injection pump as described on Job Card 07.04.01. S/BV 9 M 628 Tools: - Standard tools Deutz DW 59 locking compound (Section 3.6) Job Cards: - 07.02.06 05.04.14 Job: Removing Control Rod of Pump No. 1 - Fig.
Job Card No.: 07.02.03 Injection Pump Control Rod Removal / Refitment Page 2 of 4 Engine: S/BV 9 M 628 Filing No.: 0178-17-10 2055 Slacken hex. bolts (57) and lever (313) at the RH and LH sides of the control rod. Unscrew hex. bolts (62) and take down washer (61). Withdraw bush(es) (391) and bush (59), if any. Check pertaining shaft seal (60) and renew, if necessary. Pull out shaft(s) (390) complete with circlip (55), tube (326), washers (227, 228).
Injection Pump Control Rod Removal / Refitment Job Card No.: 07.02.03 Page 3 of 4 Engine: Filing No.: 0178-17-10 2055 S/BV 9 M 628 Refitting Control Rod of Pu mp No. 1 The installation of the control rod is carried out in the reverse order to removal. Introduce the rod into the pump case, seeing to it that the adjusting pins (21) engage in the forks (3) - Fig. 3). © 25 345 1 Fig. 3 When fitting the shafts, set clearance to 0,2 +02 mm Fig. 4 - with shims (227, 228). Lead-seal hex. bolts (320) - Fig.
Job Card No.: 07.02.03 Injection Pump Control Rod Removal / Refitment Page 4 of 4 Engine: S/BV 9 M 628 Filing No.: 0178-17-10 2055 Removing Control Rod of Pump No. 2 - Fig. 1 Remove connection rods (55) between the fuel injection pumps (job 05.04.14). Now proceed as described for pump No. 1. Refitting Control Rod of Pump No. 2 Reinstallation is carried out as described for pump No. 1. Removing Control Rod of Pump No. 3 - Fig. 1 Remove connection rod (55) (job 05.04.14).
Job Card No.: Injection Pump Element Seal Reconditioning 07.02.04 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-17-10 2053 Reconditioning Tools - Where leaks are discovered near ring (295) - Fig. 1, renew O-seal (392) - Fig. 2 - and supporting ring (393). Standard tools Slide gauge Parker-O-Lube compound Job Cards: - If a pump element is to be renewed, renew also O-seal (392) and supporting ring (393) of the element sealing pack. 07. 00. 01 07 . 02 .
Job Card No.: 07.02.04 Injection Pump Element Seal Reconditioning Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-17-10 2053 Example (assuming A = 13.6 mm): hx = A - 13 hx = 13,8 - 13 hx = 0,8 mm When fitting a shim of 0.3 mm thickness, a clearance of 0.2 mm remains (0.8 - 0.6 = 0.2), which is within the tolerance of = to 0.2 mm. Refitting the Seal Install element (Job Card 07.02.01). Insert seal components as per Fig. 2.
Job Card No.: Constant Delivery Setting 07.02.05 Engine: Filing No.: S/BVM 628 0178-17-10 1960 Job Cards: Maintenance - Prior to installing a new pump element, it is necessary to set the pump element for constant delivery. 05.00.01 11.01.05 Tools: - Standard tools Job Check thermocouples as per Job Card 11.01.05. Slacken locknut (13) - Fig. 1. By means of guide (16) - eccentric - adjust lug (3) so that it is positioned at an angle of 90° relative to the control rod. Tighten locknut.
Job Card No.: Constant Delivery Setting Enfgine: Filing No.
Job Card No.: Valve Tappet Removal / Refitment 07.02.06 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-17-10 1963 Job Cards: If the tappet bush or roller has become defective, the entire tappet assembly (11) - Fig. 1 must be renewed. - 07.02.01 07.02.03 Tools: - Standard tools Spring assembly device Job Removing the Tappet Remove pump element (293) (job 07.02.01) and control rod (310) (job 07.02.03). Turn engine by barring gear until roller of relevant tappet rests on cam peak.
Job Card No.: 07.02.06 Valve Tappet Removal / Refitment Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-17-10 1963 Replacing the Spring Push lower fork (7) - Fig. 3 - into tube (6) and place the spring in tube with device. Push upper fork (7) into tube and turn short screw (3) out of device. Now screw in the longer screw (5) - Fig. 3 - and compress the spring a little. Remove top fork and turn out longer screw. The spring is now unloaded. Spring loading is effected in the reverse order.
Firing Pressure and Exhaust Temperature Correcting Job Card No.: 07.02.07 Engine: Filing No.: S/BVM 628 0178-17-10 1961 Servicing Job Cards: After setting the idle stroke and constant delivery, checking and correcting of the firing pressure and exhaust temperature becomes necessary. - 07.00.01 07.02.02 07.02.05 11.01.05 Tools: - Standard tools Job Check thermocouples (job 11.01.05). Apply full load to engine as described in the acceptance documents.
Job Card No.: Firing Pressure and Exhaust Temperature Correcting Engine: Filing No.
Job Card No.: Removing and Refitting Injection Piping 07.03.01 Engine: Filing No.: S/BVM 628 0178-21-10 1812 Mark piping by paint or labels with the associated cylinder No. before removal. Job Cards: - 07.03.02 07.07.01 Tools: - Standard tools Dog and socket wrench with tommy bar (Section 1.8) Job: Removing the Piping - Fig. 1 Stop engine. Release bolt (7), unscrew bolts (12) and take down clip (10). Slacken union screw (1) through one or two turns, so the inner seal will not be damaged.
Job Card No.: Removing and Refitting Injection Piping Engine: Filing No.
Job Card No.: Fuel System Bleeding 07.03.02 Engine: Filing No.: S/BVM 628 0178-20-10 1847 Servicing Tools: - Before using reconditioned (overhauled) or new injection pumps, or following fitment of fuel piping, filter or overflow valve, the entire fuel system must be filled up with fuel and bled. Standard tools Claw grip spanner with tommy bar (Section 1.8) Job Bleeding the Low Pressure System - Fig. 1 Stop engine. Place control rod of injection pump in full-load position.
