Manual d3 Engine 30 08 08
Manual d3 Engine 30 08 08
Manual d3 Engine 30 08 08
Operating Instructions
for Diesel Engine
D3 Series
PREFACE
FQRWORD
This instruction book has been prepared so that the operator can
understand the engine in his care, and can maintain and service it, so
that maximum efficiency and utilization may be obtained.
The book should be studied before the engine is run for the first time
and thereafter be readily available for reference by the actual operator
or servicing staff. It is therefore advisable that the book be kept at the
operating site. Additional copies may be purchased f r o m
GREAVES COTTON LTD., AUXILIARY POWER DIV., Chinchwad,
Pune- 4 1 1 0 1 9 or our Agents
The fact that reference is made in these notes to any particular item of
equipment whether imported or indigenous does not in itself imply that
such equipment is an integral part of any particular engine This manual
is issued for the purpose of information and instruction and cannot be
taken as a specification of The engine as there would be modifications
due to continuous improvements in design and manufacturi ng process.
Some photographs which might appear little different are given only for
explaining the skim/system. As a book of reference therefore, its
usefulness is to enable the operator to clear up difficulties often of a
minor nature without reference to us.
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USER'S MANUAL GREAVES DIESEL ENGINE D3
CONTENTS
01 PREFACE, NOTES
01.1 General
U1.2 Assembly Breakdown"
01.3 Technical Status
01.4 Warranty Claims
01.5 Units System
1. 1 Engine Data
1.2 Overall Dimensions
13 Description of Engine
Part3 SERVICING
3. 1 : Tools and Expedients
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USER'S MANUAL GREAVES DIESEL ENGINE D 3
01 DIRECTIONS
It is assumed that the reader and user of these Operating Instructions is familiar with the basic
mode of operation of a four stroke combustion engine and is able to fo llow Technical Drawings
reasonably well.
T h e t e x t h a s b e e n k e p t , t h e r e f o r e , a s s hort a s p o s s i b l e f o r t h e s a k e o f c l a r i t y . T h e i n f o r m a t i o n
content is backed by photographs and sectional drawings.
00 Separate Parts
01 Crankcase and Oil pan
02 Cylinder Heads
03 Crank Assembly
04 Gear Drive. Cam shaft
05 Fuel System
06 Governor
07 Lubricating system
28 Cooling System
09 Turbocharger
10 Starting System
11 Control and monitoring
The figures are numbered according to the corresponding sections and in Part 1 - according to
the assemblies
Example:
Fig No.
Section of Operating Instructions
Assembly
Serial No
Technical Status of these Operating instructions applies to standard design al the time of going
to print. Subsequent changes can result in deviations regarding the type made available Where
differences result from idiomatic usage in German and Foreign language texts. the German text
shall govern . Any legal or other claims are thus excluded
Within the scope of our conditions require that all requirements as to fuels, lubricants. Cooling
agents and servicing instructions have been duly observed and carried out
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USER'S MANUAL GREAVES DIESEL ENGINE D-3
Minute
Second
{Weight)
J Rotary mass Kgm2 Moment of inertia
J = GD2 0.25
t Time S Second min (Minute)
h (Hour)
Velocity m/s Meter per second m/min(Meter per Distance change per unit
v
Minute} of time
a Acceleration Meter per square Change of speed per unit
Second of time
Standard acceleration
Due to gravity
Gn=9.80665
n Speed 1/s Revolution per second 1/min (revolution per minute)
1C=1K(As difference
temperature of t
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USER'S MANUAL GREAVES DIESEL ENGINE D 3
Prefixes
The units stated overleaf may be provided with prefixes expressing a decimal multiple or a decimal
part of the basic unit
Units for temperatures, angles and time (except for seconds) should be applied without a prefix
The following table is giving some prefixes with abbrevations and value.
CertTi L 10-2 = 0 01
Mi Mi 10-3 = 0.001
Micro 10-5 = 0.000001
Sxn
cm = —"— mfs 30000
2. Torque
9550x P
MD = .....................-" Nm
N
3. Mean effective pressure
1200x P
pD = .......................-" bar
N
B
b = ................... g/kvVh8431
11 : ................. %
b.
s mm Piston stroke
p Kw effective power
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11
USER'S MANUAL GREAVES GAS ENGINE G2
12
1 Crankshaft 12 Crankcase ventilation
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USER'S MANUAL GREAVES DIESEL ENGINE D3 1/5
1.1.5 Operating data All values apply to ISO standard performances – blocked (continuous net brake power)
as per DIN 6271 and/or ISO 3046/I
Intake air temperature 27° C Atmospheric pressure 1000 mbar
Relative air humidity 60%
Other operating conditions result in changes of the operating data. (Please do
also refer to test bed certificate.)
`Temperatures in °C
Cooling water, max. 85 85 8546
Exhaust gas, max.
650 650 650
Lube oil, max. (in oil pan)
120 120 120
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1.2 Dimensions and Weights
TBD3V8 1250 kg 275 1154 1454 910 366 1140 200 700
TBD3V12 2100 kg 275 1600 1850 910 366 1140 200 700
Weights (kg.)
Subject to modification
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USER'S MANUAL GREAVES DIESEL ENGINE D3
Operating principle
In the reciprocating motion of the engine pistons the following procedures take place in the
individual cylinders, as is the same in any four-stroke diesel engine:
On the induction stroke, the inlet valve is opened. The engine piston speeding downwards
draws in air into the cylinder base (Fig. 5/1).
On the subsequent upward stroke, the air is compressed, causing it to heat up.
Just before top dead centre of the piston fuel is injected into the hot air by the injection pump
via the injector into the cylinder combustion chamber where it ignites and burns (Fig. 5/2).
This results in the pressure increasing in the cylinder combustion chamber speeding the
piston downwards. This is the working stroke. The connecting rod transmits the force to the
rotating crankshaft (Fig. 5/3).
The subsequent upstroke expels the burnt gases through the open exhaust valve and the
silencer into the atmosphere (Fig. 5/4).
On the next down stroke, air is again drawn into the engine and the above procedures are
repeated.
The energy stored in the flywheel keeps the engine turning steadily.
Fig. 5
Function
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USERS MANUAL GREAVES DIESEL ENGINE D3
These two components form the load-bearing elements of the engine. They absorb the forces
occurring during operation in the cylinder and at the crank assembly.
In addition to the weight of the engine, the crankcase transmits to the foundation the residual
forces and the support forces caused by the torque delivered.
The crankcase accommodates the cylinder liners the crank assembly and the camshaft.
Fig. 8 Crankcase
1 Crankcase
2 Cylinder liner
3 Main bearing cover
4 Main bearing shell
5 Thrust bearing for
crankshaft
5 4
1 Oil pan
2 Dipstick
3 Oil filling neck
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Particularly for cooling of the valve seat rings, coolant piped through cooling chambers arranged in the
cylinder head. The cooling-water overflow bores are sealed O-rings. Please refer to the following figures for
further detail
2 Pushrod
3 Rocker arm bracket with rocker arms
4 Exhaust valve
5 Injection valve
6 Exhaust pipe
7 Inlet valve
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USER'S MANUAL GREAVES DIESEL ENGINE D3
The camshaft is driven by the gear drive at damper end. i.e. by the crankshaft, from gear 1 via gear 2. An
additional gear 3, also arranged on the crankshaft, serves as a drive for lubricating-oil pump 4.
