Operation Manual
Table Of Contents
- Operation Manual
- S/BV6/8/9M628
- 0297 7945 en
- Imprint
- Please read all the information ...
- Foreword
- General
- Register CoverSheet
- Table of contents
- 1 Guide to this Manual
- 2 Layout and Description of Engine
- 2.1 01 Cylinder Head
- 2.2 02 Crankshaft System
- 2.3 03 Engine Frame
- 2.4 04 Timing System
- 2.5 05 Speed Control System
- 2.6 06 Exhaust / Turbocharging System
- 2.7 07 Fuel System (see also 5.1)
- 2.8 08 Lubricating Oil System (see also 5.2)
- 2.9 09 Cooling Water System (see also 5.3)
- 2.10 10 Pneumatic System (see also 5.4)
- 2.11 11 Engine Protective System
- 2.12 12 Engine Auxiliaries
- 2.13 Engine Assemblies and Subassemblies
- 2.14 Cutaway View of Engine (8-cyl. engine)
- 3 Specification Data
- 3.1 Model Designation: S/BV 6/8/9 M 628
- 3.2 Designations of engine sides, cylinders and rotation direction
- 3.3 Basic Data
- 3.4 Weight of Engine Components
- 3.5 Tightening Specification for Heavy-Duty Screwed Joints
- 3.6 Sealing, Locking, Lubrication and Heat Conductor Compounds
- 3.7 Use of Liquid Nitrogen
- 3.8 Dye Checking of Metal Surfaces
- 4 Operating the Engine
- 4.1 Preparations for Operating the Engine on Distillate Fuel
- 4.2 Running the Engine on Distillate Fuel
- 4.3 Attendance in Service
- 4.4 Stoppage / Layoff of Engine Running on Distillate Fuel
- 4.5 Taking Combustion Indicator Diagrams
- 4.6 Run-in Instructions
- 4.7 Running the Engine with Defective Turbocharger
- 4.8 Emergency Operation
- 5 Engine Media Systems
- 5.1 Fuel System
- 5.2 Lubricating Oil System
- 5.3 Cooling Water System
- 5.3.1 Legend for Piping Diagrams
- 5.3.2 Single-Circuit Cooling System
- 5.3.3 Single-Circuit Cooling System
- 5.3.3 Double-Circuit Cooling System
- 5.3.4 Double-Circuit Cooling System
- 5.3.4 Triple-Circuit Cooling System
- 5.4 Pneumatic System
- 5.5 Sealing-Oil System
- 5.6 Injection Nozzle Cooling
- 5.7 Symbols Used in Piping Diagrams (Definitions to DIN 30600)
- 6 Operating Media
- 7 Trouble-shooting
- 8 Maintenance Schedules, List of Job Cards and Job Cards
- 8.1 Summary of Maintenance Schedules
- 8.1.1 Initial Maitenance Jobs
- 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.
- 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).
- 8.2 List of Job Cards
- 01.00.00 CYLINDER HEAD
- 02.00.00 CRANKSHAFT SYSTEM
- 03.00.00 ENGINE FRAME
- 04.00.00 TIMING SYSTEM
- 05.00.00 SPEED CONTROL SYSTEM
- 06.00.00 EXHAUST / TURBOCHARGING SYSTEM
- 07.00.00 FUEL SYSTEM
- 08.00.00 LUBRICATING OIL SYSTEM
- 09.00.00 COOLING WATER SYSTEM
- 10.00.00 PNEUMATIC SYSTEM
- 11.00.00 ENGINE PROTECTIVE SYSTEM
- 12.00.00 TORSIONAL VIBRATION DAMPER
- CYLINDER HEAD
- 01.01.01 Valve Clearance Checking
- 01.02.02 Rocker Arm Removal / Refitment
- 01.02.03 Rocker Arm Inspection / Reconditioning
- 01.03.01 Valve Rotator Inspection
- 01.03.02 Valve Rotator Reconditioning
- 01.04.01 Cylinder Head Removal
- 01.05.01 Inlet Valve Removal / Refitment
- 01.05.01 Exhaust Valve Removal / Refitment
- 01.05.04 Inlet and Exhaust Valves Inspection (by Endoscope)
- 01.05.05 Valve Spring Removal / Refitment
- 01.06.01 Valve Guide Clearance Checking / Reconditioning
- 01.07.01 Valve Seat Ring and Valve Cone
- 01.08.01 Cylinder Head, Servicing, Inspection
- 01.09.01 Cylinder Head Refitment
- 01.11.01 Starting Valve Inspection
- 01.11.02 Starting Valve Servicing
- 01.12.01 Safety Valve Servicing
- 01.13.01 Valve Seat Ring Removal / Refitment
- CRANKSHAFT SYSTEM
- 02.00.01 Crankshaft System Overhaul Safety Precautions
- 02.01.01 Crankshaft System Inspection
- 02.02.01 Crankweb Deflection Gauging
- 02.03.02 Bearing Shell Spread Gauging
- 02.03.03 Bearing Clearance Gauging
- 02.04.01 Bearing Shell Inspection
