Manual d3 Engine 30 08 08

GREAVES COTTON LTD
Operating Instructions
for Diesel Engine
D3 Series
Please read prior to putting Generating set into service

DIESEL ENGINE D3 SERIES
USER'S MANUAL GREAVES DIESEL ENGINE – D3 0/2
PREFACE
This User's Manual is prepared for use by the Operating Personnel,

no mailer how useful it may be in administration.
These Operating Instructions are Intended to facilitate operating the engine and in
maintaining its reliable function.
They accordingly explain the design, function and operation of the engine. The
necessary housekeeping and servicing tasks are grouped together in a servicing
schedule and described for better surve y in Job Sheets.
Our Service Department will be glad to provide any further information you may
require.
AUXILIARY POWER DIV.

Chinchwad, Pune- 411 019. INDIA
Tel. : (091-020) 27473564/67308200
Fax: (091-020) 27472276
e-mail : [email protected]
USER'S MANUAL GHEAVES DIESEL ENGINES D3
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.
Should any information be required our Service Department and Agents

are always at the disposal of our users.
5
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
Part 1; ENGINE DATA AND DESCRIPTION
1. 1 Engine Data
1.2 Overall Dimensions
13 Description of Engine
Part 2 : OPERATION AND POL PRODUCTS
2.1 Preparation for First-Time Operation

2.2 Engine Control
2.3 POL Specifications for Small Size Engines.
Part3 SERVICING
3. 1 : Tools and Expedients
3. 1.1 Other Additives

1
3. 1.2 Trouble Tracing Table
1
3. 1.3 Servicing Schedule
1
3. 1.4 Job Sheets for Servicing
1 Servicing
6
USER'S MANUAL GREAVES DIESEL ENGINE D 3
01 DIRECTIONS
01.1 General Remarks
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.
01,2 Assembly Breakdown
1 of these Operating Instructions are broken down in the following assemblies

possible;
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
1 these assemblies are shown in (he engine sectional drawings.
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
01.4 Warranty claims
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
7
USER'S MANUAL GREAVES DIESEL ENGINE D-3
01.5 Measuring Units

The measuring units applied in this Operation Instructions manual are complying with the
International Unit System (Sl).
Symbol Value Unit Denomination Further units Remarks/conversions

I Length m. Meters
A Area M2 um=0.001 mm
V Volume M3
a Plane angle rad Radian * Degree 1 rad = 1 m/m=360
Minute
Second
m Mass Kg Kilogram g (Grams)
{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)
f Frequency Hz Hertz 1 Hz= 1/S

Vibration per second
i Angular velocity ¦ rad/s O/s (degree per Peripheral speed at
Second) radius 1
i =2 II n
u l/min applies to
I = n x u 1/s
30
F Force N. Newton 1N=1Kgm/s2=1Ws/m
1N=0.10197Kg
G Weight G = m.g
M Torque Nm Moment of a force on
lever arm
1N=0.10197Kgm
P Force of liquids bar Pa (Pascal) 1pa=1N/m2

And gases
Mm WS millimeter 1bar=10 5 pa=10n/cm2
Water gauge =1.0197Kg/cm
E Energy J joule Ws (watt second) 1J = 1 Ws = 1Nm
W Work KW/h (kilowatt hour) 1kwh=3600 KJ

Q Quantity of heat
p Power W Watt 1W=1J/S=1 Nm/s
=1Kgm2/s
T Temperature K kelvin 'C (degrees Celsius) O c =273.15K
1C=1K(As difference
temperature of t
8
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.
Prefix Abbrevation Value
Mega M 105 = 1000000

Kilo K 103 = 1000
Hecto h 102 = 100
Deca da 101 = 10
DECl a 10-1 = 0.1
CertTi L 10-2 = 0 01
Mi Mi 10-3 = 0.001
Micro 10-5 = 0.000001
Equations for engine characteristic values:
1- Mean piston speed
Sxn
cm = —"— mfs 30000
2. Torque
9550x P
MD = .....................-" Nm
N
3. Mean effective pressure
1200x P
pD = .......................-" bar
N
4 Specific fuel consumption
B
b = ................... g/kvVh8431
11 : ................. %
b.
(calculated witn a lower cal. valuo ol J2 7 hJ/g)
s mm Piston stroke
n t/ mm revolutions per minute
p Kw effective power
Vh dm3 Total swept volume
B g/h fuel consumption per hour
9
1/1Part 1 ENGINE DATA AND DESCRIPTION
1.0 Views of Engine
1.1 Engine Data

1.1.1 Explanation of Model Designation
1.1.2 Cylinder Numbering
1.1.3 Construction Data
1.1.4 Adjusting Data
1.1.5 Performance Data
1.1.6 Filling Quantities
1.2 OVERALL DIMENSIONS AND WEIGHTS
1.3 DESCRIPTION OF ENGINE
1.3.0 Function of Engine
1.3.1 Cylinder Crankcase and Oil Pan
1.3.2 Cylinder Heads
1.3.3 Crank Assembly
1.3.4 Gear Drive and Camshaft
1.3.5 Fuel System
1.3.6 Lube. Oil System
1.3.7 Cooling System
1.3.8 Turbo charging System
1.3.9 Starting System
1.3.10 Control Pane!
1.3.11 Engine Monitoring
10
1 Engine Data and Description
1.0 Views of Engine
Fig. 1 Engine TBD 3,
1 Radiator fan 7 Injector

2 Dynamo 8 Oil filler neck
3 Sump 9 Tension roller
4 Engine foot 10 Exhaust manifold
5 Starter 11 Cyl head cover

6 Turbo charger 12 Air intake manifold
11
USER'S MANUAL GREAVES GAS ENGINE G2
Engine data and description

1.0 Views of engine
Fig 1001 Generating set, A-Side

.
1 RADIATOR
2 STARTOR
3 DYNAMO
4 TURBOCHARGER
5 AIR FILTER
6 EXHAUST OUT LET
7 FUEL FILTER
8 COVER FOR EXHAUST MANIFOLD
9 THERMOSTAT
12
1 Crankshaft 12 Crankcase ventilation
2 Camshaft 13 Injection pump
3 Camshaft bearing 14 Speed governor
4 Big-end bearing 15 Speed fine adjustment
5 Main bearing 16 Fuel pressure pipe
6 Flywheel 17 Injection pump drive
7 V-belt pulley 18 Injection pump couplin

8 Anti-vibration damper 19 Intake pipe
9 Oil pan 20 Intercooler
10 Lube oil intake pipe 21 Turbo charger
1! Oil drain plug 22 Tacho generator
13
USER'S MANUAL GREAVES GAS ENGINE D3
1. Engine data and description
1.1 Engine data
1.1.1 Type code
1.1.2 Numbering of cylinder Flywheel end
14
USER'S MANUAL GREAVES DIESEL ENGINE D3 1/5
1.1.4 Adjusting data TBD3 V6 TBD3V8 TBD3 V12
Inlet valve clearance mm 0.3 0.3 0.3

Exhaust valve clearance mm 0.5 0.5 0.5
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.)
TBD3 V6 TBD3V8 TBD3 V12

Rotational speed in min*1 1500 1500 1500
Nominal speed
115 115 115
Ignition speed
Lowest idling speed 650 650 650
Pressure in bar
Compression, min. 23 23 23
Ignition pressure 150 150 150
Lube oil pressure max. 3.6 3.6 3.6
Lube oil pressure at n= 750 min-1 0.8…3 0.8..3 0.8…3
`Temperatures in °C
Cooling water, max. 85 85 8546
Exhaust gas, max.
650 650 650
Lube oil, max. (in oil pan)
120 120 120
0.6 0.6 0.6