A gear is also mounted on the crankshaft at flywheel end on 6 and 8-cylinder engines. The additional
balancing shaft, provided for these number? of cylinders respectively involved, is driven by this gear.
(Example, see Figure 1032).
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1 Fig. 1032 Mass balance (8-cylinder engine)
2 Mass balance shaft
3 Drive gear
4 Intermediate gear
5 Crankshaft gear
6 Crankshaft
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The cams of the camshaft 5 driven by the gear drive actuate the inlet and exhaust valve 1 (exhaust
valve shown) via mushroom tappets 4, pushrod 3 and rocker arm 2.
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USER'S MANUAL GREAVES DIESEL ENGINE D3
By means of the feed pump 8 the fuel is pumped from tank 1 into the injection pump 6
via filter 5. At high pressure the fuel is pumped to the injection valves 9. By means of
the injection nozzles the fuel is squirted very finely into the comb us tion chamber.
For the purpose of cooling the injection pump 6 more fuel than required for injection is
pumped through the system by the feed pump 8. The surplus fuel is returned to the
service tank via an overflow valve at the injection pump. Any fuel spillage emerging
from the injection valves is fed back to the tank via a separate pipe.
1. Tank
2. Overflow pipe
3. Leak-off line
4. Injection pressure line
5- Fuel filter
6. Injection pump
7. Overflow valve
8. Feed pump
9. Injection valve
10. Fuel pre-filter
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Fig. 10
Gear drive for balance weights
1 Crankshaft
2 Flywheel
3 Crankshaft gearwheel
4 Balance weight gear
5 Balance weight
Fig. 11
Controlling the valves via
the camshaft
6 Camshaft
2 Cams
3 Pushrod
4 Rocker arm
5 Inlet and exhaust valve
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1 Cylinder head
2 Intake pipe
3 Injection pump with governor
4 Stop linkage
5 Electric speed adjustment device
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1.3.06 Governor
The function of governor is to hold the set engine speed as constant as possible even
when there is a change in engine loading.
This governor, working by measuring centrifugal forces, is mounted on the injection pump.
Any change in load on the engine causes initially a difference between the power required
by the engine and the power momentarily produced by the engine. This difference must
be compensated for by the energy of the rotating masses (flywheel and crank assembly).
This taking or giving of energy from the rotating masses changes their rotational speed,
i.e. changes the engine speed.
The variations from the set engine speed are measured by the governor and are converted
into mechanical adjusting movements.
In the Injection pump these adjusting movements ensure that the quantity of fuel supplied
to the engine (= quantity of energy) is again adapted to the changed load on the engi ne.
As a result, the variations from the set engine speed are again finally, fully or partially
eliminated. (Depending on the speed drop setting on the governor.)
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To reduce the friction existing between parts in sliding contact with each other and to
carry off the heat, all bearings and the inside walls of the cylin der liners are supplied
with lubricating oil.
This oil is drawn from the oil sump 1 by the lube oil pump 2 and delivered to the oil
galleries through the oil cooler, the oil filter.
From the galleries the lube oil reaches the individual bearings on the crankshaft, the
camshaft and also lubricates the rocker arms. A further pipe supplies the injector
nozzles which inject lube oil on the inside walls of the pistons for cooling.
The oil which is slung off by the main big-end bearings lubricates the inside walls of the
cylinder liners. The oil draining off then collects in the oil pan from where it is
reintroduced into the lube oil circuit.
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USER'S MANUAL GREAVES DIESEL ENGINE D3
Fig. 30
Dry sump lubrication
Fig. 32
Engine oil pump
1 Housing
2 Drive gearwheel
3 Pump gearwheel
4 Cooling oil pump gearwheels
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1 Filter cartridge
2 Filter head
3 Excess pressure valve,
]]
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1.3.06 Cooling system
The thermal energy generated during fuel combustion can only be partly converted into
mechanical energy.
By means of the fresh water, cooling the combustion chamber walls, part of the residual
heat is eliminated and in a heat exchanger or a finned radiator passed on to a
corresponding fluid raw water, ambient temperature). A further part of the waste heat is
absorbed by the lub oil by means of the piston cooling (turbocharged engine) and bearing
friction. In the oil cooler this heat is passed on to the fresh water.
The decision for a particular cooling system depends on the given conditions at the
place of operation. The following scheme shows diagrams for indirect cooling, fan cooling
and outer skin cooling. The coolant's direction of flow is indicated by arrows in illustrations.
1 Intake bend
2 Cooling water outlet to A - bank
3 Pump housing
4 V-belt pulley
5 Ball bearings
6 Axial sealing ring
7 Impeller
8 Cooling water outlet to oil cooler (B - bank)
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Fig. 36
Lube oil centrifuge
1 Housing
2 Housing cover
3 Rotor
4 Hollow shaft
5 Nozzle
6 Paper sleeve
7 Pressure valve
SECTION A - B
Fig. 37
Engine oil cooler
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1 Flap valve
2 Gasket
3 Ball bearing 6303
4 Ball bearing 6203
5 Shaft
6 Oil seal
7 Mechanical seal
8 Gasket
9 Key for impeller
10 Impeller
11 Washer
12 Pump assembly KGEC 11.3
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1.3.09 Turbo-charging
The purpose of turbo-charging the engine is to boost the output without altering the speed.
To achieve a higher output for a given capacit y, added heat must be introduced into
the operating process for each operating cycle i.e. an increased amount of fuel must be
burnt. This can only be achieved, however, when at the same time a greater weight of
air is available. This is achieved by charging the cylinders with a higher pressure.
1 Intercooler
2 Intake air pipe from turbocharger
3 Raw water supply
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1.3.10 Starting system
1 Electrical connections
2 Starter pinion
3 Driving shaft leading to the starter pinion
4 Clutch housing
5 Steep-angle thread sleeve of the clutch
6 Meshing rod
7 Steep-angle thread
8 Clutch discs
9 Rim gear of the flywheel
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USER'S MANUAL GREAVES DIESEL ENGINE D3
Depending on the design the engine can be operated e.g. when starting, changing speed
or stopping it, directly or by remote c ontrol.
The engine speed can be actuated manually or by means of an electrical device. The
same is true for stopping the engine. In general the engine is started electrically. Remote
control is possible via the electrical control elements.
A pressure switch within the oil circuit serves for monitoring the oil pressure. The cooling
water temperature is controlled by means of a temperature switch. When the limiting
values are reached this is indicated both acoustically and optically or the engine is
automatic ally being shut down by the shutdown solenoid.