Job Card No.: Fuel System Bleeding Engine: Filing No.
Job Card No.: Injection Piping Renewal 07.03.03 Engine: Filing No.: S/BVM 628 0178-21-10 2057 Job Card: Reconditioning If, due to frequent reassembly or excessive tightening, the end of the injection piping has been contracted, i.e. the inside diameter is less than 3.0mm, the piping must be renewed. 07.03.01 Tools: - Standard tools Socket spanner with tommy bar (Section 1.8) Job Remove injection piping (job 07.03.01).
Job Card No.: Injection Piping Renewal Engine: Filing No.
Job Card No.: Injection Pump Removal / Refitment 07.04.01 Page 1 of 8 Engine: Filing No.: 0178-18-10 2059 The described job sequence must be strictly adhered to and followed for each removal and refitment of injection pump. S/BV 6/8/9 M 628 Tools: - If an injection pump has to be disassembled for repair purposes it has to be brought to a DEUTZ- Service station and calibrated there - following its reassembly - to the same injection quantity and set to maximum fuel stop power.
Job Card No.: 07.04.01 Injection Pump Removal / Refitment Page 2 of 8 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-18-10 2059 Removing pumps P1, P2, or P3 - fig. 3 ● Unscrew the 4 fitted bolts (1) and (8) - Fig. 2. Remove coupling with washers (9) and (10), coupling disc (5) and bushes (2) and (3). Loosen cheese head bolts (7), remove washers (23) and shaft (14) - pump 1 or (24) pump 2 or 3 - paying attention to dowel sleeve (22). © 50 288 1 Fig. 2 ● Retain injection pump - Fig. 3 - with hoist.
Injection Pump Removal / Refitment Job Card No.: 07.04.01 Page 3 of 8 Engine: Filing No.: 0178-18-10 2059 S/BV 6/8/9 M 628 Before refitting injection pumps ● Make sure that only genuine DEUTZ gaskets are fitted under crankcase covers - behind injection pumps - and spacers (25) - Fig. 3 - otherwise alignment errors may result. Refitting pump 1 (6/8/9-cyl. engine) ● Fit shaft (14) - Fig.
Job Card No.: 07.04.01 Injection Pump Removal / Refitment Page 4 of 8 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-18-10 2059 Axial alignment of shaft and assembly of coupling ● Check whether all tappets of injection pump are out of function (see job card 07.01.01). ● Move shaft to both end positions - drive end and free end - Fig. 6. © 50 296 1 Fig. 6 ● Gauge in each end position - Fig. 7. Clearance = maximum dimension “C” minus minimum dimension “C”. © 50 294 1 Fig.
Injection Pump Removal / Refitment Job Card No.: 07.04.01 Page 5 of 8 Engine: Filing No.: 0178-18-10 2059 S/BV 6/8/9 M 628 Checking easy movement of shaft ● Turn shaft (14) - Fig. 9 - by hand at least one full revolution and check for easy movement. Reassembling injection pump retainer ● Fasten retainer loosely, but without clearance, with hex. bolts (13) and (101). © 50 292 1 Fig. 9 ● Check with feeler gauge 0.05mm between: retainer - crankcase, retainer - injection pump - Fig. 10.
Job Card No.: 07.04.01 Injection Pump Removal / Refitment Page 6 of 8 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-18-10 2059 Tightening drive shaft bolts ● Make sure that scriber marks on injection pump drive gear (8) - Fig. 1 - and shaft section (19) correspond. Tighten cheese head bolts (17), as specified (Section 3.5, line 16). ● Tighten fitted bolts (1) crosswise - Fig. 11 - and (8), as specified (Section 3.5, line 14). ● Tighten cheese head bolts (7) - Fig. 12 - as specified (Section 3.
Injection Pump Removal / Refitment Job Card No.: 07.04.01 Page 7 of 8 Engine: Filing No.: 0178-18-10 2059 S/BV 6/8/9 M 628 ● Turn crankshaft in direction of engine rotation - depending on engine design - two complete revolutions, while recording intensity and direction of dial gauge deflection. Max. permissible dial gauge deflection: - Coupling disc +/- 0.03mm - Injection pump 0.
Job Card No.: 07.04.01 Injection Pump Removal / Refitment Page 8 of 8 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-18-10 2059 ● Check shaft (14) for easy movement. For this purpose loosen cheese head bolts (17) - Fig. 1 - as described under heading “Before removing injection pumps”. Make several crankshaft revolutions by hand and check for smooth and even running.
Job Card No.: Injection Pump Camshaft Removal / Refitment 07.05.01 Page 1 of 2 Filing No.: Filing No.: S/BVM 628 0178-17-10 1156 Defective cams etc. will require the entire camshaft to be replaced. Job: Remove injection pump from engine (job 07.04.01). Lock out all roller tappet bushes. Job Card: - 07.04.01 Tools: - Standard tools Dial gauge Removing the Camshaft Injection Pump without Engine Auxiliaries Unscrew bolts (5 and 15), remove retainer (3) and pull out flanges (2 and 11).
Job Card No.: 07.05.01 Injection Pump Camshaft Removal / Refitment Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-17-10 1156 Injection Pump with Engine Auxiliaries (fig. 2) Remove components at the end opposite the auxiliaries as described before. Detach casing 18 for auxiliaries by unscrewing bolts (17), circlip (25) and ring (25). Pull out camshaft toward either end of pump case. Refitting the Camshaft Clean all components in diesel fuel and replace any worn components.
Job Card No.: Injection Timing 07.06.01 Page 1 of 2 Engine: Filing No.: 0178-17-10 1157 S/BV 6/8/9 M 628 Injection Timing Tools: (Setting the Commencement of Injection) Following any work on the injection pump drive, test the commencement of injection on the pump element for the No. 1 cylinder. - Adjusting the commencement of injection and hence the firing pressures is permissible only when the pressures depart from the Acceptance Certificate.