Oil consumption, max. g/kWh
1.1.6 Filling quantities in dm 3 TBD3 V6 TBD3V8 TBD3 V12
Cooling water capacity (without radiator) 20 24 35
Lub oil capacity to top notch on

Dipstick by first filling. 22.5 29 60
Oil change capacity 16 16 52
Lub. oil filter capacity 2 3.5 3.5
15
1.2 Dimensions and Weights
Engine Engine Additional Dimension in mm

type weight weight for SAE
worthv
packing kg. A A1 B C D E F
approx.
TBD3V6 1050 kg 275 984 1284 910 366 1140 200 700
TBD3V8 1250 kg 275 1154 1454 910 366 1140 200 700
TBD3V12 2100 kg 275 1600 1850 910 366 1140 200 700
Weights (kg.)
Engine (dry, without extras)
For flexible bearing : Cooling water and oil filled in
With flywheel flange SAE 1
Subject to modification
16
1.3 Description of engine

Being thoroughly informed as to the design and function of the engine provides the
understanding which facilitates handling the engine.
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
17
USERS MANUAL GREAVES DIESEL ENGINE D3
1.3.01 Crankcase and oil pan
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.
The illustrations below show more details.
Fig. 8 Crankcase
1 Crankcase
2 Cylinder liner
3 Main bearing cover
4 Main bearing shell
5 Thrust bearing for
crankshaft
5 4
Fig. 9 Oil pan
1 Oil pan
2 Dipstick
3 Oil filling neck
18
1.3.03 Crank assembly

The crank assembly is consisting of the crankshaft connecting rod, piston flywheel and torsional-vibration
Damper.
The crankshaft is provided with underslung bearing inside the crankcase.
The counter weights, bolted on the crank webs, a t ensuring the reduction in internal mass actions and therefore,
the discharge of the crankshaft bearing The masses on 6 and 8-cylinder engines are fully conpensated .by an
Additional rotating mass (mass-balancer shaft).The flywheel serves to reduce the irregular of the crankshaft rotation.
A damper, reducing torsional vibrations , is attached to the opposite end of the crankshaft.
The crankshaft is driven via the connecting rods by the gas forces acting upon the pis tons.
Fig. 1031 Driving mechanism (Example 233 V12)

1 Small-end bushing
2 Connecting rod
3 Gudgeon pin
4 Piston
5 Piston rings
6 Vibration damper
7 Cranking disc
8 V-belt pulley
9 Crankpin
10 Main bearing journal
11 Counterweight
12 Crankshaft
13 Flywheel
19
1.3.02 Cylinder heads

1.3.02- The cylinder heads dose off the combustion chamber towards the top. Each one is attached to the
cylinder crankcase by means of four screws.
Each cylinder head contains the inlet and exhaust valves as well as the injection valve. The inlet and
exhaust valves, provided with valve-rotating appliances, a actuated by the rocker arms, mounted on the
cylinder head.
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
Fig. 1021 Cylinder head

1 Inlet pipe with integrally casted
cooling water sampling pipe
2 Pushrod
3 Rocker arm bracket with rocker arms
4 Exhaust valve
5 Injection valve
6 Exhaust pipe
7 Inlet valve
Fig. 1022 Cylinder head (section)
1 Injection valve 7 Spring plate

2 Valve springs 8 Valve turn device
3 Rocker arm (Roto cap)
4 Rocker arm bracket 9 Exhaust valve
5 Cylinder head cover 10 Valve seat ring
6 Valve clearance 11 Inlet valve
setscrew
20
1.3.04 Gear drive and camshaft
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).
Fig. 1041 Gear drive

1 Crankshaft gearwheel
2 Camshaft gearwheel
3 Oil pump drive gear wheel on
crankshaft
4 Lube oil pump
21
1 Fig. 1032 Mass balance (8-cylinder engine)
2 Mass balance shaft
3 Drive gear
4 Intermediate gear
5 Crankshaft gear
6 Crankshaft
Fig. 1033 Piston

7 Gudgeon, pin
8 Piston
9 Oil scraper ring
10 Plain compression ring
11 Trapezoidal ring
12 Locking ring
13 cooling chamber for
piston cooling
22
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.
Fig. 1042 Valve drive

1 Exhaust valve
2 Rocker arm
3 Pushrod
4 Mashroom tappet
5 Camshaft
23
1.3.05 Fuel system

In order to drive the engine, at every second revolution fuel is injected into the cylinder
chamber just before the piston reaches top dead centre. The fuel ignites and burns in
the compressed-heated air.
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.
Fig. 1051 Fuel system
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
24
The balance weights are driven by the crankshaft via

gearwheels 3 and 4, the object of the balance
weights being to ensure smooth running of the
engine.
Fig. 10
Gear drive for balance weights
1 Crankshaft
2 Flywheel
3 Crankshaft gearwheel
4 Balance weight gear
5 Balance weight
The cams 2 of the camshaft 1 driven by the gear

drive actuate the inlet and exhaust valve 5 (exhaust
valve shown) via the pushrod 3 and rocker arm 4.
Fig. 11
Controlling the valves via
the camshaft
6 Camshaft
2 Cams
3 Pushrod
4 Rocker arm
5 Inlet and exhaust valve
25
Fig. 1052 Injection pump on engine
1 Cylinder head
2 Intake pipe
3 Injection pump with governor
4 Stop linkage
5 Electric speed adjustment device
Fig. 1053 Injection pump
1 Fuel supply from filter 10 Roller tappet

2 Overflow valve (Fig.1051, pos.7) 11 Piston
3 Governor 12 Control sleeve
4 Speed adjustment lever 13 Control rod
5 Fuel supply 14 Pump cylinder
6 Fuel feed pump {see also Fig.1055) 11 Inlet drilling
7 Lubricating oil return 16 Delivery valve
8 Pipe to filter 17 Pressure connection to the injection valve
9 Camshaft for injection pump
26
Single acting Fig. 1054 Injection valve

1 Holder for injection valve
2 Delivery pipe connection
3 Edge-type filter
4 Leak-off connection
5 Compression spring
6 Nozzle holder
7 Thrust piece
8 Cap nut
9 Nozzle body
10 Nozzle needle
Fig. 1055 Fuel feed pump
1 Delivery pipe connection

2 Plunger chamber
3 Roller tappet
4 Piston rod
5 Piston spring
6 Intake valve
7 Intake connection
8 Intake chamber
9 Piston
10 Delivery valve
27
USER'S USE USERS MANUAL GREAVES DIESEL ENGINE D3
Fig. 1056 Fuel filter with filter cartridge
1 Fuel inlet pipe

2 Vent screw
3 Fuel return pipe
4 Filter head
5 Filter cartridge
28
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.)
Fig. 1061 Speed governor Bosch EP / RSV
1 Fish plate 10 Adjusting pin on

2 Governor cover centrifugal pendulum
3 Lower filling limit 11 Governor housing
4 Guide lever 12 Flyweight
5 Governor lever 13 Injection pump camshaft
6 Tension lever 14 Swivel lever
7 Supplementary idling 15 Rocker
spring 16 Injection pump control rod
8 Spring retainer {adjusting movement)
9 Full load stop 17 Governor spring
29
Fig. 1062 Speed governor Bosch EP / RSUV
1 Speed adjustment device 10 Supplementary idling spring