In a similar way operating data like e.g. speed, oil temperature, cooling water temperature,
lub oil pressure etc. can be monitored. Operating data indicator can be mounted to the
engine or be a part of the control panel for remote control.
1 Tachometer
2 Lub. Oil pressure
3 Ammeter
4 Water temperature
5 Lub. Oil temperature
6 Stop switch
7 Pilot lights
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(2) T o m a n u a l l y s t a r t t h e e n g i n e p r e s s e s t h e S T A R T b u t t o n . T h e T r i -P a n e l w i l l i n i t i a t e a
start
sequence which will include a heating period, fuel pump on, a cranking period and an oil
monitor delay period. The starting sequence status is shown on the LCD upper window.
(3) If the engine start is successful the ENGINE RUN output is activated. If the start was
u n s u c c e s s f u l t h e T r i - P a n e l w i l l e x p e c t t h e S T A R T b u t t o n t o b e p r e s s e d a g a i n f o r m a n ual
configurations.
(4) If the engine starts independently the Tri -Panel detects the condition and begins monitoring.
The PREALARM output is activated to give warning of an uncontrolled engine. Should a fatal
f a u l t c o n d i t i o n a r i s e , o r t h e e n g i n e i s r u n o u t s i d e t h e s e t o p e r a t i n g v a l u e s t h e T r i -P a n e l i s
unable to halt the engine.
(1) The Tri -Panel stops the engine by controlling the fuel solenoid.
(2) To manually stop an engine. Press the STOP button. HALT is shown on the LCD upper
window during the halt phase.
(3) I f t h e S T A R T b u t t o n i s p r e s s e d d u r i n g c o o l d o w n t h e T r i -P a n e ! r e t u r n s t o t h e E N G I N E R U N
mode but now requires a press of the STOP button to stop the engine. A manual start always
requires a manual stop.
(4) Activating EMERGENCY STOP stops the e ngine immediately. When EMERGENCY STOP or
the STOP button is activated for 10 or more seconds the Tri -Panel will display ESTOP on the
LCD upper window. The EMERGENCY STOP must be deactivated before the engine restart.
The engine can not be restarted during this period.
(5) A t t h e e n d o f H A L T t h e T r i -P a n e l c h e c k s f o r c o m p l e t e e n g i n e r e s t a n d c o n t i n u e s t o c o n t r a !
the fuel solenoid for 10 seconds after engine rest to prevent sudden engine restart. The
engine can not be restarted during this period.
(6) if the fuel s olenoid does not operate properly the Tri -Panel will be unable to stop the engine.
If the engine fails to stop, the Tri -panel will activate the alarm output and display STOP in the
LCD upper window.
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(2) The start sequence continues with a HEATING phase. The heating period is specified
during setup. If the engine temperature is below 30°C, the HEATER output is activated. If
the engine temperature is above 30°C, the heating phase is omitted. HEAT is shown in
the LCD upper window during the heating phase. Heat is usually set to off.
The heating period can be cut short by pressing the "START" button. There is always a
short delay between the heating and fuel pump phases.
(3) The start sequence continues by energizing the alternator via the CHARGE LAMP. The
lamp will glow indicating lack of charging current. When the engine is running and the
battery is charging the charge lamp will extinguish.
(4) The FUEL PUMP is controlled according to the PUMP type specified in setup. There is
always a short delay between fuel pump and the cranking phases.
(5) The current engine valves are checked prior to cranking. If oil pressure is detected, a
PAUSE state is entered until the oil pressure reduces below the oil pressure threshold
specified in setup. This ensures that the cranking will not occur into an already rotating
engine. PAUSE is shown on the LCD upper window for 60 seconds. A fail to START alarm
activates the ALALRM output if the condition persists.
(6) The start sequence continues with a cranking phase. The CRANK output is activated until
the engine starts or until the crank period specified in setup expires. The engine is
considered to have started when the engine speed exceeds the crank -disconnect speed.
The crank disconnects speed, or CREV, is specified in setup. CRANK is shown in the
LCD upper window during cranking.
(7) For a manual configuration if the engine does not start successfully the START button
must be released and pressed again.
(8) Regular sensor and engine condition checks are made during the startup sequence.
The displays show the current status. During the CRANK and PAUSE phases, the
displays switched off.
(9) As the engine starts the Tri-Panel enters the DELAY phase. The oil pressure in a
starting engine takes time to rise to a satisfactory level. The engine speed also takes time
to stabilize and usually overshoots the normal engine operating speed momentarily. The
DELAY phase allows time for the engine to settle before actively monitoring engine
conditions. DELAY is shown in the LCD upper window during monitor delay.
The type and time out of DELAY is specified during setup. The auto selection monitors ris ing oil
pressure and times out when the oil pressure is above the low oil pressure set point, plus
2 seconds. The maximum time out is 30 seconds. If a time is selected the Tri-Panel will s tart
monitoring the engine after the time out period.
During DELAY the engine speed is constantly monitored. If the speed overshoots the over
speed point by 25% or more a HIREV alarm occurs. The engine will be stopped. The
ALARM output will be activated. HIREV will be shown in the LCD upper window.
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USER'S MANUAL GREAVES DIESEL ENGINE D3
If an engine value is initially too low or too high its value is shown red but no alarm is raised. If
the abnormal condition is present at DELAY time out then the engine is stopped and the ALARM
output activated. The LCD upper window will show the cause of the abnormal condition.
(10) With the completion of DELAY the unit enters the ENGINE RUN phase. The ENGINE RUN
output is activated. The Tri -Panel continuously monitors the engine for abnormal conditions.
The engine RPM is shown in the LCD upper window during ENGINE RUN.
(11) The ENGINE HOURS are incremented every six minutes while engine is running. The hour
glass icon and total engine hours flashes while the engine is running and the total engine
hours are shown in the LCD lower window.
(12) Battery charging is constantly monitored for under and over voltage conditions. If an abnormal
condition is detected the PREALARM output is activated and cause of the alarm is shown in
the LCD upper window. For a low voltage the message is LVOLT. For high voltage the message
is HVOLT. Battery alarms do not stop the engine.
(13) The engine may be stopped as a result of an alarm condition or a stop signal. In any event
the engine is brought to rest by entering the HALT phase. HALT causes the FUEL supply to
be shut off. The engine is monitored for zero engine speed and zero oil pressure. HALT is
shown in the LCD upper window during the HALT phase.
If the engine stops, as it should, HALT continues to control the FUEL output for 10 seconds
after engine rest to ensure the engine does not restart. At the expiry of HALT the unit enters
STANDBY mode.
If the engine does not stop the ALARM output is activated. FSTOP is shown in the LCD
upper window. Operator intervention is required for an FSTOP condition.
(14) If the engine is stopped by an alarm both the PREALARM and ALARM output will be activated.
The cause of the alarm will be shown in the LCD upper window. The cause of the alarm must
be rectified before the Tri-Panel can be reset. Reset is achieved by pressing the STOP button
after the HALT time out phase.