Job Card No.: 07.06.01 Injection Timing Page 2 of 2 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-17-10 1157 Conversion to degrees crank angle „ α “ where „d“ = flywheel diameter(810 and 970 mm) α = 360 x b dxı The crank angle "α" thus found must roughly meet the Acceptance Certificate, the engine reaching full load. Following this, adjust the coupling, paying attention to the normal direction of rotation of the injection pump drive. To do so, unscrew plug (11) on cover (8) near the pump drive.
Injector (Uncooled) Removal / Refitment Job Card No.: 07.07.01 Page 1 of 2 Engine: Filing No.: 0178-19-10 1637 S/BVM 628 Job Cards: - 07.03.01 07.03.02 Tools: - Standard tools Injector removing device (Sect. 1.8) Deutz S1 lubricating compound (Sect. 3.6) Deutz F5 lubricating compound (Sect. 3.6) © 51 317 0 Job Removing the Injector (see also Fig. 3): Stop engine. Open indicator valves. Remove injection piping. Remove rocker chamber cover.
Job Card No.: 07.07.01 Injector (Uncooled) Removal / Refitment Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-19-10 1637 Refitting the Injector: Apply light film of Deutz S1 heat-resistant lubricating compound to new washer (29) and its seat, as well as to sliding surface of nozzle (15). Fit washer on injector. If necessary, fit new O-seals 2 and apply light film of Deutz F5 compound. Install injector with the aid of dowel pin (30). Clean joints of injection piping.
Job Card No.: Injector (Cooled) Removal / Refitment 07.07.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-19-10 1638 Job Cards: - 07.03.01 07.03.02 Tools: - Standard tools Removing device (Section 1.8) Deutz S 1 lubricating compound (Section 3.6) Deutz F 5 lubricating compound (Section 3.6) Job Removing the Injector: Stop engine. Open indicator valves. Cut out injector coolant pump. Disconnect injection and coolant piping, paying attention to the seals. Remove rocker chamber cover. Unscrew hex.
Job Card No.: 07.07.01 Injector (Cooled) Removal / Refitment Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-19-10 1638 Refitting the Injector Apply light film of Deutz S1 heat-resistant lubricating compound to new washer (29) and its seat, as well as to sliding surface of nozzle (15). Fit washer on injector. If necessary, fit new O-seals 2 and apply light film of Deutz F5 compound. Install injector with the aid of dowel pin (30). Clean joints of injection piping.
Job Card No.: Injector (Uncooled) Inspection / Testing 07.08.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-19-10 1928 Inspection / Testing Tools: - Apart from the intervals specified in the Maintenance Schedule, injectors must be inspected and tested whenever they fail to work properly. Standard tools Injector testing device (Section 1.
Job Card No.: 07.08.01 Injector (Uncooled) Inspection / Testing Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-19-10 1928 Correcting the Injection Spray Pressure ● For this purpose unscrew cap (12) and loosen sleeve (11). ● Adjust pressure with adjusting screw (10) and secure by sleeve (11). ● Check O-seals (2) and gasket (13), and replace, if necessary. ● Apply some lubricating compound Deutz F5 to O-seals. Screw on cap (12).
Job Card No.: Injector (Cooled) Inspection / Testing 07.08.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-19-10 1929 Tools: Inspection / Testing - Apart from the intervals specified in the Maintenance Schedule, injectors must be inspected and tested whenever they fail to work properly. Standard tools Injector testing device (Section 1.
Job Card No.: 07.08.01 Injector (Cooled) Inspection / Testing Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-19-10 1929 Correcting the Injection Spray Pressure ● ● ● ● ● For this purpose turn clamping nut (18) to remove adapter (19) from housing (4). Release sleeve (11). Set correct pressure with hexagon of adjusting screw and retighten sleeve (11). Check 0-seals (2) and gasket (17) and replace, if necessary. Apply some lubricating compound Deutz F5 to 0-seals.
Job Card No.: Injector (Uncooled) Reconditioning 07.09.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-19-10 1926 Reconditioning When injectors are due for reconditioning according to the Maintenance Schedule, replace nozzles. Job Cards: - 07.07.01 07.08.01 Tools: Exercise utmost cleanliness when reconditioning an injector. Use no metallic tools for cleaning, apart from wire brushes. - Standard tools Deutz S1 compound (Section 3.6) Deutz S2 compound (Section 3.
Job Card No.: 07.09.01 Injector (Uncooled) Reconditioning Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-19-10 1926 Inspecting the Nozzle Introduce needle (16) - Fig. 2 - with diesel fuel into nozzle element(15). When pulled out halfway by its thrust pin, the needle must sink back onto its seat by its own weight. Should the needle (16) bind, it must be renewed as a unit with nozzle element (15). Nozzles may not be reworked.
Job Card No.: Injector (Uncooled) Reconditioning 07.09.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-19-10 1927 Reconditioning When injectors are due for reconditioning according to the Maintenance Schedule, renew nozzles. Exercise utmost cleanliness when reconditioning an injector. Use no metallic tools for cleaning, apart from wire brushes. Job Cards: - 07.07.01 07.08.01 Tools: - Standard tools Deutz S1 compound (Section 3.6) Deutz S2 compound (Section 3.
Job Card No.: 07.09.01 Injector (Uncooled) Reconditioning Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-19-10 1927 Inspecting the Nozzle Introduce needle (16) (Fig. 2) with diesel fuel into nozzle element (15). When pulled out halfway by its thrust pin, the needle must sink back onto its seat by its own weight. Should the needle (16) bind, it must be renewed as a unit with nozzle element (15). Nozzles may not be reworked.
Job Card No.: Fuel Duplex Filter 07.10.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-20-10 2051 Servicing Tools: Cleaning fuel duplex filter - While the engine is running, only one of the two filter chambers should be operative, lever (7) - Fig. 1 - of the 3-way cock being in the LH or RH position accordingly. Should the fuel pressure fall off, or if a red indicator appears in the window of the pressure differential monitor (30) - Fig.
Job Card No.: 07.10.01 Fuel Duplex Filter Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-20-10 2051 Take out element (6). Wash out any contamination in filter housing with diesel fuel and brush. Clean strainer filter in diesel fuel as well. Renew filter cartridges. By no means refit any damaged paper filter cartridges. Before reassembling, check condition of O-seal (9) and gasket (8) - renew if necessary. Install element (6) and fit cover (1).