2 Lower filling limit 11 Guide lever
3 Stop motion rods 12 Spring retainer for
4 Injection pump compensation
control (adjusting movement) 13 Maximum filling limit
5 Fish plate 14 Flyweights
6 Starting spring 15 Governor cover
7 Swivel lever 16 Governor housing
8 Tension lever 17 Drive gear wheel
9 Governor spring (speed increasing device)
18 Injection pump camshaft
30
1.3.07 Lub. oil system
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.
Fig. 1071 Schematic diagram of lub. Oil system

1 Oil pan 11 Big-end bearing
2 Lube oil pump 12 Camshaft bearing
3 Cooling oil pump 13 Injection nozzle
4 Suction pipe 14 Piston
5 Oil cooler 15 Mushroom tappet
6 Bypass pipe for oil cooler 16 Pushrod
7 Lube oil change filter 17 Rocker arm
8 Bypass valve 18 Exhaust turbocharger
9 Gallery 19 Pipe to injection pump
10 Crankshaft bearing 20 Return to oil pan
31
Dry sump lubrication
Dry sump lubrication is of advantage on engines subject to a large inclination, so that it is

impossible for the lube oil pump range to run dry. The elementary lube oil circuit is shown in Fig. 29.
In addition, a suction pump 2 incorporating three gearwheels is provided which draws off the lube oil
from the two suction spaces 3 of the oil pan 4. and returns it to the centre portion of the oil pan via
the return piping 5. From here, the engine oil pump I delivers the lube oil to the lube oil circuit of the
engine and to the cooling oil nozzl es for piston cooling.
Fig. 30
Dry sump lubrication
1 Engine oil pump

2 Three-gear suction pump
3 Suction spaces
4 Oil pan
5 Return piping
6 Cooling oil pump
7 Suction piping
Fig. 32
Engine oil pump
1 Housing
2 Drive gearwheel
3 Pump gearwheel
4 Cooling oil pump gearwheels
32
Fig. 1075 Lub. oil filter
1 Filter cartridge
2 Filter head
3 Excess pressure valve,
]]
Fig. 1076 Oil cooler

1 Oil cooler cartridge
2 Oil cooler housing
3 Cooling water pipe
33
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.
Fig. 1081a Indirect cooling (diagram)
1 Thermostat 7 Cooling water pumps

2 Expansion tank for 8 Cooling water supply
Intercooler circuit cylinder bank - A
3 Expansion tank for engine circuit 9 Outer skin cooler for
4 Intercooler intercooler circuit
5 Cooling water supply 10 Outer skin cooler
cylinder bank - B for engine circuit
6 Oil cooler 11 By-pass line
12 Venting pipe
34
Fig. 1082 Heat exchanger

1 Header
2 Expansion space
3 Cooling water filler neck
4 Water level mark
5 Tube bundle
6 Cooling water outlet to engine
Fig. 1083 Fresh water pump
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)
35
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
1 Cooling water inlet

2 Cooling water outlet
3 Headers
4 Cooling shell
5 Tube bundle
6 Bypass valve
7 Water drain
8 Oil drain
9 Bypass line
36
Centrifugal Pump (Raw Water) Stork KGEC 11.3
Fig. 1084 Centrifugal pump (Raw water)
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
37
Fig. 1085 Thermostat
1 Cooling water inlet

2 Thermostat
3 By pass to water pump
4 To cooler
5 Thermo element
6 Valve disc
38
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.
Fig. 1091 Turbo-charging system

1 Air filter
2 Turbocharger-blower
3 Turbocharger-turbine
4 Intercooler
5 Exhaust gas
6 Charge air
7 Inlet valve
8 Exhaust pipe
9 Outlet valve
10 Coolant or cooling
air 39
Fig. 1092 Exhaust turbocharger
1 Turbine 2 Lub. oil inlet

3 Compressor 4 Intake air inlet
5 Compressor impeller 6 Axial sealing compressor side
7 Axial bearing 8 Radial bearing
9 Lub. oil connection 10 Heat shield
11 Axial sealing turbine side 12 Turbine wheel
13 Exhaust outlet 14 Exhaust inlet
15 Lub. oil return pipe
Fig. 1093 Supply lines to intercooler
1 Intercooler
2 Intake air pipe from turbocharger
3 Raw water supply
40
1.3.10 Starting system
The starter is designed to speed up the crankshaft of the engine to ignition

speed. When this speed is reached, an inflammable fuel/air mixture has been formed
inside the engine cylinders. This fuel/air mixture ignites and brings the engine into
operation.
Electric starting
The starter pinion is driven by an electric motor via a disc clutch that can axially
be shifted. By means of the meshing rod the meshing relay presses the starter
pinion in the gear rim of the flywheel and thus drives the crankshaft. Only then is
the full starter torque transmitted by the disc clutch in order to prevent the tooth
flanks from being damaged. As soon as the engine starts the disc clutch is released
via the steep-angle thread and the starter pinion is disengaged.
Fig. 1101 Electric start
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
41
1.3.11 Engine control and monitoring
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.
Fig. 1111 Control panel (examples)
1 Tachometer
2 Lub. Oil pressure
3 Ammeter
4 Water temperature
5 Lub. Oil temperature
6 Stop switch
7 Pilot lights
42
Fig. 1113 Cooling water temperature sensor
1- Cooling water sampling pipe

2-Cooling water temperature sensor
H Fig. 1113 Cooling water temperature sensor
1- Hand stopping button

2- Stopping lifting solenoid
43
STARTING THE ENGINE
(1) The Tri -P a n e l c a n s t a r t a n e n g i n e i n t h e f o l l o w i n g w a y s . F o r m a n u a l start configurations the

engine can be started by pressing the START button.
(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.
STOPPING 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.
44
STARTING AND STOPPING SEQUENCE
(1) The starting sequence is initiated by pressing the START button.
(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.
45
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.
• A manual stop signal from the STOP button

• An EMERGENCY STOP signal.
(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.
46
ALTERNATOR WIRING
WIRING OVERVIEW
47
CLEARING ALARMS
(1) When an alarm occurs :

• The cause of the alarm is shown in the LCD upper window.
• The gauge shows the current status.
• The P R E A L A R M o u t p u t is activated.
• The ALARM output activated.
• The engine is usually stopped.
(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.
(4) Deactivate the EMERGENCY STOP switch if i t is activated.