Each behaves differently depending on the configuration and initial starting method.
(15) If the engine is stopped by a stop signal it will be one of two types.
(16) If the engine was started by a press of the START button and the engine is stopped by a
press of the STOP button the unit will enter the HALT phase. After the halt time out, the unit
returns to STANDBY. This applies for both automatic and manual configurations.
(17) If the engine was started by a press of the manual START button and the engine is stopped
by the EMERGENCY STOP switch the unit will enter the HALT phase. After the HALT time
out the unit will enter the ESTOP mode. When t he EMERGENCY STOP is deactivated the
unit returns to STANDBY. This applies for both automatic and manual configurations.
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ALTERNATOR WIRING
WIRING OVERVIEW
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CLEARING ALARMS
(2) From the alarm shown on the LCD upper window determine and rectify the cause of the
Alarm.
(3) Wait for the Tri -Panel to exit the HALT phase.
SPECIFICATIONS
Dimensions
• width : 280 mm
• height : 118mm
• depth : 60 mm
Power Supply
• Operating voltage 8 to 32 V DC
• Negative Earth
• Standby current 20 mA
• Operating current 570 mA
Inputs
• Transient protected
• Reverse-voltage protected
Outputs
• Protected against short -circuits
• Protected against over current
• Maximum load 500 mA
Communications
• RS485 twisted pair link (option)
Environmental conditions
• Operating 10°C to 60°C
• Storage 20°C to 70°C
• Humidity 85% RH at 50°C (non-condensing)
• Splash-proof
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USER'S MANUAL GREAVES DIESEL ENGINE D3
(1) The Tri-Panel incorporates many self check and system check features. They ensure that faults which
may cause engine damage or pose a safety risk are detecte d and alarms raised. The pre-alarm is the
primary warning output for this purpose. If the pre-alarm is activated the cause should be investigated
and rectified right away. The table below will be of some assistance in trouble shooting based on the
alarm conditions.
ALARM SUMMARY
START Engine did not start Check engine for correct operation
TACHO Tacho input not available Check alternator and engine wiring
OIL Low oil pressure detected Check oil level, sensor, wiring
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2.1.0 General
2.1.1 Cooling water
2.1.2 Fuel
2.1.3 Lubricating oil
2.1.4 Starting air
2.1.5 Special measures for operation
in winter
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The legal regulations for prevention of accidents (obtainable from professional associations
or specialized dealers) must generally be observed. These regulations depend on the
site, type of operation as well as the operating and auxiliary materials being used.
Special protecting measures, depending on each operation involved, are stated in the
description of work and marked with
Wear tight-fitting clothes and ear protection during engine operation in the
engine room.
Install first-aid boxes and appropriate fire extinguishers. Their content and
readiness for service must be checked regularly.
Combustible substances may only be stored inside the engine room if they
are needed for operation of the installation
Smoking and naked flames are prohibited inside the engine room.
Start the engine only if all protecting appliances are attached and if the j
cranking device has been removed. Ensure that nobody stays within the
danger zone.
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2.1 Preparation for first -time operation and for starting-up after several idle days
2.1.0 General
The following operations and checks described below are necessary for efficient operation
as well as for accident prevention. It is above all the correct functioning of crank assembly
and speed governor that is necessary for the trouble-free operation.
Clean new lines and tanks before filling with fuel, coolant and lubricating oil. After filling
please check pipes and tanks for fuel and cooling water for leakage.
Prior to first -time operation please check alignment of the engine and proper mounting
of the foundation.
Please clean engine - only then can leakages be ident ified and localized unmistakably.
If the engine was preserved, please pay attention to section 2.2.6 "Restarting after
preservation".
The engine cooling system shall only be filled with treated coolant according to section
2.3 up to the lower limit in the filler neck {for filler neck see Fig. 2001) and bleeded (for
bleed plugs see Fig. 2002) Since the operating temperature of the engine is kept as
high as possible (approx. 85 ° C cooling water temperature) unsuitable cooling agents
can cause deposits and corrosion damage. Please check pipes and engine for leakages
after filling.
Fig. 2001 Filler neck Fig. 2002 Bleed plugs for cooling system
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If a Gilkes or Steime! raw water pump (Fig. 2003) is attached to the engine the pump
housing must be filled with water through the filler tube (1)- Due to the centrifugal forces
the water forms the water ring during operation. It is necessary for the suction effect of
the pump. This is why the raw water pump has to be filled once again each time it was
drained.
Fig. 2003
Raw water pump
2.1.2 Fuel *
• Fill fuel tank with proprietary fuel complying with DIN 51601 requirements (see
section 2.3)
• Loosen banjo bolt 1 and operate hand priming pump 2 until fuel emerges free of
bubbles, tighten banjo bolt again.
1 Pressure connection
2 Hand priming pump
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USER'S MANUAL GREAVES DIESEL ENGINE D3
• Loosen bleed screws 3 on fuel filter, operate hand priming pump 2 until fuel
emerges free of bubbles. Continue to operate priming pump while tightening bleed
screws 3.
Note : In case of a reversible dual fuel filter the above applies to both chambers
(cock position : vertically upwards).
• Loosen overflow valve 4 on the injection pumps and operate hand priming pumps
2 until fuel emerges free of bubbles. Continue to operate priming pump while
tightening again overflow valves 4.
Do not use lub oil other than specified in section 2.3.1. The viscosity depends on t he
ambient temperature. The following table gives the corresponding viscosity required for
different ambient temperatures.
Caution!
Wrong viscosity can result in starting difficulties or very low oil pressure.
54
USER'S MANUAL GREAVES DIESEL ENGINE D3
Loosen plug 1 and fill in lub. oil up to the upper dipstick mark 2. After short engine
operation refill lub. oil up to the upper dipstick mark.
1 Plug
2 Dipstick
This POL specification is being updated every year and can be obtained from Greaves
after-sales services at the beginning of each year.
In case of an air-started engine fill up the starting air receiver with starting air compressor
or carbonic acid bottle (carbonic dioxide). The starting air pressure must be 30 bar.
Open valves of the air bottle and check lines for leakage. Air leaks waste energy and
cause premature wear of the starting air compressor.
55
USER'S MANUAL GREAVES DIESEL ENGINE D3
• Winter-grade fuel
In winter, use winter-grade diesel fuel only, otherwise the fuel may cloud and block the system,
which may even occur with winter-grade fuel when frost is severe. Therefore, when only
summer-grade fuel is available or winter-grade fuel must be used in severe cold, mix it with
kerosene or normal gasoline in accordance with the table below. The admixture of gasoline,
however, is permissible for one tank charge only.
Caution : prepare the blend in the tank itself fill in gasoline first, then add diesel fuel.
-10°C(+14°F) 90 10 100
-14°C(+7°F ) 70 30 100
- 20°C (- 4°F) 50 50 * * ) 80 20
- 30°C (- 22°F) 50 50 * *)
A mixture containing filling station fuel should only be used in case of need, otherwise
difficulties may occur due to vapour bubble formation. Due to the additives the engine
output will be lower than with Diesel fuel. For that reason only the urgently needed
additives shall be added.