Job Card No.: Fuel Feed Pump Removal / Refitment 07.11.01 Engine: Filing No.: S/BVM 628 0178-20-10 1644 Job Job Card: Removing Pump Close shut-off valves from and to daily service tank. Disconnect fuel piping from pump, draining fuel emerging into a suitable receptacle. Unscrew bolts (1) and (2), and carefully remove pump. - 07.03.02 Tools: - Standard tools MOLYCOTE Longterm 2 (Sect. 3.
Job Card No.: Fuel Feed Pump Removal / Refitment Engine: Filing No.
Lubricating Oil System Precautionary Measures Job Card No.: 08.00.01 Engine: Filing No.: 0178-16-10 1838 S/BVM 628 When working on the lubricating oil system, the following safety precautions and environment-protective regulations are to be observed: ● Beware of hot oil! ● Prior to any dismantling work, shut down engine (see Section 4.4). Collect any escaping oil in a suitable receptacle and dispose of properly in accordance with anti-pollution regulations.
Job Card No.: Lubricating Oil System Precautionary Measures Engine: Filing No.
Job Card No.: Oil Sampling 08.01.01 Engine: Filing No.: 0178-15-10 1164 Inspection S/BV 6/8/9 M 628 Tools: - 1 litre container (sheet metal or plastics) Regular inspection of the lube oil is essential for determining the engine’s working condition. With the engine running, oil samples should preferably be taken by the same man at some 60°C oil temperature. Job: Hold a waste container under hose connector (2). Slacken bolt (1) until oil slowly comes out through connector (2).
Job Card No.: Oil Sampling 08.01.01 Engine: S/BV 6/8/9 M 628 Filing No.
Job Card No.: Oil System Inspection 08.02.01 Engine: Filing No.: S/BVM 628 0178-15-10 1165 Inspection Tools: - Standard tools Carry out inspection and servicing work on the lubricating system. Unsuitable lube oil may cause sticking of piston rings, seizure of pistons, hot running of bearings and increased wear and tear of the entire engine. Be sure, therefore, to use a lube oil meeting the minimum quality requirements specified (Section 6).
Job Card No.: Oil System Inspection Engine: Filing No.
Job Card No.: Lube Oil Change 08.02.02 Engine: Filing No.: S/BVM 628 0178-15-10 1166 Oil Change The oil change period largely depends on the quality of the fuel and lube oil used, the quantity of oil in the engine lubrication system, the operating conditions, the lube oil consumption of the engine, and the efficiency of the filter. Job Cards: - 08.00.01 08.01.01 08.02.01 08.10.01 Tools: - Standard tools For the above reasons, the manufacturer is unable to state standard times for lube oil change.
Job Card No.: Lube Oil Change Engine: Filing No.
Job Card No.: Lube Oil Pump Servicing 08.04.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-14-10 1814 Servicing Tools: - Dismantling of pump and inspection of gear shafts, bearings and relief valves. Standard tools Puller Deutz DW 55 compound (Section 3.6) Deutz DW 48 compound (Section 3.6) Deutz DW 50 compound (Section 3.6) Job Card: - 04.08.01 Job Removing the Pump (Fig. 1) Stop engine. Disconnect suction line (1) and delivery line (2) from pump (3). Remove bleed and filling line (4).
Job Card No.: 08.04.01 Lube Oil Pump Servicing Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-14-10 1814 © 51 327 0 Fig. 3 Relief Valve (Fig. 3) Unscrew nuts (20) and remove valve (21). Clean components. Check valve. Reassembling the Pump Install gear (15) (Fig. 3) in pump cover (9). Install key (22) - Fig. 2 - and fit gear (12). Screw bolt (10) with washer (11) in place and tighten with Deutz DW 55 locking compound (Section 3.5, item 22). Apply Deutz DW 50 to sealing face of cover (8) - Fig. 3 -.
Lube Oil Pump Servicing Job Card No.: 08.04.01 Page 3 of 3 Engine: Filing No.: 0178-14-10 1814 S/BVM 628 Apply a continuous bead of Deutz DW 48 compound (bead not exceeding 3 mm in width for optimum sealing) to cover (8) - Fig. 4 -. Fit cover(25) and tighten by hex. bolts (24). bead © 51 328 0 Fig. 4 Refitting the Pump (Fig. 5) Secure pump (3) with new O-seal (23) by hex. bolts (5) to pump chest. Reconnect all piping: Fill pump with oil. Make sure that pump never runs dry.
Job Card No.: Lube Oil Pump Servicing Engine: Filing No.
Job Card No.: Oil Filter Combination (Non-Backflushing Wire Edge Filter) 08.09.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-15-10 6507 Tools: Servicing and Repair Inserted in the lube oil primary flow is a filter combination comprising a paper microfilter preceding the wire edge filter (see also Job 08.10.01). The wire edge filter can be equipped at option with a differential pressure warning system which responds in case of excessive contamination.
Job Card No.: 08.09.01 Oil Filter Combination (Non-Backflushing Wire Edge Filter) Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-15-10 6507 ● Undo hex. nuts (9) - Fig. 2 - with withdraw edge filter element (14) from filter body. ● Remove square flange gasket (8). To prevent dirty cleaning fluid from getting inside the element, close open end with a cap of 55 mm dia. ● Dip element in diesel fuel, actuate rotary knob (5) alternately and clean element with the brush.
Job Card No.: Oil Filter Combination (Backflushing Wire Edge Filter) 08.09.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-15-10 6508 Tools: Servicing and Repair - Inserted in the lube oil primary flow is a filter combination comprising a paper microfilter preceding the wire edge filter (see also Job 08.10.01). The wire edge filter can be equipped at option with a differential pressure warning system which responds in case of excessive contamination.
Job Card No.: 08.09.01 Oil Filter Combination (Backflushing Wire Edge Filter) Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-15-10 6508 Job: Removing and refitting wire edge filter element; cleaning filter chamber. ● Stop engine ● Remove drain plug (3) along with joint washer (2). ● Drain oil. ● Remove back flushing line from filter elements. ● Undo hex. nuts (9) and withdraw element (14) from filter body. ● Remove square flange gasket (8).