(5) Press the STOP button.
(6) The Tri -P a n e l w i l l r e t u r n t o S T A N D B Y m o d e .
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
48
(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
NAME CONDITION REMEDY
ERROR 1:2 Tacho uncalibrated Calibrate Tacho
ERROR 1:3 System not set up Set up Tri-Panel
START Engine did not start Check engine for correct operation
FSTOP Engine will not stop Check fuel control
HIREV Engine went over speed Check governor
TACHO Tacho input not available Check alternator and engine wiring
ESTOP Emergency stop activated Deactivate emergency stop
UREV Engine was running too slowly Check governor
OREV Engine was running too fast Check governor
OIL Low oil pressure detected Check oil level, sensor, wiring
TEMP High temperature detected Check coolant, airflow, sensor, wiring
LVOLT Low battery charge Check battery condition, alternator
HVOLT High battery charge Check voltage regulator
HALT Engine stopping Wait for engine to stop
49
Part 2 Operation and POL products
2.0 Prevention of accidents, safety instructions
2.1 Prior to first -time operation
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
2.2 Engine control
2.2.1 Prior to starting

2.2.2 Starting engine
2.2.3 Setting speed
2.2.4 Stopping engine
2.2.5 Instructions for prolonged storage
2.2.6 Restarting after prolonged storage
2.3 POL specifications for small size engines
50
2 Operation and POL products
2.0 Prevention to accidents, safety instructions
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
The following prescriptions are generally valid
• For the staff:
The engine may only be operated or maintained by trained staff. Unauthorized

persons are not permitted to enter the engine room.
Wear tight-fitting clothes and ear protection during engine operation in the
engine room.
Trained staff only may be engaged for repairs or maintenance operations.
• For the engine room:
Ensure sufficient ventilation (do not cover ventilating vents).
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.
• For operation and maintenance of the engine:
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.
Cleaning, maintenance and repair operations should only be carried out if

the engine is stopped and secured against starting.
51
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".
2.1.1 (Cooling water * )
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
52
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.
Fig. 2004 Hand priming pump
1 Pressure connection
2 Hand priming pump
53
• 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.
Fig. 2005 Dual fuel filter Fig. 2007 Injection pump

3 Bleed screw 4 Overflow valve
2.1.3 Lubricating oil *
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.
Brand Ambient temperature
SAE 40 constantly above 30°C

SAE 30 between 0°C and 30°C
SAE 10W constantly below 0°C
SAE 20W20 between -10°C and +10°C
Caution!
Wrong viscosity can result in starting difficulties or very low oil pressure.
54
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.
Fig. 2008 Oil filler neck
1 Plug
2 Dipstick
* Please refer to POL specification 6.000.0.005.4431 e, given in this operating instructions

manual.
This POL specification is being updated every year and can be obtained from Greaves
after-sales services at the beginning of each year.
2.1.4 Starting air
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.
Caution ! The starting air receiver must not be filled with

oxygen or inflammable gases due to danger of
explosion.
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
2.1.5 Special measures for operation in winter
• Winter engine oil

Effect in time oil change and use oil of low viscosity. See prescription 6.000.0.005.4431 of
this operating instruction .
• 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.
Caution ! Smoking and each use of an open flame is strictly

forbidden. The blend is as easily inflammable as pure gasoline. Danger
of explosion!
Ambient temp. Summer-grade Kerosene or Winter grade diesel Kerosene or

limit down to diesel fuel % Gasoline % *) fuel % Gasoline % *)
-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 * *)
For using a commercial additive, please consult your service points.
*) never use premium fuel

**) not allowable for gasoline admixture
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
2.2 Engine control
2.2.1 Prior to starting

• Slightly open drain valve of the starting air compressor (air starting)
• Check engine stopping device for easy movement
• Switch on engine room ventilation, if available
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.
2.2.1.1 Checking supply of POL products

In order to prevent operational failures and stoppages, it is necessary to ensure that all
POL products are available in sufficient quantities. Since the level of these products
decreases as a result of consumption, evaporation or leakages, their level should be
checked daily.
It should be ensured that use is made only of correct, clean POL products, meeting the
requirements of section 2.3
• Checking the fuel supply
Check the fuel level in the service tank and replenish if necess ary. Depending on the
size of the tank and the engine load, the service tank must be replenished several times
per day.
Caution ! When refuelling, smoking and all any naked flames are strictly
forbidden due to the explosion hazard. The same applies to the switching on
and off of electric appliances of all types.
• Open cooling water valves (raw water circuit) if attached.
• Checking the coolant level
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%).
Fig. 2009 Cooler
1 Filler neck
2 Cooler cap
57
• Checking the lub. Oil level
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.
Fig. 2010 Oil Filter
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.
If necessary, connect battery charger to battery (positive to positive and negative to

negative) and recharge battery. The recharging current is equai to 1/10 of battery capacity
number e.g. for 145 AH - recharging c urrent is 14.5 ampere.
Caution ! Hydrogen-oxygen mixture (oxy-hydrogen gas) is released during

recharging. No naked flames, no smoking. The plugs (Item 1) must be open.
After recharging, replace plugs, clean battery terminals and grease with anti-
acid grease.
Note : Unused batteries must be recharged every 4 to 6 weeks.
Fig. 2011 Battery
1 Plugs
2 Battery terminals
58
2.2.2 Starting the engine
• Set speed governor to low engine speed
• Switch on monitoring device (in case of a key-operated switch; position 1)
• If fitted, position switch "Betrieb - Stop" (Operation - Stop) to "Betrieb" (Operation)
• 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.
During operation maintain key-operated switch on position 1, otherwise (position '0')

the monitoring facility will be out of circuit.
Fig. 2012 (Examples)

Switch and control board
Engine start with flame starting system
• Turn key-operated switch to position I
• 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)
• When engine- starts press push-pull switch inwards to stop limit.
59
2.2.2.2 Emergency start with Hansa quick starter
1. Remove cylinder head cover from the cylinder with

which the quick starter is connected.
2. Crank the engine until both valves are closed (push

rods can be easily turned, ignition top dead
centre). Continue cranking until the starting mark
"S" on the V -be!t pulley (Fig. 2013) and the mark
on the indicator coincide. Remove cranking bar
and replace cylinder head cover.
3. In order to open ihe starting valve of the cylinder

head loosen lock nut 1 and unscrew threaded Fig. 2013
spindle 2 as far as it will go (Fig. 2014).
4. Switch on monitoring device (in case of key -

operated switch : position 1) and position injection
pump control rod to complete filling.
5. Remove cap 3, loosen valve seat of the main valve

by means of tightening the nut 5, back off nut 5
again.
Note : cap 3 blocks the main valve, tighten cap

again only after, starting the engine.
Fig. 2014
6. Check whether cap screw 6 is tightened (hand-
tight only).
7. Loosen screw 7, place ignition film strip (max,

length 1,5 m) over the film strip fork 8. Rescrew
and tighten screw 7 again.
8. Strike (storm proof) match and throw it through

bore 9 into the pressure container. Close aperture
9 by means of lever 10. The engine starts due to
the developing pressure.
Caution ! Keep away from the safety valve 11 as

there is danger of accident due to gases emerging
under high pressure
9. Once the engine has started, close starting valve

on the cylinder head (main valve spindle 2) and
tighten lock nut 1.
Dismantle Hansa quick starter and oil all threads

and conical items.
Fig. 2015
60
2.2.3 Speed Adjustment
After cold start of the engine wait a few minutes until running the engine at full load and
speed; increase speed and load gradually.
Manual speed adjustment device (Fig. 2016)

Loosen lock nut 1 and operate handwheel 2 until the required speed is attained. Tighten
lock nut 1 again.
Electrical speed adjustment (Fig. 2017)
Operate speed switch unti! the required speed is attained. The highest and lowest
adjustable speed is blocked by means of limit switches.
Fig. 2016 Manual speed adjustment device Fig. 2017

1 Lock nut switch for speed adjustment Switch for speed adjustment
2 Hand wheel
Checking operating values

Checking the operating values is an important preventive measure with regard to the
reliability of the engine. By means of periodical controls, malfunctions can be recognized
in time, thus avoiding damages. The test report gives the normal operating values read
off in order to be able to determine gradual changes by comparing them with previous
test results over a long period of time.
Data to be controlled and indications as to possible sources of error are mentioned
below:
Lub. oil pressure (Pressure gauge 2)
Possible reasons for an inadequate lub. oi! pressure :
• 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
Possible reasons for a too high lub. oil pressure :