56
USER'S MANUAL GREAVES DIESEL ENGINE D3
Caution ! Remove any objects that have been put down on the engine. It is
particularly dangerous to leave anything in the crankcase saddle. It may
result in serious accident and damage.
Check coolant level in radiator 1 by opening radiator cover 2. When the engine is cold
the coolant should reac h the under mark (arrow).
When coolant is lacking, fill in coolant up to the corresponding mark.
Note : When refilling coolant at normal running temperature, let the engine run in order
to prevent sudden drop in temperature of the engine. In the event of a frequent cooling
water shortage check the cooling system for leakage. Compensate losses due to
evaporation by means of water that is free of lime. In case a considerable amount of
cooling water is filled in, check the percentage of the corrosion agent (0. 5% up to 1.5%)
and of the anti-freezing agent (at least 33%).
1 Filler neck
2 Cooler cap
57
USER'S MANUAL GREAVES DIESEL ENGINE D3
Pull out dipstick 2 and wipe dry with a clean rag. Reintroduce dipstick 2 and wait for a
short time until dipstick is wet with oil. Pull out dipstick again and check lub. oil level.
Caution ! Do not keep dipstick upwards, as otherwise the oil running down would falsify
the measuring result. When the lower dipstick mark is reached, top up oil.
1 Plug
2 Dipstick
Check battery
Remove plugs (Item 1) and measure density of electrolyte with hydrometer. Electrolyte
density 1.23 to 1.28 kg/I is normal. If electrolyte density is less than 1.21 kg/I recharge
the battery. The water level should be approx. 15 mm above the plate edge, if not, top
up using distilled water.
1 Plugs
2 Battery terminals
58
USER'S MANUAL GREAVES DIESEL ENGINE D3
• Start engine by means of starter switch (In case of a key-operated switch; press
key inwards and turn it to the right as far as it will go)
• As soon as engine starts release switch. The s tarter switch automatically returns
to position "Betrieb" (Operation)
Caution ! Should the engine race (ever increasing speed) or the oil pressure does not
develop adequately, stop engine immediately and close fuel cocks.
• Draw out push-pull switch up to first notch (Preheating of the flame glow plug)
• When the corresponding temperature (pilot lamp flashes up) has been reached
draw out push-pull switch as far as possible (starting position)
59
USER'S MANUAL GREAVES DIESEL ENGINE D3
Fig. 2015
60
USER'S MANUAL GREAVES DIESEL ENGINE D3
After cold start of the engine wait a few minutes until running the engine at full load and
speed; increase speed and load gradually.
Operate speed switch unti! the required speed is attained. The highest and lowest
adjustable speed is blocked by means of limit switches.
• Lub. oil too hot (oil cooler or cooling system clogged, engine overloaded)
• Oil control valve 3 seizes
• Lub. oil filter clogged
• Lub. oi) too thin (wrong viscosity, oil change)
• Pressure gauge faulty
• Too high bearing claeranco on driving mechanism
61
USER'S MANUAL GREAVES DIESEL ENGINE D3
Thermostat faulty
In order to prevent heat from being retained in the cylinder liners and cylinder heads,
avoid stopping the engine at full load. Allow the engine to run at low speed and output
for approx. 5 minutes before stopping it.
1. Shut down engine by pressing stop push-button on monitoring panel.
2. Switch off monitoring appliances by means of ignition-lock key on switch position .
3. The engine can also be stopped manually (Fig. 2020) using the solenoid.
4. If the engine be stopped for a long time, close the fuel cocks.
62
USER'S MANUAL GREAVES DIESEL ENGINE D3
If the engine is taken out of service for a longer period, it must be preserved in order to
prevent corrosion damage. This also applies if the engine is put into service later than 3
months after delivery. See Job Sheet No. 3.3.003 for preservation instructions.
The anti-corrosion agents used for preservation influence the way the engine runs and
therefore have to be removed prior to operation. Clean engine and remove protecting
grease from the blank parts, e.g. control rod.
Remove covers and blank flanges from intake and exhaust pipe.
Fill engine cooling system with clean cooling water without admixture (section 2.1.1)
Empty fuel filter and fuel tank (see also Job Sheet No. 3.2.053), fill in fuel (section
2.1.3) followed by bleeding of the fuel tank.
Clean air-filter (job sheets 3.2.002 D), Drain lub oil filter (see Job Sheet 3.2.025) and fill
in lub. oil (section 2.1.3).
Carry out the operations and checks described in section 2.2.1 and start engine (section
2.2.2). For about 15 minutes, let the engine run at low speed and output, then stop it
and drain off water. Fill in cooling water in accordance with section 2.1.1.
63
USERS MANUAL GREAVES DIESEL ENGINE D3 2/14
The class of lubricating oil viscosity depends on the prevailing ambient temperature
Ambient temperature Class of viscosity
Above 30° C SAE 40
0 - 30º C SAE 30
below 0ºC SAE 10W
- 10ºC to 10º C 20W- 20
Special regulations, enclosed to the operating instructions manual, may be valid for engines with manual starting appliances Multi-grade oils
are only provided for use in automotive engines Only Multi-grade oils. Perfectly meeting the requirements of specifications MIL- L-21O4C/D
and API-CD to CD+ may be used. Multi- grades oils are not permissible, when using MDF fuels
Cooling water Admixture, initial and subsequent dosage of the anticorrosion agent as well as regular
Clean water with the lowest possible lime contents should be used as a concentration checks should be performed according to the instructions of the
Cooling water within the limiting values mentioned below for analysis. The respective manufacturer.
analysis values may be 10% higher or lower than the liming values An Caution No chemical anticorrosion agents should be used for internally
anticorrosion agent approved by Greaves . must be added to the cooling galvanized piping
water
PH value 7 9 Only water of Chemical anticorrosion agents may also acc to the
Contents of chlonde IONS Mg/1 100 this qualit y should be used with water from desalinization
Contents of sulfate ions Mg/1 100 and vaporizations. Instalations (not valid
instruction of the
Total contents of anions Mg/1 150 . for TBD3) manufacturer
When using antifreeze should be mi xed involved
Total (german) hardness dGH 3 12 with One of the ___________________________________________________________________
(gernan) cart nate hardness dKGH 3 additives
when using chemical mentioned Antifreeze/frost protection down to 2Oº
anti- corrosion agents overleaf c. An antifreeze concentration of at least 33% 5QO/o
Total German hardness dGh. 0 12 33% should be complied with during the
Whole year to prevent corrosion
Damage
Caution Replace antifreeze every 2 years and chemical anticorrosion agents every year.