Oil Filter Combination (Backflushing Wire Edge Filter) Job Card No.: 08.09.01 Page 3 of 3 Engine: Filing No.: 0178-15-10 6508 S/BVM 628 © 51 333 0 Fig.
Job Card No.: Oil Filter Combination (Backflushing Wire Edge Filter) Engine: Filing No.
Combined Lube Oil Filter (with Paper Micro Filter) Servicing Job Card No.: 08.10.01 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-15-10 1659 Servicing Tools: The combined full-flow oil filter comprises a wire edge-type filter (job 08.09.01) preceded by a cartridge-type micro filter. Service gauge 17 indicates when the filter cartridge is due for replacement. - Standard tools Pail New filter cartridge Diesel fuel Cleaning brush Job Card: - 08.09.
Job Card No.: 08.10.01 Combined Lube Oil Filter (with Paper Micro Filter) Servicing Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-15-10 1659 Job Change paper filter cartridge (Fig. 3) and clean filter chamber. Stop engine. Place pail beneath hose connector 24 (Fig. 2) and open plug 25 to drain oil from filter. Release hex. nuts 7 (Fig. 3) and work loose cover 12 by lever or screwdriver. Remove O-seal 6 and nut 11. Clamping piece 16 is under spring pressure.
Job Card No.: Oil Pressurestat Inspection 08.11.01 Engine: Filing No.: 0178-16-10 1171 S/BV 6/8/9 M 628 Inspection Tools: When the oil pressure falls off, inspect pressurestat. - Standard tools Pocket lamp The pressurestat is not adjustable. With the engine hot, the oil pressure should conform to the acceptance test sheet (see also Specification Data under 3.3.2).
Job Card No.: Oil Pressurestat Inspection 08.11.01 Engine: S/BV 6/8/9 M 628 Filing No.
Job Card No.: Centrifugal Oil Cleaner 08.13.01 Page 1 of 2 Engine: Filing No.: S/BV 6/8/9 M 628 0178-15-10 2010 Servicing Tools: Clean centrifugal oil cleaner. Inspect valve. - Clean only when engine is stationary or the feed line is isolated. Change paper lining in rotor at regular intervals and clean centrifuge. Standard tools Cleaning brush Wooden scraper Job Card: - 08.00.01 Job: Stop engine or close feed line. Remove screw plug (11) - Fig. 1 - together with sealing ring.
Job Card No.: 08.13.01 Centrifugal Oil Cleaner Page 2 of 2 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-15-10 2010 Following this, clean all parts and blow out with compressed air, particularly the nozzles and all bores. Install valve (9) complete with spring (10), and screw plug (11) together with sealing ring. Fit new lining (3) Fig. 2. Push rotor upper part carefully over rotor lower part, paying attention to the fixing location of both parts. Tighten fastening nut (13) - Fig. 1.
Job Card No.: Valve Seat Lubrication System 08.14.01 Page 1 of 2 Engine: Filing No.: S/BV 6/8/9 M 628 0178-16-10 1640 Checking Tools: - Standard tools Inspect the valve seat lubrication system. Check volume of valve seat lubrication. Job: Visual inspection: View through inspection window of dropper (1). If the valve seat lubrication system is working, drops will form at the valve of the dropper and drip off in slow sequence. If not, find out the cause and remedy.
Job Card No.: 08.14.01 Valve Seat Lubrication System Page 2 of 2 Engine: S/BV 6/8/9 M 628 Filing No.: Detail "X" 0178-16-10 1640 Detail "Y" © 51 340 0 Check volume of valve seat lubrication: The delivery volume is measured in drops (1), and is specified in Section 3.3.2. If necessary, correct volume by means of detent screw (2) on oil pump. To increase volume, turn screw clockwise, and vice versa.
Job Card No.: Sealing Oil Two-way Valve Servicing 08.20.01 Engine: Filing No.: S/BV M 628 0178-16-10 1154 Servicing Remove two-way valve of injection pump plunger hydraulic seal (Section 5.1.4), dismantle and clean. Following commissioning of a new engine, valve element 3 may bind due to dirt coming from the sealing oil high-level tank. In this case clean not only valve, but also tank and line to valve. Tools: - Standard tools, Detergent Job Card: - 07.03.01 Job: Stop engine.
Job Card No.: Sealing Oil Two-way Valve Servicing Engine: Filing No.
Job Card No.: Oil Micro Filter Servicing 08.20.02 Engine: Filing No.: S/BVM 628 0178-16-10 1170 Servicing Tools: Replace filter element. - The microfilter is arranged in the oil circuit bypass line ahead of the lubricator to ensure an especially high degree of cleanliness of the oil supplied to the injection pump and, if provided, the air compressor. The air flows through the element outside in and deposits its impurities on the impregnated filter paper perforated with minute holes.
Job Card No.: Oil Micro Filter Servicing Engine: Filing No.
Cooling Water System Draining Job Card No.: 09.00.01 Page 1 of 2 Engine: Filing No.: 0178-37-10 1549 S/BV 6/8/9 M 628 See also Sections 6.4 and 6.5 Jobs on cylinder head, crankcase, turbocharger, heat exchanger, water pump(s), piping, etc., may require the cooling water to be drained partially or entirely. Where the engine is shut down for a major period and frost is imminent, drain all water from engine and attachments, unless an anti-freeze is provided.
Job Card No.: 09.00.01 Cooling Water System Draining Page 2 of 2 Engine: S/BV 6/8/9 M 628 Filing No.: 0178-37-10 1549 © 51 414 0 ● Unscrew plug(s) (26) from centrifugal pump(s). © 51 415 0 ● Unscrew plug (14) from charge air cooler. ● Drain water from air bottles (job 10.01.01). ● Drain water from pressure reducing stations (job 10.06.01). ● Drain water from all pipe sockets by unscrewing plug. Where no plug is provided, disconnect associated pipe.