• Lub. oil (still) too cold
• Oil control valve 3 seizes
• Lub. oi! too thick (wrong viscosity, oil change)
• Pressure gauge faulty
61
Cooling water temperature (thermometer 1)
Possible reasons for high cooling water temperat ure

Engine overloaded
Cooling water level too low
V-belt for water pump drive is broken or loos e
Cooler clogged
Thermostat faulty
Possible reasons for low cooling water temperature:
Thermostat faulty
Fig. 2018 Control board Fig. 2019 Lub oil filter
1 Cooling water temperature 3 Oil pressure valve

2 Lubricating oil pressure
2.2.4 Stopping the engine
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.
Fig. 2020 Manual stopping device
62
2.2.5 Engine preservation
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.
2.2.6 Engine operation after preservation
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
G R E A V E S POL-Specification small-size engines Oct 97 1.000.0.0054401

----------------------------------- ------------------------------------------------------------------- ---------------- --- ----------------------------------
Lubricating oil grades B= API-CF-4 Explanations

GENERAL
Fuel Distrillates as per DIN 51601 IMDF as per MDF as per Normal and heavy- duty operation in vehicles
BS 2869 class A1 OR A2 BS 2869 BS 2869 installations and generating sets
ASTM-D 975 No. 1 D and/or 2D __________ Class B 1 Class B 2
Sulphur contents in % by weight to 0.5 to-1 to-1. 5 CHPM/heat pumps
Application in combined heat and power modules
Emergency CHPM
Type of application GENERAL power heat GENERAL EMERGENCY POWER Supply
supply pumps
------------------------------------ ------------------------ -------------- ---------------------------------------------------- Operation in emergency generating sets
TBD B B B In case of operating periods less than 20h/ month
turbo charged
please consults our factory.

B B B Oil change every 6 months at least
Engine type
Lubricating oil grade
---------------------------------------------------------------------------------------------------------- (See overleaf)
Oil change interval 250 250 250 250 or ace. 125 125
in operating hours to analysis
Lubricating - oil viscosity
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
Lubricating oil change Limiting values for analysis mm max

Viscosity at 100° mm7 /s(cSt) DIN 51562
The lubricating - oil level must regularly be checked and completed up to SAE 20W 20 7.0 11.0
the top dipstick mark SAE 30 9.5 14.0
In cases of operation involving a mostly constant engine load (e.g. CHPM) SAE 40 11.0 17 0
the oil change interval may be extended, if the optimum oil-change interval Flashpoint ºC 200 ISO2719
has been determined by a series of used- oil analyses. Oil companies and Fuel contents % by vol. 6
technical institutions may be asked to carry out these analyses or Greaves solid foreign matters
against reimbursement of the costs involved The lubricating oil must be (Heaptane) % by weight 1.5(2)" DIN51365
changed, in any case, if the results of the used- oil analysis are exceeding Water contents % by weight 0.2 ISO3733
one or several limiting values stated in the opposite table Base number (TBN) % 50% of value when new AST M664
____________________________________________________________________________1) The values in brackets are permissible in exceptional cases only._________________
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
Water quantity mm max Anticorrosion agents min | max
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
anticorrosion 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
NALFLEET 9-111 ENGINE COOLING

SYSTEM TREATMENT
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
Principal Uses Nalfleet 9-111 functions as a It is approved for use in an engine

protective film forming corrosion cooling system circulating as the
inhibitor and scale suppresant. It is heating medium for generator
effective in hot and in cold fresh producing fresh water for drinking
water and is fully compatible with and culinary purposes, provided the
glycol/water mixtures. It also contains recommended dosage rates are
an anti-incrustant to prevent adhered to.
deposition on hot surfaces and keep
waterways in radiators clear.
General Nalfleet 9-111 has the following Odor : None

Description typical characteristics. Color : Dark Solubility in Water
blue Soluble in small proportions.
Feeding Nalfleet 9-111 may be fed directly Empty and fresh the cooling system
from drums but because of the thoroughly before commencing as
alkalinity of the neat product plastic much old rust as possible. If the
taps should be used for dispensing. system is exceptionally rusty it is
advisable to repeat this procedure
Nalfleet 9-111 should be added after after the first week or two of
the circulation of the cooling water treatment.
system.
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
Agip Agip Antifreeze Plus
Aral Aral- Kuhlerfrostschutz
Avia Avia FROSTSCHUTZ
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
IND Mobjl IND-MOBIL DELVAC SUPER 1300i I5W- 40 Frostschutz 500
Motur MOTUL HP4D 15W40
BHG Fricofin
Snell GlycosheH
Texaco Texaco Frostschytz
Total Total Frostfree
veedol Veedol Antifreeze
Winte shall Kuhle'schutz
• SHIM>()!<•
66
LUBRICATION FOR GREAVES ENGINES
LUBRICATING OIL CHANGE PERIODS ARE RECOMMENDED FOR

GUIDANCE. THESE PERIODS CAN BE ALTERED DEPENDING UPON THE
WORKING CONDITIONS, ENVIRONMENT, QUALITY OF LUB. OIL AND
MAINTENANCE OF THE ENGINE. THE LIFE OF LUB. OIL AND FUEL
FILTER ELEMENTS DEPENDS ON THE QUALITY OF LUB. OIL AND
DIESEL USED RESPECTIVELY.
REGULAR OIL CHANGE AND GOOD PREVENTIVE MAINTENANCE

GIVE THE ENGINE LONG LIFE AND SMOOTH WORKING.
RECOMMENDED LUB. OILS
i) API - CF4 OR EUIVALENT

ii) CASTROL RX-SUPER PLUS 15W-40
iii) IND-MOBIL DELVAC SUPER 1300 15W-40
iv) elf PERFORMANCE 3D 15W-40
v) IOCL SERVO PREMIUM CI4 15W-40
67
USER'S MANUAL GREAVES DIESELENGINE D3
Part 3 Servicing
3.1 Tools and expedients

3.1.1 Other additives
3.1.2 Trouble tracing table
3.1.3 Servicing schedule
3.1.4 Job sheets for servicing
68
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.
3.1 Tools and expendients for servicing
The following tools and expedients are required for carrying out the servicing tasks.
1. Set of tools 6.000.0.018.500.7

Servicing set
2. Set of tools 6.000.0.018.501.7

Servicing set
3. Set of tools 6.232.0.018.009.7

Supplementary kit
4. Set of tools 6.234.0.018.003.7

Servicing set
69
1. Set of tools
Servicing set
Order No. 6.000.0.018.500.7
Item Qty. Description Part No.
1 1 Tool case 6.085.610.2001.3

2 1 Wrench 10 x 12 DIN 3110 6.086.417.0101.2
3 1 Wrenc h 13 x 17 DIN 3110 6.086.417.0131.7
4 1 Wrench 14 x 15 DIN 3110 6.086.417.0141.5
5 1 Wrench 19 x 22 DIN 3110 6.086.417.0192.2
6 1 Socket insert 13 x 12.5 DIN 3124 6.086.424.0013.2
13 1 Cross handle A 12,5 x DIN 3122 6.086.445.0112.2
14 1 Extension B 12.5 x 125 DIN 3123 6.086.445.1120.2
15 1 Screwdriver A 0,8 x 5,5 x 125 6.086.460.5000.9
DIN 5265
16 1 Set of feeler gauges 0,2-0,45 6.086.104.0004.0
17 1 Square spanner, spanner opening 3,5 6.086.422.2000.1
70
2. Set of tools
Servicing set Order No.
6.000.0.018.501.7
Item Qty. Description Part No.
1 1 Tool case 6.085.610.2001.4