- 02.05.01 Big-end Bearing Removal
- 02.06.01 Big-end Bearing Refitment
- 02.07.01 Main Bearing Removal
- 02.08.01 Main Bearing Refitment
- 02.09.01 Piston Removal
- 02.10.01 Piston Inspection
- 02.10.02 Piston Ring Grooves Checking
- 02.10.04 Piston Reconditioning
- 02.11.01 Piston Ring Grooves Reconditioning
- 02.12.01 Piston Pin Removal / Refitment
- 02.13.01 Piston Pin, Piston Pin Bush, Piston Pin Bore Gauging / Reconditioning
- 02.14.01 Piston Refitment
- 02.15.01 Piston Coolant Nozzle Inspection
- 02.16.02 Hydraulic Tool for Annular Nuts Servicing
- 02.17.01 Flexible Coupling (Vulkan-type with Flange)
- 02.17.01 Flexible Coupling (Vulkan-type w/o Flange)
- ENGINE FRAME
- 03.01.01 Crankcase Relief Valve
- 03.02.01 Cylinder Liner Servicing
- 03.02.03 Cylinder Liner Servicing
- 03.03.01 Cylinder Liner Inspection / Gauging
- 03.04.01 Cylinder lining removal
- 03.05.01 Cylinder liner Refitment
- 03.06.01 Honing Cylinder Liner
- 03.07.01 Foundation Bolts Inspection
- 03.08.01 Crankshaft System - Reconditioning of Resiliently Mounted Engines
- TIMING SYSTEM
- 04.01.01 Camshaft Bearings Inspection / Gauging
- 04.02.01 Lower Valve Drive
- 04.02.01 Lower Valve Drive Inspection
- 04.04.01 Timing Gear Train Removal / Refitment
- 04.05.01 Engine Timing, Camshaft Removal
- 04.06.01 Engine Timing, Camshaft Refitment
- 04.06.02 Valve Timing Checking
- 04.08.01 Timing Gear Train Inspection / Gauging
- 04.09.01 Flywheel Removal / Refitment
- 04.11.01 Crankshaft Gear Removal / Refitment
- 04.13.01 Water Pump Idler Gear Removal / Refitment
- 04.14.01 Pump Chest Removal / Refitment
- 04.16.01 Crankshaft Coupling Flange Removal / Refitment
- 04.16.02 Coupling Flange Oil Pump Filling
- SPEED CONTROL SYSTEM
- 05.02.01 Speed Control System Safety Precautions (Barber-Colman Electronic Governor Plus 8)
- 05.01.01 Speed Control System Safety Precautions (Woodward UG 8 D/L Hydraulic Governor)
- 05.00.01 Speed Control System Safety Precautions Regulateurs Europa Ltd. Hydraulic Governor
- 05.03.11 Regulateurs Europa Ltd. Hydraulic Governor Servicing
- 05.03.11 Woodward UG 8 D/L Hydraulic Governor Servicing (Oil Change)
- 05.03.12 Woodward UG 8 D/L Hydraulic Governor Setting
- 05.03.12 Regulateurs Europa Ltd. Hydraulic Governor Setting
- 05.03.13 Setting the Magnetic Frequency Generator
- 05.03.14 Regulateurs Europa Ltd. Hydraulic Governor Servicing / Reconditioning
- 05.03.14 Woodward UG 8 D/L Hydraulic Governor Servicing / Reconditioning
- 05.03.14 Barber-Colman Plus 8 Electronic Governor Servicing / Reconditioning
- 05.04.01 Hydraulic Governor Drive Inspection
- 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting, S/BV 6/8 M 628
- 05.04.14 Regulateurs Europa Ltd. Hydraulic Governor Linkage Setting, S/BV 9 M 628
- 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting, S/BV 6/8 M 628
- 05.04.14 Woodward UG8D/UG8L Hydraulic Governor Linkage Setting, S/BV 9 M 628
- 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting, S/BV 6/8 M 628
- 05.04.14 Barber-Colman plus 8 Electronic Governor Linkage Setting, S/BV 9 M 628
- 05.04.15 Control Linkage
- EXHAUST / TURBOCHARGING SYSTEM
- 06.01.01 Exhaust Manifold, S/BV 6 M 628
- 06.01.01 Exhaust Manifold, S/BV 8 M 628
- 06.01.01 Exhaust Manifold, S/BV 9 M 628
- 06.01.03 Exhaust Elbow
- 06.02.01 Charge Air System
- 06.03.11 Intake Air Cleaner (Plastics) Servicing
- 06.04.01 Charge Air Cooler Removal / Refitment
- 06.04.02 Cleaning Charge Air Cooler air side Engine-Mounted
- 06.04.02 Cleaning Charge Air Cooler airside Cooler Removed
- 06.05.01 Turbocharger Servicing, Servicing
- 06.06.01 Turbocharger Servicing, Servicing and Reconditioning
- 06.12.01 Turbocharger Servicing, Cleaning of the charger at full load.