Water quality is to be determined by consulting the water-works or Warranty claims concerning damage caused by POL-products can only
using Greaves test kit case 6 088 801.6020 4 When in doubt, have be met. if above regulations are carefully observed and adhered to
the water analyzed in chemical laboratory See next page for cooling-water additives
Never use non-analyzed water'
64
USER'S MANUAL GREAVES DIESEL ENGINE D3
Benefits Protects all metals in engine cooling Reduces maintenance time and
systems including copper, copper costs.
alloys, lead solder and aluminium
from corrosive attack. Liquid form for simple application add
directly to the engine radiator or
Protects against liner pitting and cooling system.
cavitation-erosion.
Treated water does not cause
Water pump lubricant. dermatitis or other skin conditions.
Keeps engines free from heat Does not affect nonmetallic materials
absorbing sludge and mineral scale in engine cooling systems and rubber
deposits-prevents over heating. gaskets or hose.
Extends antifreeze life
Dosage The concentration of Nalfleet 9-111 Nalfleet 9-111 should be added fresh
in the cooling water should be in the after every 'B' check.
proportion of 1 part Nalfleet 9-111 in
125 parts cooling water by volume {8
liters/tonne).
Storage & Nalfleet 9-111 may cause irritation to Keep away from heat, sparks and
Handling skin and eyes Avoid contact with skin open flames. Keep drums closed
and eyes or cloths. Prolonged or when not in use. In case of contact,
repeated breathing of vapor should wash skin with soap and water, for
be avoided This chemical is to be eyes immediately flush with large
used with adequate ventilation. Do amounts of water for at least 15
not take internally. minutes and get medical attention.
Remove contaminated clothing and
wash before reuse.
65
All POL- products mentioned below are meeting our requirements according to the manufacturers portion all the products appearing as suitable ones. This is why other POL - products which are data
even if some engine oils do not comply with classificatio ns as per API and or Mil in certain not stated here, may be used provided that they meet our requirements Each manufacturer cases
In view of t h e l a r g e n u m b e r o i l p r o d u c t s , i t i s i m p o s s i b l e f o r u s t o m e n i s s o l e l y r e s p onsible for the constant quality of his POL - products at t h e international level
FIRM B Engine oil API CF-4 Antifreeze Chemical anticorrosion agent
Supplier Denomination
bavwa Fricifir
c
M
mx
BP BP Anti-Frost c/5
Castrol Castrol RX-SUPER PLUS 15W/40 Castrol Antl-Free?c Pern Pretty Filter >C
Chevron'' naifloc Om
CalMn Naftlesl
Deutzpr Glysantin Forte Cooianl Condrtione* m
0m KG
Coolant Flush
g
m
<fl
EH GlaceK m
r
m
Esso Esso Kuhlerfrostsohutz z
D
I
m
Fina Fina Termidor P 100
Fuchs Fncofm
BHG Fricofin
Snell GlycosheH
• SHIM>()!<•
66
USER'S MANUAL GREAVES DIESEL ENGINE D3
67
USER'S MANUAL GREAVES DIESELENGINE D3
Part 3 Servicing
68
USER'S MANUAL GREAVES DIESEL ENGINE D3
3. Servicing
Unavoidable pollution of the environment which can enter the engine through the POL
products (air, fuel, lubricating oil, grease and coolant) as well as other loads in operation
can endanger satisfactory operation of the engine. Servicing has the task of preventing
these dangers and responsible servicing enhances the safe reliable operation and life of
the engine, thus saving costs.
The following tools and expedients are required for carrying out the servicing tasks.
69
USER'S MANUAL GREAVES DIESEL ENGINE D3
1. Set of tools
Servicing set
70
USER'S MANUAL GREAVES DIESEL ENGINE D3
2. Set of tools
6.000.0.018.501.7
Item Qty. Description Part No.
71
USER'S MANUAL GREAVES DIESEL ENGINE D3
72
USER'S MANUAL GREAVES DIESEL ENGINE D3
73
USER'S MANUAL GREAVES DIESEL ENGINE D3
causes
Engine does not turn When
Engine overheating
No control current
Battery discharged
Insufficient fuel
74
USER'S MANUAL GREAVES DIESEL ENGINE D3
75
USER'S MANUAL GREAVES DIESEL ENGINE D3
3.1.3.1 Overhauls
The reliability of the engine is affected over long periods by wear and corrosion. In order to avoid
engine failures, we suggest to carry out the overhauls indicated in the following table. The first
overhaul operations must be performed after 10.OOO operating hours or, if not reacted, after 2
years. The work sequence is described in the Workshop Manual, which can be obtained n our
Spare Parts Department.
Inspection Operating hours
Partial overhaul
Replacing pistons Replacing cylinder liners Cleaning 20 000 h
and checking oil relief valves Replacing crankshaft X
seals, checking axial clearance Checking big-end X
bearings, replace connecting rod bushes, if necessary X
Exchanging anti -vibration dampers (Holset) X
Basic overhaul
Measuring crankshaft (grind, if necessary) 40 000 h
Replacing main and connecting-rod bearings X
Overhauling starter (Bosch) Checking gear drive X
Checking control unit, replacing wearing parts X
Replacing oil pump X
X
• The harmful constituents should be measured with electronic measuring appliances by MWM-
staff only. It is recommended to measure the harmful constituents after the first 5000 h
and/or to have the O2 - regulating unit checked and measured by the TOV and to replace
defective parts, if necessary.
The above-mentioned operating-hour 4ntervals are average values and valid for standard operating
conditions and appropriate maintenance in accordance with the descriptions. These are standard
values without warranty obligations. Deteriorating operating conditions are caused by
• frequent starting
• long operating periods at zero load
• extremely rapid and frequent load charges
• frequent operation at overload
The execution of the repairs (maintenance and overhauls) requires skill and special knowledge.
Should you have no skilled staff at your disposal, our After-Sales Service Department will be
pleased to give you information about maintenance contracts involving various work scopes.
76
USER'S MANUAL GREAVES DIESEL ENGINE D3
For a better survey, the jobs are subdivided and described on Job Sheets.
When carrying out these jobs a good knowledge of the various functions of the engine
and how they interact is necessary.
Information to this extent is provided in part 1 and part 2 of these Operating Instructions.
• Servicing interval
The object of the Job Sheets is to facilitate preparations and for implementing actual
servicing tasks.
77
USER'S MANUAL GREAVES DIESEL ENGINE D3
TBD3
Just after starting, run the engine at 1/3 load only. After
approximately 10 minutes it can be run at 3/4 load and after a
further 5 minutes at full load (nominal output). When the engine
has reached normal running temperature, check the operating
values (section 2.2.3.1). Before stopping the engine, let it run
for another approx. 10 minutes at 1/3 load.
2. Stopping the engine
78
Engine type Job Sheet No
Date first time after
GREAVES Job Sheet
5.97 TBD3 3 14 1
need thoroughly
prior to beginning
Necessary tools Necessary materials and auxiliaries Spare Table No.
D u r i n g o p e r a t i o n , k e e p k e y -o p e r a t e d s w i t c h i n p o s i t i o n
1, Position O means that the monitoring system is out
of operation
79
Engine type Job sheet No.