2 1 Wrench 10 x 12 DIN 3110 6.086.417.0101.2
3 1 Wrench 13 x 17 DIN 3110 6.086.417.0131.7
4 1 Wrench 14 x 15 DIN 3110 6.086.417.0141.5
5 1 Wrench 19 x 22 DIN 3110 6.086.417.0192.2
6 1 Wrench 24 x 27 DIN 3110 6.086.417.0242.7
14 1 Cross handle A 12,5 DIN 3122 6.086.445.0112.1
15 1 Extension B 12.5 x 125 DIN 3123 6.086.445.1120.2
16 1 Extension B 12.5 x 250 DIN 3123 6.086.445.1120.1
17 1 Universal joint C 12.5 DIN 3123 6.086.445.2120.1
18 1 Head of ratchet 12. 5/0 - 400 Nm 6.086.440.9000.1
19 1 Pipe handle 6.086.440.9002.2
20 1 Torque wrench 0-210 Nm 6.086.440.1021.1
21 1 Extension lever 0-420 Nm 6.086.440.9002.5
22 1 Screwdriver A 0.8 x 5.5 DIN 5265 6.086.460.5000.9
23 1 Set of feeler gauges 0.05 1 mm 6.086.104.0001.0
24 1 Square spanner, spanner opening 3.25 6.086.422.2000.1
71
Special tool set, item number 6.232.0.018.009.7
Item Description Part No.
1 Tool box C 1613/01 6.085.610.2001.6

2 Screwdriver A1 x 7 x 150 6.086.460.5001.0
3 Screwdriver 2 DIN 5262 6.086.461.1002.1
4 Plier C 19 DIN 5256 (for piston 6.086.009.0000.2
pin retaining ring)
5 Piston ring pliers 110 - 150 RD 6.087.105.1000.3
6 Testing device CH 1612/4 (to check 6.088.801.2031.4
the cylinder liner set back and upper
distance of piston)
7 Dial guage A 10 DIN 878 (to 6.086.001.0002.1
testing device CH 1612/4)
8 Overflow pipe CH 1612/6 6.088.801.4010.7
(to check injection timing)
9 Overflow cup 1774/21.2 (to 6.088.801.4010.8
overflow pipe CH 1612/6)
10 Screwdriver insert SW 8, square 6.086.425.0008.1
12.5 (for fastening bolt of injection
pump)
11 Socket wrench insert CH 1983.1/6 6.088.801.4011.0
21 x 24 (for pressure pipe
connection on injection pump)
72
Set of tools - Servicing set 6.234.0.018.003.7

Tool case 6.085.610.2003.5
Hydrometer 6.0759.80.0.0001
Cooling water test kit 6.088.801.6020.4
Strap wrench for disposable filter 6.086.442.1000.1
Square spanner for Zinc protection 6.086.423.0001.4
73
3.1.2 Fault-Tracing Table

The fault-tracing table lists faults in engine operation with a description of how they may occur
and their causes. The potential causes are given in the order in which the true cause is likely to be
localized with the least effort.
The sections given under "Remedy" contain information on how to remedy the fault. The
cause; of deviations in lube oil pressure, lube oil temperature and coolant temperature as well
as information on how to remedy them are given in Job Sheets 3.1.4.2 and 3.1.4.3.
causes
Engine does not turn When
Engine running irregularly
Abnormal exhaust gas

Engine does not achieve
Or stop after a few ignite
Engine stop operating

specified out put /speed
Engine does not ignite
Engine overheating
Engine over speed

Engine knocking
Water in lub oil.

colorings
started
No control current
Battery discharged
Insufficient fuel
Monitoring system has workshop

tripped
Engine too cold
Turbocharger defective workshop
Starting system defective workshop
Oil cooler leaking workshop
Governor defective or workshop

governor linkage sticking
Defect at crank assembly workshop
Cylinder line in crankcase workshop

leaking
74
3.1.3 Servicing schedule

The following table shows the servicing tasks, subdivided according to servicing intervals. The servicing
work has to be carried out at the latest as soon as the operating hours, indicated in the columns on the
left page, have been reached.
The servicing tasks must be repeated according to the given number of operating hours.
for the first time on Checking exhaust back pressure 3.2.033

commissioning
only once after Engine oil change 3.2.001
50 operating hours Checking V-belt drive 3.2.003
Replace engine oil filter cartridges 3.2.025
for continuous operation for emergency & stand
by
daily 250h 1000 h 2000 h Servicing tasks No. of operation.
to be repeated every X Job Sheet
•Engine oil change 3.2.001 monthly 1 year
Checking coolant level prior to starting engine and 2years
3.1.4.2
X
checking coolant temperature during operation
X Checking oil level and oil pressure 3.1.4.3
X Check battery 3.1.-1.4
X Checking maintenance indicator on the air filter 3.1.4.5
X X Replace exhaust gas filter (after visual check) 3.2.002A
Replace dry-type air filter clement 3.2.002B X
X (Note maintenance indicator)
X Clean after cooler & heat exchanger 3.2.003 X
X Checking any resetting valve clearance 3.2.028 X

X Checking exhaust back pressure 3.2.033 X
Renew sparking plugs @250 Hrs 3.2.052 X
X Checking monitoring 3.2.059 X
X Lubricating the bearings (generator type T1) 3.:2.060 X
* Tightening torques of main screw connections 3.3.001
according to in Nm
requirements Engine preservation 3.3.003
** Cleaning heat exchanger & After cooler. 3.3.007
Cleaning exhaust-gas heat exchanger 3.3.008
Checking control unit for ignition point and 3.3.009
ignition
coils as well as cleaning impulse solenoids
• Determine service life of lubricating oil according to POL
products specification 6.000.0.005.4432 e of this operating instruction.
**Caution: Cylinder-head screws, bearing cover and connecting-rod

bolts should never be retightened
• In case of higher cooling-water temperature, check heat pieces

visually and clean, if necessary.
• Monitor H 2S, CH4, H 2O, Content in gas line
75
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
Checking bearing clearance on turbocharger 5 000h