Job Card No.: Coolant Circulation Pump Servicing 09.07.01 Engine: Filing No.: S/BVM 628 0178-37-10 1815 Servicing Tools: Water leaks at outlet hole ”X” of bearing housing (9) suggest defective seal (31); oil leaks suggest defective seal (25). Replace as necessary. - Standard tools Holding device for impeller (Sect. 1.8) Deutz F2 compound (Sect. 3.6) Deutz S4 compound (Sect. 3.6) Job Card: - 09.07.02 Job Stop engine. Close shut-off valves in suction and delivery lines of water pump.
Job Card No.: Coolant Circulation Pump Servicing Engine: Filing No.
Job Card No.: Coolant Circulation Pump Reconditioning 09.07.02 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-37-10 1816 Reconditioning Tools: Dismantle coolant circulation pump, clean and inspect. In the case of mounted vibration damper, the coolant circulation pump is partly dismantled on the engine. - Standard tools Circlip pliers Holding device for impeller (Sect. 1.8) Puller for bearing Timber block The coolant pump is driven via an idler gear from the crankshaft gear.
Job Card No.: 09.07.02 Coolant Circulation Pump Reconditioning Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-37-10 1816 Job: Removing the Pump (Fig. 1) Stop engine. Close shut-off valves in suction and delivery lines of pump. Drain water from pump by removing plug (26). Disconnect suction and delivery lines between pump and shut-off valves. Unscrew hex. bolts (2) and take down intake (1). Fasten holding device (lock) (21) - Fig. 2 - by means of bolts (2) to volute casing (6).
Pneumetic System Testing / Servicing Job Card No.: 10.01.01 Engine: Filing No.: 0178-32-10 1185 S/BVM 628 Testing Check entire compressed-air system for correct functioning. To prevent seizure by rust of the system’s control valves, drain water from system including air receivers daily. Drain water from the compressed air receivers after each charging cycle as specified by the Accident Prevention Regulation. Job Drain water from air receivers. If an automatic drain valve is provided, inspect this.
Job Card No.: Pneumetic System Testing / Servicing Engine: Filing No.
Starting Pilot Air Distributor Inspection Job Card No.: 10.02.01 Page 1 of 2 Engine: Filing No.: 0178-30-10 1639 S/BVM 628 Tools: - Standard tools Job Card: - 02.00.01 The control disc (9) - Fig. 2 - contacts the distributor ring (13) only during the starting procedure. Ring (10) seals off the air passage to the crankcase. At the end of the starting procedure, control disc (9) runs free. Inspection Remove distributor ring (13) and control disc (9) for inspection. © 25 217 1 Fig.
Job Card No.: 10.02.01 Starting Pilot Air Distributor Inspection Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-30-10 1639 Screw out hex. bolts (2). Withdraw shaft (1). Clean all components. Check seals, control disc and distributor ring, renewing if necessary. Refitting Starting Pilot Air Distributor Make sure that lock pin (3) is present in camshaft and fit shaft (1) located by the lock pin. Screw in hex. bolt (2) and tighten (see Section 3.5, item 30).
Job Card No.: Starting Air Master Valve Servicing 10.03.01 Engine: Filing No.: S/BVM 628 0178-32-10 1187 Servicing Tools: Dismantle master valve and clean. - Standard tools Deutz S2 lubricating compound (Section 3.6) Job Card: - 05.00.01 Job Observe safety precautions (job 05.00.01). Disconnect control air pipe. Remove valve from starting air pipe. Dismantling the Valve Carefully unscrew bolts (1). Cover (3) is spring-loaded. Remove cover (3).
Job Card No.: Starting Air Master Valve Servicing Engine: Filing No.
Job Card No.: Dirt Collector 10.03.02 Engine: Filing No.: S/BVM 628 0178-32-10 1866 Servicing Before servicing the dirt collector in the starting air line, make sure that the shut-off valve on the compressed air receiver is closed. Tools: - Standard tools, Cleaning agent Daily: Open shut-off valve (1) on dirt collector and allow condensation water (if any) to drain off. Then reclose shut-off valve. Clean the Sieve as per Maintenance Schedule. Job: Loosen hex. nuts (3) and take out hex. bolts (2).
Job Card No.: Dirt Collector Engine: Filing No.
Starting Air Master Valve Running-in Screen Servicing Job Card No.: 10.03.91 Engine: Filing No.: 0178-32-10 1817 Servicing Clean screen ahead of master valve. At the end of 250 hours (or later) replace screen by a ring. All new engines are delivered with a screen ahead of the starting air master valve for the purpose of protecting the valve from piping scale or other foreign matter. After 50 running hours the screen must be cleaned or replaced.
Job Card No.: Starting Air Master Valve Running-in Screen Servicing 10.03.91 Engine: S/BV 6/8/9 M 628 Filing No.
Job Card No.: Pressure Reducer Station Servicing 10.06.01 Engine: Filing No.: S/BV M 628 0178-32-10 1383 Servicing Tools. - Standard tools Drain condensate and clean filter elements. This is possible while the engine is running. In hand lever position I and III, the H.P. lien is connected to the L.P. line through one filter and one pressure reducer each. The low pressure is indicated by gauge (6) direct; it can be adjusted with screws (5).
Job Card No.: Pressure Reducer Station Servicing Engine: Filing No.
Job Card No.: Temperature Switch (OIl, Water, Air) Testing / Reconditioning 11.01.01 Page 1 of 3 Engine: Filing No.: S/BVM 628 0178-48-10 1189 Testing Check the switch for correct setting and proper functioning. The switch comprises sensor (1) with pocket (2) - test site - and a setting unit (4) - cable terminal box -. Tools: - Standard tools Ohmmeter Thermometer Heat conducting compound Be sure lead (7) between setting unit (4) and sensor (1) will not chafe.
Job Card No.: 11.01.01 Temperature Switch (OIl, Water, Air) Testing / Reconditioning Page 2 of 3 Engine: S/BVM 628 Filing No.: 0178-48-10 1189 Reconditioning (Temperature sensor and setting unit cannot be repaired). Replacing the Sensor With engine running, remove screws (6) and take sensor (1) out of pocket (2). Before fitting a new sensor, check that sensor and setting unit are a match, i.e., their model designations must have the same figures.