Job Sheet
Date First time
after TBD3 3.1.4.4
after and every Page of
Checking the battery 1 1 page
daily
read thoroughly
prior to beginning
Necessary tool* Necessary materials and auxiliaries Spares Table No
80
Job Sheet No.
Date first time after after and every Engine type
GREAVES Job Sheet 3.2,002 D
06.86 TBD3
Page
Checking dry air filter for dirt (Visual check on read thoroughly prior
to beginning 1
Necessary tools maintenance indicator)
Necessary materials and auxiliaries Spare Table No.
81
Job Sheet No.
Date first time after after and every Engine type
Job Sheet 3.2.003
GREAVES 5.85 60 h 500 h TBD3
read thoroughly prior Page of
Checking V -belt drive/Lubricating raw water pump 1
to beginning 1 page
Necessary tools Necessary materials and auxiliaries Sparc Table No.
The V-belt drives on the opposite end of the main P.T.O. are
used to drive the raw water pump (Fig. 1, Item 1), fresh water
pump (Fig. 1, Item 2) and alternator (Fig. 1, Item 3)
5. Tighten screws 4
3.3.001)
Caution !
82
Date first time after after and every Engine type Job Sheet No.
GREAVES Job Sheet TBD3
4.38 500 h 500 h 3.2.005
Checking zinc protective coating read thoroughly prior Page of
to beginning 1 1 page
Necessary tools Necessary materials and auxiliaries Spare Table No.
* Quantity as required
Due to the aggressive substances contained in the cooling water, (he cooling water passages are exposed to corrosion.
To avoid destruction of the walls, plugs with a zinc protective coating are provided in the cooling water and raw water
circuits. Since the zinc protective coating (base metal) will decompose with time, it must be checked at the intervals
given in the servicing schedule.
83
Date first time after after and every Engine type Job Sheet No.
Job Sheet
GREAVES 1.86 60 h 500 h D3
TBD3
3.2-025
Within the lub. oil circuit, the oil filter is installed in such a way
that all particles of dirt are kept away from the bearings. These
particles clog the filter. As a result the oil pressure decreases.
Therefore, the filter cartidges have to be replaced from time to
time.
3. Fill the new filter element/s with fresh oil up to full and
quickly tighten it to the filter head. (Some amount of oil
may fall down)
84
Date first time after Engine type Job Sheet No.
Job Sheet
GREAVES 1.86 after and every D3
3.2.028A
TBD3
read thoroughly prior Spare Table No.
1000 h
to beginning Page
Checking and readjusting valve clearnce (6 cylinder engine)
1
Necessary materials and auxiliaries
Necessary tools
Set of tools 19 21
Turning rod
Inlet and exhaust valves can only reliably close tightly if there
is a certain clearance set between camshaft and valve stem
inside the valve-drive unit. Valves which do not close tightly may
cause the valve seat and valve plate to burn off. On the other
hand, excessive valve clearance would cause considerable wear.
Maintaining the valve clearance of the correct setting increases
service life and engine reliability.
85
Engine type Job Sheet No.
GREAVES Job Sheet
Date first time after D3
1.86 TBD3 3.2.028B
read thoroughly prior Page of
Checking readjusting valve clearance (8 + 12 cylinder- engine) to beginning 1 1 pages
Necessary tools Necessary materials and auxiliaries Spare Table No.
Set of 19
tools 21
fuming rod
Checking and/or setting sequence (ignition TDC) 8 naturally-aspirated engine 0.2 mm 0.3 mm
Cylinder Fly wee I end 0.3 mm
turbocharged engine 0.5 mm
first
The feeler gauge should be inserted with a certain
amount of force. In case of deviation the valve clearance
must be readjusted.
4. Loosen locking nut 4 and setting screw 5. Screw in setting
nut by screw driver until the feeler gauge begins to clamp.
Tighten locking nut and check valve clearance as above.
5. Checking and/or adjusting sequence :
The checking and adjusting of the valve clearance is
effected as per the ignition sequence, starting with
cylinder A 1 as described in section 2. After having
Beginning of the -Beginning of the second checked and/or adjusted the valve clearance on cylinder
Crankshaft rotation Crankshaft rotation A1, the engine is to be checked further, progressively,
12 Cylinder in firing order and direction of rotation for additional
checks as follows:
Ignition TDC A1 B2 A3 B1 A4 B3 A2 B4
Valve over A4 B3 A2 B4 A1 82 A3 B1
lapping
8 - Cylinder engine
see also figure 2
Ignition A1 B5 A5 B3 A3 B6 A6 B2 A2 B4 A4 B1
TDC
Valve over A6 A2 A2 B4 A4 B1 A1 B5 A5 B3 A3 B6
lapping
12 - Cylinder engine see also fig. 2
6. Fix cylinder-head covers, taking care of gaskets.
86
Job Sheet No.
Date first time after and every Engine type
GREAVES Job Sheet 3.2.053
5.85 2000h T8D3
read thoroughly Page of
Renewing fuel finer cartridges of fuel fitter element
prior to beginning 1 2 Page
Necessary tools Necessary materials and auxiliaries Spare Table No.
In order to protect the fuel injection pumps and injectors, a fuel filter
is incorporated in the fuel system upstream of the pumps and
injectors. A contaminated filter element reduces the flow of fuel and
must therefore be replaced after the above-mentioned operating
hours .
Caution!
Only when the filter elements are changed must the
corresponding filters be shut down. During normal operation
leave both filter in circuit! Fitter switching diagram, see figure 5.
87
GREAVES Job Sheet Date 5.85 first time after alter and every
Engine type Job Sheet No.
2000H 3-2053
Renewing fuel filter cartridges of fuel filter element. TBD3
Page of
read thoroughly prior 2 I 2 pages
6a beginning
Necessary tools Necessary materials and auxiliaries Spare Tab » c No-
88
Job Sheet after and every Engine type Job Sheet No.
GREAVES Date first time after
2000 h D3 3.2.055
1.86 TBD3
read Page of
Checking monitoring and engine stopping device. thoroughly prioi to
1 1 page
beginning
Necessary tools Spare Table No.
Necessary materials and auxiliaries
If the pilot lamp does not light up, check fuses 4 in the
instrument panel or change the bulb. If this is of no use, short
circuit connection 5 on the oil pressure switch on - it it is a
unipolar connection - ground them. If the pilot lamp lights up,
renew oil pressure switch. If not, check cable con nection. After
checking, switch off monitoring device.
Checking cooling water monitoring device
Switch on monitoring device (in case of key - operated switch :
pos. *) and position switch "Operation-Stop" to "Operation".
Short-circuit connection on temperature sensor or - if it is a
unipolar connection - ground it. Pilot lamp "cooling water
temperature" lights up, siren sounds. If this is not the case,
renew fuses 4 in the instrument panel or change the bulb. If
still not illuminating, check cable connections .