Replacing exhaust- gas filter (probe end) after at the X
latest or earlier depending on the blackening degree 10 000 h
(visual check) Replacing exhaust- gas filter (pump X
end) after at the latest or earlier depending on the X
blackening degree (visual check) Replacing exhaust- X
gas pump X
Carry out measurement of harmful constituents * X
Overhauling cylinder heads Cleaning combustion X
chamber Checking cylinder liners Cleaning oil cooler X
Checking rocker arms and rocker-arm bracket X
Cleaning and checking cooling-water regulator X
Replacing cooling-water hose* and expansion joints X
Cleaning and checking gas-pressure regulator, gas X
solenoid valve and mixing valve Checking ignition unit X
* Replacing starter wearing parts * Checking X
exhaust installation for wear
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
3.1.4 Job Sheets for Servicing
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.
The Job Sheets describing the jobs are numbered.
The individual Job Sheets contain the following information:
• Description of job involved and Sheet No.
• Servicing interval
• Remarks on tools, fixtures and expedients required
• Information on any spare parts required
• General servicing directions
• Step-by -step description of servicing procedures
• Figures illu strating the text
• Important items in these figures are numbered
• Necessary reference relating to further Job Sheets
The object of the Job Sheets is to facilitate preparations and for implementing actual
servicing tasks.
77
TBD3
If the engine is used for standby or emergency service, corrosion

may occur due to condensation of water. In order to prevent
this and to test the operational readiness of the engine, a trial
run should be performed once in a month.
Starting the engine
1. Check the supply of POL products (Section 2.2.1.1)
2. Open the cooling water cocks and, if fitted, switch on

pump sets.
3. Open the fuel supply.
4. Switch on monitoring system {for key -operated switch :

position 1 fig. 1) and set speed governor to low speed.
5. If fitted, set switch 1 "Betrieb - Stop" (Operation - Stop)

to "Betrieb" (Operation) and start engine by means of the
u starting switch (for key - operated switch : press key
inwards and turn clockwise as far as possible)
Caution : if the engine races out of control (engine speed

continues to rise) or if no oil pressure is built up, switch
off the engine immediately and close the fuel supply.
During operation, keep key -operated switch in position

1, Position O means that the monitoring system is out of
operation.
1. Running the engine
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
Press manual stopping device (Fig. 3) in stop- direction until

flywheel stands still or set instrument panel lever to "Stop" (item
1 or 2). If fresh water pump units are fitted, they should run for
a few more minutes after stopping in order to prevent the buildup
of heat at the cylinder liners and cylinder heads.
Close fuel and cooling water cocks and switch of f monitoring

svstem.
78
Engine type Job Sheet No
Date first time after
GREAVES Job Sheet
5.97 TBD3 3 14 1
after and every Page of

Trial run 1 I 1 page
month
need thoroughly
prior to beginning
Necessary tools Necessary materials and auxiliaries Spare Table No.
If the engine is used for standby or emergency service, corrosion

may occur due to condensation water. In order to prevent this
and to test the operational readiness of the engine, a t r i a l run
should be performed once a month
Starting and monitoring of engine
1 Check the supply of POL products (Section 2 . 2 . 1 . 1 )

2 O p e n t h e c o o l i n g w a t e r cocks and, if fitted, switch on
pump sets.
Engine Protection Unit
3 Open the fuel supply.
4 To start the engine switch ON the control supply key
switch. Press the bypass button and start the engine from
start push button. The bypass button may be released
when the engine achieves oil pressure.
Caution : n' the engine races oui of control (engine

speed continues to rise) or if no oil pressure is built up,
switch off the engine immediately and close the fuel
supply
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
1. Running the engine

1-RPM Meter Just after starting, run the engine at 1 / 3 load only After
2- L O Pre Gauge approximately 10 minutes it can be run at 3/4 load and after a
3-W T Gauge further 5 minutes at full load (nominal output) When the engine
4-Ammeter has reached normal running temperature, check the operating
5 - L O T Gauge (optional) values (section 2 . 2 . 3 1) Before stopping the engine, let it run
6- Stop push button for another approx 10 minutes at 1 / 3 load
7-Warning Lamp
2. Stopping the engine
The engine is stopped f r o m t h e stop push button on the
Instrument panel by putting the switch in OFF position
E rig i n e Protection
Description
The e n g i n e m o u n t e d s w i t c h e s c o n s i s t o f l o w lub oil pressure

switch (operating at 1 5 t C 0 5 bar f a l l i n g pressure), high water
temperature switch (operating at 96 Deg C )2 Deg C rising
temperature) that stops the engine if either of the conditions are
achieved T h e condition annunciated by a hooter and displayed
by respective DC lamp
For generator set supplied with control panel by GDEU the engine
p r o t e c t i o n c o m e s i n t e g r al with panel control with circuit. If fresh
water pump units are fitted they should run for a few more minutes
after stopping in order to prevent the buildup of heat at the cylinder
liners and cylinder heads.
Close fuel and cooling water cocks and switch off monitoring
system.
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
Hydrometer 6.0759.80.0.0001 Distilled water

Cloth Anti-acid grease Bosch No. 5 700 102 005
When the engine is not operating, the battery supplies current to

consumers and delivers the high power required for starting. The
capacity of the battery deteriorates during long periods of non-
operation or as the result of excessive loading. For these reasons the
battery must be checked at the intervals indicated in the servicing
schedule.
Caution: The charging gases are explosive. Do not, in

any case, manipulate naked flame, produce sparks or
smoke in the vicinity of the batteries.
Wear protecting glasses when working on batteries
being connected to the charger.
Allow frozen batteries to thaw before charging.
Checking battery and recharging it, if necessary

1. Wipe battery using a humid cloth. Remove corrosion marks
and rinse the poles using a solution composed of water and
natron and coat with acid-resisting grease. Check, whether
connecting terminals are tightened.
2. Unscrew battery-cell caps (item 1) and measure electrolyte
density of the battery using a hydrometer (item 2).
Electrolyte density: 1.23 to 1.28 kg/I normal
Electrolyte density below 1.21 kg/I recharge.
Reference temperature 20°C.
3. Unscrew all battery-cell caps (item 1) and fill up, if necessary
with distilled-water to approx. 15 mm above plate edge.
4. If the battery has to be recharged, disconnect battery cables
(beginning with negative pole) and connect battery charger.
Positive to positive pole and negative to negati ve pole.
Switch charger on and recharge battery.
The charging current represents 1 / 1 0 th of the numerical value of
the battery capacity, e. g. 143 Ah = charging current of 14.3 A. The
battery is charged when the acid density and charging voltage do
not rise any more within 2 hours.
5. Switch off and disconnect charger. Close all battery-cell caps
and connect battery cables (beginning with positive pole).
Note:
Recharge stopped batteries every 4 to 6 weeks.
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.
Set of tools Cleaning agent 79 -

Compressed air
Gaskets
In dry-type air filter, the intake air is directed through a paper

filter insert retaining the dirt particles. The filter gets clogged as
a result of the dirt particles accumulated inside the filter insert,
thus increasing the vacuum downstream of the filter. This
vacuum is measured inside maintenance sensor. In case of
excessive vacuum i.e. a contaminated dry-type air filter, the
maintenance sensor incorporated in the switchboard switches a
signal lamp on. It is now time to perform maintenance operations
or after one year at the latest. Filter element 3 must be replaced
to make the engine ready for operation again.
In order to increase the service life of the filter element a pre-
filter is installed in front of the filter. It retains the coarser
particles of dirt of the intake air.
Caution! Operations may be performed on the air filter
only if the engine is stopped. "Risk of accidents"
Check dust collector 1 mounted on Pre-filters clean
pre-filter
Check dust quantity in dust collector 1. When the mark 2 is
reached, empty dust collector 1 and carry out the following
operations :
1. Loosen clamping screw 3 and remove pre-filter
2. Clean air intake openings 4 and dust discharge slot of
the dust collector 1 by means of a piece of wire.
3. Clean all parts with a detergent solution and dry them.
4. Reassemble in reverse sequence. Pay attention to seal
Check maintenance indicator, renew dry air filter elem ent
Check sight glass 6 of the maintenance indicator while the
engine is out of operation. If the red mark continues to be seen,
carry out the following operations :
1. Remove nut 7, cover 8 and renew filter element 9.
2. Reassemble in reverse sequence. Pay attention to seal
10.
Cleaning the dry-type filter element (only in exceptional
cases)
1. Remove filter element as described under "Renewing
filter element".
2. With the clean room closed the filter element is to be
blown out in longitudinal direction of the folds a n d
afterwards from inside.
Note : The filter elements can also be washed out with
detergent 053 or P 3 RST (Messrs. Henkel). We advice
however, not to do so for reasons of safety. Beating the
filter element is not recommended either.
3. Reassemble in reverse sequence.
Note : Afler having cleaned the filter element 5 times,
or every 2 years, at the latest, the filter element has to
be renewed.
81
Job Sheet No.
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.
Tool set Lithium saponified grease 57 -