Temperature Switch (OIl, Water, Air) Testing / Reconditioning Job Card No.: 11.01.01 Page 3 of 3 Engine: Filing No.
Job Card No.: Temperature Switch (OIl, Water, Air) Testing / Reconditioning Engine: Filing No.
Pressure Switch (Oil, Water, Air) Inspection/Testing/Servicing Job Card No.: 11.01.02 Engine: Filing No.: 0178-48-10 1190 S/BVM 628 Tools: - Standard tools, testing gauge, setting mandrel Testing hose with standard test flange (Section 1.8) Commercial test pump Inspection / Testing Inspect and test the switch for proper functioning Pressure switches are available for the following media: lube oil, fuel, raw water, fresh water, injector coolant, control (pilot) air, starting and charge air pressure.
Job Card No.: Pressure Switch (Oil, Water, Air) Inspection/Testing/Servicing Engine: Filing No.
Job Card No.: Pressure Switch for Oil, Water and Air 11.01.02 Page 1 of 2 Engine: Filing No.: S/BVM 628 0178-48-0010 1919 Inspection / Testing Tools: Inspect and test the switch for proper functioning. - Pressure switches are available for the following media: lube oil, fuel, raw water, fresh water, injector coolant, control (pilot) air, starting and charge-air pressure. Settings are indicated on the switch in bar (kp/cm2).
Job Card No.: 11.01.02 Pressure Switch for Oil, Water and Air Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-48-0010 1919 Servicing Setting the trip point For altering the setting (trip point), remove housing cover (5) and loosen fixing screw (6) located inside the housing. The trip point is set at the adjusting screw (7) with the aid of a screwdriver: clockwise raises pressure, counterclockwise reduces pressure.
Job Card No.: Pressure Transmitter Noris VD 61 - 2,5 11.01.02 Engine: Filing No.: S/BVM 628 0178-48- 297 6502 Inspecting Pressure Transmitter Tools: - Pressure transmitters are available for the following media, depending on the scope of monitoring equipment: lube oil, fuel, control air, starting and charge air pressure. Settings are indicated on the pressure transmitter in “bar”. The inspection is carried out during operation according to the intervals specified in the Maintenance Schedule.
Job Card No.: Pressure Transmitter Noris VD 61 - 2,5 Engine: Filing No.
Job Card No.: Flow Switch (Fuel Injection) Testing 11.01.03 Engine: Filing No.: S/BVM 628 0178-48-10 1191 Testing Check that flow switch for shielded injection lines works properly. Tools: - Srandard tools Tundish The switch can work properly only when the fuel back leakage line is installed with consistent gravity feed to the collector tank. Alarm by the flow switch in service may be caused by a broken line or a leaky connection.
Job Card No.: Flow Switch (Fuel Injection) Testing Engine: Filing No.
Exhaust Gas Thermocouples Removal / Refitment Job Card No.: 11.01.04 Engine: Filing No.: 0178-48-10 1841 S/BVM 628 Tools: - Standard tools The fastening location point (3) of the coupling socket is the temperature comparison point. Job Removing the Thermocouple Stop engine. Unscrew bolts (1) and remove cap (2). Pull plug (5) out of socket (4). Undo clamping union (9) and pull out complete thermocouple.
Job Card No.: Exhaust Gas Thermocouples Removal / Refitment Engine: Filing No.
Job Card No.: Exhaust Gas Thermocouples Testing 11.01.05 Engine: S/BVM 628 0178-48-10 1842 Filing No.: Testing Job Card: Carry out a comparative measurement if readings between thermocouples differ widely or a thermocouple has entirely failed. - 11.01.04 Tools: - Standard tools mV meter Thermometer Job Stop engine. Remove thermocouple (job 11.01.04). Carry out a comparative measurement either with a new thermocouple or one that has been removed from an adjacent cylinder.
Job Card No.: Exhaust Gas Thermocouples Testing Engine: Filing No.
NORIS-KN Safety System Job Card No.: 11.03.01 Engine: Filing No.: 0178-48-10 9988 S/BVM 628 NORIS-KN safety system The NORIS-KN safety system is designed for monitoring marine diesel and stationary engines. A description of the operation of the system can be found in the separate manufacturer’s documentation, which is enclosed. Maintenance work must only be carried out by DEUTZ service or by an authorised specialist workshop.
Job Card No.: NORIS-KN Safety System 11.03.01 Engine: S/BVM 628 Filing No.
Crankcase Oil Mist Detector Job Card No.: 11.05.01 Engine: Filing No.: 0178-48-10 1971 S/BVM 628 Checking and Servicing ● Cleaning the optical components, initially after 25 hours ● Cleaning the optical components, periodically every 250 hours ● Checking and servicing, periodically every 1000 hours All checking and servicing work should be carried out in accordance with the manufacturer’s operating manual.
Job Card No.: Crankcase Oil Mist Detector Engine: Filing No.
Job Card No.: Charge Air Water Detector Testing 11.06.01 Engine: Filing No.: S/BVM 628 0178-48-10 1197 Testing Tools: - Standard tools Test water detector for proper functioning. The detector is located beneath the charge air pipe. When water collects in the charge air pipe, due for instance to a charge cooler leak or the temperature not reaching the dew point, the water level will rise in container (4) and release an alarm. In this case be sure to remedy the trouble immediately.
Job Card No.: Charge Air Water Detector Testing Engine: Filing No.
Job Card No.: Oil Level Float Switch Testing 11.07.01 Page 1 of 2 Engine: S/BVM 628 0178-48-10 1546 Filing No.: Testing Tools: With engine stationary, test switch response. - The switch is provided where required. Where a high-level oil tank is fitted, the switch gives alarm for maximum level; where lubrication is from the regular sump, the switch gives alarm for minimum level. Standard tools Blunt wooden stick, 8 mm diameter, about 100 mm in length Job Card: - 02.00.