- 06.13.01 Turbocharger Turbine, Servicing
- 06.13.02 Scavenging Nozzles, Servicing
- 06.13.03 Turbocharger Scavenging Nozzles, Check
- FUEL SYSTEM
- 07.00.01 Precautions when Working on Fuel System
- 07.01.01 Injection Pump Locking Control Rod Inspection
- 07.02.01 Injection Pump Element Removal / Refitment
- 07.02.02 Idle Stroke Setting
- 07.02.03 Injection Pump Control Rod Removal / Refitment, S/BV 6/8 M 628
- 07.02.03 Injection Pump Control Rod Removal / Refitment, S/BV 9 M 628
- 07.02.04 Injection Pump Element Seal Reconditioning
- 07.02.05 Constant Delivery Setting
- 07.02.06 Valve Tappet Removal / Refitment
- 07.02.07 Firing Pressure and Exhaust Temperature Correcting
- 07.03.01 Removing and Refitting Injection Piping
- 07.03.02 Fuel System Bleeding
- 07.03.03 Injection Piping Renewal
- 07.04.01 Injection Pump Removal / Refitment
- 07.05.01 Injection Pump Camshaft Removal / Refitment
- 07.06.01 Injection Timing
- 07.07.01 Injector (Uncooled) Removal / Refitment
- 07.07.01 Injector (Cooled) Removal / Refitment
- 07.08.01 Injector (Uncooled) Inspection / Testing
- 07.08.01 Injector (Cooled) Inspection / Testing
- 07.09.01 Injector (Uncooled) Reconditioning
- 07.09.01 Injector (Uncooled) Reconditioning
- 07.10.01 Fuel Duplex Filter
- 07.11.01 Fuel Feed Pump Removal / Refitment
- LUBRICATING OIL SYSTEM
- 08.00.01 Lubricating Oil System Precautionary Measures
- 08.01.01 Oil Sampling
- 08.02.01 Oil System Inspection
- 08.02.02 Lube Oil Change
- 08.04.01 Lube Oil Pump Servicing
- 08.09.01 Oil Filter Combination (Non-Backflushing Wire Edge Filter)
- 08.09.01 Oil Filter Combination (Backflushing Wire Edge Filter)
- 08.10.01 Combined Lube Oil Filter (with Paper Micro Filter) Servicing
- 08.11.01 Oil Pressurestat Inspection
- 08.13.01 Centrifugal Oil Cleaner
- 08.14.01 Valve Seat Lubrication System
- 08.20.01 Sealing Oil Two-way Valve Servicing
- 08.20.02 Oil Micro Filter Servicing
- COOLING WATER SYSTEM
- PNEUMATIC SYSTEM
- ENGINE PROTECTIVE SYSTEM
- 11.01.01 Temperature Switch (OIl, Water, Air) Testing / Reconditioning
- 11.01.02 Pressure Switch (Oil, Water, Air) Inspection/Testing/Servicing
- 11.01.02 Pressure Switch for Oil, Water and Air
- 11.01.02 Pressure Transmitter Noris VD 61 - 2,5
- 11.01.03 Flow Switch (Fuel Injection) Testing
- 11.01.04 Exhaust Gas Thermocouples Removal / Refitment
- 11.01.05 Exhaust Gas Thermocouples Testing
- 11.03.01 NORIS-KN Safety System
- 11.05.01 Crankcase Oil Mist Detector
- 11.06.01 Charge Air Water Detector Testing
- 11.07.01 Oil Level Float Switch Testing
- 11.08.01 Service-warning Switch Checking
- TORSIONAL VIBRATION DAMPER
- 12.01.01 Viscous-type Vibration Damper (Version without Auxiliary Drive)
- 12.01.01Viscous-type Vibration Damper (Version without Auxiliary Drive)
- 12.01.01 Viscous-type Vibration Damper (Version with Auxiliary Drive)
- 12.01.02 Rubber-type Vibration Damper Inspection / Reconditioning
- 12.01.03 Rubber-type Vibration Damper (Version without Auxiliary Drive) Removal / Refitment
- 12.01.03 Rubber-type Vibration Damper (Version with Auxiliary Drive Removal / Refitment
- 8.1 Summary of Maintenance Schedules
- Service
Job Card No.:
Engine:
Filing No.:
Charge Air Cooler
Removal / Refitment
0178-58-10 1136
06.04.01
S/BV 6/8/9 M 628
© 0595
Refitting the Cooler
Inspect gasket (8) and (10) and replace if defective. Cooler refitment is made in the reverse order. Connect
feed and discharge piping as well as breather pipe. Fill up system with a newly prepared coolant (see Section
6.4).
Fig. 1
Tools:
- Standard tools
- Hoist
Job:
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 sup-
port to prevent turning sideways. Retain cooler (2) by
hoist. Unscrew (6) bolts (7) and remove pipe (5).
Unscrew bolts (9) and remove cooler (2).
© 51 405 0