Drain off cooling water (drain cocks 7), pinch off cable
connections on temperature sensor 6 and dismantle temperature
sensor. Repinch temperature sensor, suspend in a water bath
and heat it. At approx. 95°C pilot lamp must light up and siren
sound. If this is not the case, renew temperature sensor.
89
Date first time after after and every Engine type Job Sheet No.
GREAVES Job Sheet 3.2.057
5.85 2000 n TBD3
Cleaning the intercooler. read thoroughly prior Page of
to beginning 1 1 page
Necessary tools Necessary materials and auxiliaries Spare Table No.
Container, size at least Approx, 20 dm3 Henkel neutralizing agent P3-croni 77 - ...
500 mm x 200 mm x 200 mm Approx, 20 dm3 Henkel detergent solution P3T-
Tool set 1166
Hexagon socket wrench SW 6 (Messrs. Henkel, 4000 Dusseldorf)
The intercooler serves for cooling the air coming from the
turbocharger, whereby the weight of the air inside the cylinder
is further increased. As a precondition the walls of the cooling
lubes must be free of dirt and deposits.
90
Job Sheet No.
Date first time after after and every Engine type
Job Sheet 3.2.060
GREAVES 5.85 2000 h TBD3
read thoroughly prior Page
to beginning 1
Necessary tools Necessary materials and auxiliaries Spare Table No.
as required 89 - ...
Lubricating bearings
Screw in the grease cups 2 turn. If the grease cups have already
been screwed in as far as they will go, unscrew and re-pack
with ball bearings grease.
Caution!
91
Date first time after after and every Engine type Job Sheet No.
GREAVES Job Sheet D3
06.86 3-3.001
TBD3
read thoroughly prior Page of
Tightening torques of main screw connections in Nm
to beginning 1 3 pages
Necessary tools Necessary materials and auxiliaries Spare Table No.
* Tightening torque specification for cylinder head bolts:
Lubricate screw thread and contact surface (do not use
Molykote). Tighten the bolts crosswise to 20 Nm, and then
tighten further in three stages (100 Nm, 200 Nm, 400 Nm)
• With washer ? with lock washer.
92
Job Sheet Date first time after after and every Job Sheet No.
GREAVES
6.86 Engine type 3.3.001
Tightening torques of main screw Page of
connections in Nm TBD3
2 3 pages
Necessary tools Spare Table No.
Necessary materials and auxiliaries
* 60° (1 hexagon)
93
first time after after and every Job Sheet No.
Job Sheet
GREAVES Date 3.3.001
Tightening torques of main screw 6.86 Engine type Page of
connections in Nm D3 3 | 3 pages
TBD3 Spare Table No.
Necessary tools
Necessary materials and auxiliaries
Set of tools
94
Job Sheet No.
Date first time after after and every Engine type
GREAVES Job Sheet 3.3.003 A
5.85 TBD3
read thoroughly prior Page 1 of 2
Anti-corrosion treatment for engines not yet installed to beginning
Necessary tools Necessary materials and auxiliaries
Spare Table No.
Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV
Set of tools Anti-corrosion oil for lubricating oil system,
e.g. Messrs. Fina; Rusan 20 W 20
Spray gun Anti-corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs. Castrol : Rustillo DWX 32
Anti-corrosion agent cooling water, e.g.
Messrs. Khubier-Chemie : Puriton 4110
Talcum powder
96
Job Sheet No.
Date first time after after and every Engine type
GREAVES Job Sheet 3.3.003 B
5.85 TBD3
read thoroughly prior Page of
Treating the installed engines against corrosion for lengthy standstill periods to beginning 1 2 pages
Necessary tools Necessary materials and auxiliaries Spare Table No.
Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV
Set of tools Anti-corrosion oil for lubricating oil system,
eg. Messrs. Fina; Rusan 20 W 20
Spray gun Anti- corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs. Castrol: Rustilk) DWX 32
Anti-corrosion agent cooling water, e.g.
Messrs. Khubier-Chemie : Puriton 4110
Talcum powder
7. Stop engine
12. Drain anticorrosion agent out of fuel tank, oil pan and
cooling system.
13. The intake and exhaust line being already laid must be
closed so as to keep external atmospheric influences
away from the engine interior.
97
Date first time after after and every Engine type Job Sheet No.
GREAVES Job Sheet
5.85 TBD3 3.3.003 B
read thoroughly prior Page 2 of 2
Treating the installed engines against corrosion for lengthy standstill periods to beginning
Necessary tools Necessary materials and auxiliaries Spare Table No.
98
Job Sheet first time after after and every Engine type Job Sheet No.
GREAVES Date
TBD3
9.84 3.3.007 A
Cleaning fresh water recooler (indirect read thoroughly prior
Page or
cooling) to beginning
1 2 pages
Necessary tools Necessary materials and auxiliaries Spare Table No.
1 O-rings 6.0493.10.4.1405
2 O-rings 6.0493.10.4.1655 63 -
Tool set 1 O-ring 6.0493.10.5.0803
Brush 1 Sealing ring 6.0492.01.0.1418
Stud, min. 100 mm long, M 8 1 Sealing ring 6.0492.01.0.0814
1 Sealing ring 6.232. 0.850.004.4
Wevolic 2 Sealing compound 6 0153.70.1.0205
Fuel 6.0153.70.1.0205
Caution!
Do not kink the hoses!
4. Remove raw water connections (Fig. 1, item 4) and fresh
water return (Fig. 3, item 1)
5. Remove flange connector for fresh water return (Fig. 3
arrow)
6. Unscrew bolts mounting headers (Fig. 1, item 3) and
adjusting screw (Fig. 1 item 5), Remove headers.
7. Withdraw tube bundle (Fig. 4) from shell and clean in
fuel with brush. Check the solder joints on the jacket
(Fig. 4, arrows) and re-solder if necessary.
8. Clean the remaining parts in fuel. Check the supply lines
for fouling and clean if necessary.
9. Remove gasket {Fig. 5, arrow) on flange connector for
fresh water return, clean seat and apply new gasket with
sealing compound (bond only the end face).
10. Renew all the other seals, applying grease to the O-rings.
99
Date first time after after and every Engine type Job Sheet No.
GREAVES Job Sheet D3
9.84 TBD3
3.3.007 A
11. Screw in the stud M8 x 100 (or longer) into the adjusting
tapping of the tube bundle and mount the header on
the tube bundle (Fig. 6)
Note :
17. Refit fuel filter, raw water and fresh water connections.
18. Filter the fresh water through a cloth and refill, bleed
by means of the bleeder plugs (Fig. 9, Pos. 1) and top
up fresh water up to the bottom mark (Fig. 8).
100
first time after after and every Engine type Job Sheet No.
Job Sheet Date
GREAVES 5.85 TBD3
3.3.007 B
Cleaning fresh water re cooler (indirect cooling) read thoroughly prior Page of
to beginning 1 1 page
Necessary tools Necessary materials and auxiliaries Spare Table No.
101
CODE NO. : 1.233.0.006.026.4 (01) 04/08
In view of continuous improvements the specifications are subject to change without notice.