Job Card No.: 11.07.01 Oil Level Float Switch Testing Page 2 of 2 Engine: S/BVM 628 Filing No.: 0178-48-10 1546 © 51 370 0 Fig. 1 © 51 371 0 Fig. 2 Should no alarm be given, trace cause of defect immediately or replace switch. Never move switch with a pointed tool like a screwdriver and never use brute force. Check that nothing will fall into sump and that switch lead will not chafe.
Job Card No.: Service-warning Switch Checking 11.08.01 Engine: Filing No.: S/BVM 628 0178-48-10 1859 Checking Tools: Inspect and test function of the service warning switch on lube oil filter with engine stopped. - In the case of excessive contamination of the lube oil paper microfilter, the service warning switch causes a differential pressure warning to be given. Standard tools Testing pressure gauge Testing hose (Section 1.8) Standard testing pump Job Card: - 08.00.
Job Card No.: Service-warning Switch Checking Engine: Filing No.
Job Card No.: Viscous-type Vibration Damper (Version without Auxiliary Drive) 12.01.01 Engine: Filing No.: S/BVM 628 0178-34-10 1198 Replacement of this torsional vibration damper is due at the end of 15,000 running hours. Reconditioning must be made by the manufacturers only. Tools: - Standard tools 2 puller bolts M12 x 70 Hoist Job: Removing the Damper Stop engine. Remove casing. Attach damper (3) to hoist. Remove bolts (1) with washers (2).
Job Card No.: Viscous-type Vibration Damper (Version without Auxiliary Drive) Engine: Filing No.
Job Card No.: Viscous-type Vibration Damper (Version without Auxiliary Drive) 12.01.01 Engine: Filing No.: S/BVM 628 0178-34-10 1337 Replacement of this torsional vibration damper is due at the end of 15,000 running hours. Reconditioning must be made by the manufacturers only. Tools: - Standard tools 2 puller bolts M12 x 70 Hoist Job: Removing the Damper Stop the engine. Remove casing. Attach damper (3) to hoist. Remove bolts (1) with washers (2).
Job Card No.: Viscous-type Vibration Damper (Version without Auxiliary Drive) Engine: Filing No.
Job Card No.: Viscous-type Vibration Damper (Version with Auxiliary Drive) Filing No.: 12.01.01 Engine: 0178-34-10 1361 Replacement of this torsional vibration damper is due at the end of 15,000 running hours. Reconditioning must be made by the manufacturers only. S/BVM 628 Tools: - Standard tools Puller bolt M12 x 70 Hoist Job Removing the Damper Stop engine. Remove casing. Attach damper (2) to hoist. Remove screws (1) and (4), dowel pins (6) and auxiliary drive shaft (3).
Job Card No.: Viscous-type Vibration Damper (Version with Auxiliary Drive) Engine: Filing No.
Job Card No.: Rubber-type Vibration Damper Inspection / Reconditioning 12.01.02 Page 1 of 4 Engine: Filing No.: S/BVM 628 0178-34-10 1849 The torsional vibration occurring in the critical speed range of the engine is absorbed by two or four rubber damping elements secured between fly ring and the plates attached to the crankshaft flange. Tools: - Standard tools Pocket lamp Job Card: - 12.01.
Job Card No.: 12.01.02 Rubber-type Vibration Damper Inspection / Reconditioning Page 2 of 4 Engine: S/BVM 628 Filing No.: 0178-34-10 1849 Tools: - Standard tools Dial gauge Deutz DW 55 locking compound (Section 3.6) Markings Job Remove vibration damper (Job Card 12.01.03). Dismantling (4-element Damper) Markings provided on the large castings to show relative positionings - Fig. 1. © 25 112 1 Fig. 1 Remove hex. bolts (8) - Fig. 2 - and hex. plates (1). Now unscrew hex.
Rubber-type Vibration Damper Inspection / Reconditioning Job Card No.: 12.01.02 Page 3 of 4 Engine: Filing No.: 0178-34-10 1849 S/BVM 628 Insert damping-disc pair complete with threaded ring (7) - Fig. 4 - into end plate (1). Fit hex. bolts (20) provided with Deutz DW 55. Tighten up end plate and damping-disc pair with hex. nuts (15) (Section 3.5, item 58). © 25 115 1 Fig. 4 Insert ring (2) - Fig. 5 - and disc (14), observing markings as per Fig. 1.
Job Card No.: 12.01.02 Rubber-type Vibration Damper Inspection / Reconditioning Page 4 of 4 Engine: S/BVM 628 Filing No.: 0178-34-10 1849 Dismantling (2-element Damper) - Fig. 7 Markings provided on fly ring (22) and disc (18) to show relative positioning. Remove hex. bolts (12) and (15). Take off damping discs (4) and disc (18). Clean and inspect all components, renewing as necessary. Renew damping discs (4). Do not damage rubber elements of damping discs. Reassembly (2-element Damper) - Fig.
Rubber-type Vibration Damper (Version without Auxiliary Drive) Removal / Refitment Job Card No.: 12.01.03 Engine: Filing No.: S/BVM 628 0178-34-10 1366 Tools: - Standard tools 2 puller bolts M 12 x 70 Hoist Job Card: - 12.01.02 Job Removing the Damper Stop engine. Remove casing. Attach damper (2) to hoist. Remove bolts (1) with washers (2). Use bolts (4) to pull of damper (3) from crankshaft (5). Clean all damper contact faces. Remove any high spots with oil stone.
Job Card No.: Rubber-type Vibration Damper (Version without Auxiliary Drive) Removal / Refitment Engine: Filing No.
Rubber-type Vibration Damper (Version with Auxiliary Drive Removal / Refitment Job Card No.: 12.01.03 Engine: Filing No.: S/BVM 628 0178-34-10 1367 Tools: - Standard tools Puller bolt M12 x 70 Hoist Job Card: - 12.01.02 Job Removing the Damper Stop engine. Remove casing. Attach damper (2) to hoist. Remove screws (1) and (4), dowel pins (6) and auxiliary drive shaft (3). Use bolt (7) to pull off damper (2) from crankshaft (8) and carefully put down damper. Clean all damper contact faces.
Job Card No.: Rubber-type Vibration Damper (Version with Auxiliary Drive Removal / Refitment Engine: Filing No.
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