Cranking bar 59 -
Grease gun 65 -
67 -
69 -
89 -
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)
The V-belt tension is correct when the V-belt can be pressed

in 1 to 2 cm with the thumb (Fig. 1 arrows). Otherwise (he V-belt
must be readjusted.
Checking and resetting V-belt tension
1. Remove V-belt guard
2. Check V-belt tension (Fig. 1, arrows) if required :
3. Loosen screws 4 on tensioning roller bracket or alternator
4. Regulate tension by moving the tensioning roller or

alternator accordingly
5. Tighten screws 4
Observe tightening torques of the screw connections (Job sheet
3.3.001)
Caution !
Tensioning the V-belt excessively aggravates wear just as much

as slack V-belts.
As soon as cracks or other signs of wear are noticed the V-belt

must be changed. For checking the V-belt all over, crank the
engine.
Lubricating the raw water pump
Fill the grease nipples (Fig. 2 or 3, arrows) with lithium saponified

grease (multi -purpose grease) by means of a grease gun.
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
Square wrench 11 mm : 14 mm 1 Sealing ring 6.0492.01.5.4249 63 75

Fresh water containers 2 Sealing rings 6.0492.06.5.0331
* Zinc paint 6.1489.01.0.8044
* Zine paint 6.1489.01.0.8054
* 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.
Removing and fitting zinc protective coating
1. Close the raw water inlet and return cock.

2. Drain water from engine (drain cocks are identified by item 1 in the illustration, also not forgetting to drain the
other side of the engine)
3. Remove plugs with zinc protective coating (identified by arrows in the illustrations) and check condition. If
heavily decomposed, renew.
4. Refit plugs with new sealing rings
5. Close drain cocks
6. Open raw water cocks, open cock under funnel (Item 3) and fill raw water pump. Then reclose cock under
funnel.
7. Bleed system at plugs (identified Item 2 in illustrations)
83
Job Sheet
GREAVES 1.86 60 h 500 h D3
TBD3
3.2-025
Replacing engine oil filter cartridges read thoroughly prior Page of

Tool set Filter cartridge 6.0541.29.7.0048 = 6 Cyl. 47 -

Oil pan Filter cartridge 6.0541.29.7.0039 = 8 + 1 2 Cyl.
For reversible filter : or (in case of a reversible duplex filter): 2 filter
Cock wrench SW 17 cartridges 6.0541.18.8.0008
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.
If a reversible duplex fuel filter is mounted, the filter cartridges

can be replaced while the engine is in operation, provided that
the corresponding filter chamber has been switched off (see
Fig. 3) During normal operation, both filters must be in operation.
Replacing filter cartridges
1. Loosen filter cartridge 1 with strap wrench and unscrew

it.
2. Clean seal seat and oil seat of new filter cartridge

slightly.
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)
4. Screw filter cartridge until seal contacts, then tighten

manually. Do not use tools!
5. Check filter for leakage with engine running.
Cock position 1 : left filter closed

Cock position 2 : Both filters open
Cock position 3 : right filter closed
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.
Checking and adjusting of valve clearance (on cold engine)
1. Screw out bolts 1 on all cylinder heads and remove

cylinder head covers.
2. Crank engine in direction of rotation until valve 2 close
in cylinder A1; then, crank crankshft further by approx.
half a turn, this position corresponding to ignition TDC.
3. Check valve clearance between rocker arms and valve
stem end with corresponding feeler gauge.
Valve clearance for : Inlet valve 2 Exhaust valve 3
naturally-aspirated engine 0.2 mm 0.3 mm

turbocharge d engine 0.3 mm 0.5 mm
The feeler gauge should be inserted with a certain

amount of force. In case of deviation the valve clearance
Checking and/or setting sequence (ingnition TOC) must be readjusted.
Loosen locking nut 4 and setting screw 5. Screw in
setting nut by screw driver until (he feeler gauge begins
to clamp. Tighten locking nut and check valve cleara nce
Flyweel end as above.
Checking and/or adjusting sequence :
Beginning of the second
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 checked and/or adjusted the valve clearance
on cylinder A1, the engine is to be checked further,
progressively, in firing order and direction of rotation for
additional checks as follows:
Ignition TDC A1 B2 A3 B1 A2 B3
see also figure 2
Beginning of the second 6. Fix cylinder-head covers, taking care of gaskets.

Beginning of the first
Crankshaft rotaion Crankshaft rotaion
85
Engine type Job Sheet No.
GREAVES Job Sheet
Date first time after D3
1.86 TBD3 3.2.028B
Checking readjusting valve clearance (8 + 12 cylinder- engine) to beginning 1 1 pages
Set of 19
tools 21
fuming rod
Inlet and exhaust valves can only be reliably closed 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 bum 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.
Checking and adjusting of valve clearance (on cold engine)
1. Screw out bolts 1 on all cyl inder heads and remove

cylinder head covers.
2. Crank engine in direction of rotation until cylinder A1
reaches ignition TDC. Cylinder A1 is placed on ignition
TDC when valves A4 on 8-cylinder engines or A6 on
12-cylinder engines are overlapping, i.e. when exhaust
valve 3 closes and inlet valve 2 begins to open (Load-
change TDC)
3. Check valve clearance between rocker arms and valve
stem end with corresponding feeler gauge.
Valve clearance for : Inlet valve 2 Exhaust valve 3
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
Set of tools Fuel filter Fig. 1 29 -

Filter cartridge 6.0541.18.8.0004
Fuel fitter Fig. 4
Filler element 6.0541.14.0.0003
For single-stage filter 1 each
For duplex filter 2 each
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 .
If a reversible fuel filter is provided, the filter cartridges may also

be renewed while the engine is running.
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.
Renewing fuel filter cartridge (Filter Fig. 1}
1. Close fuel cocks

2. Loosen filter cartridge 1 with strap wrench and remove it.
3. Coat seal of the new filter cartridge with fuel.
4. Screw filter cartridge into filter h ead down to the real, then
tighten by 1/2 a turn. Do not use tools.
5. Bleed the fuel filter (see last paragraph)
Renewing the fuel filter element (Filter Fig. 2....4)
1. Close fuel cocks.

2. Unscrew wing screws, item 2, and take down cover item
3, taking care of gasket
3. Slacken centre screws, item 4, and take down cover, item 5.
4. Take filter elements, item 6, out of filter housing and clean
inside of filter housin g.
5. Insert new filter elements into housing and reattach cover
in the reverse sequence, taking care of gaskets.
6. Vent fuel titter (see last paragraph)
Right - hand Both filters Left-hand

filter in operation fitter
in operation in operation
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-
Set of tools Fuel fitter Fig. 1 29 - _

Filter cartridge 6.0541.18.8.0004
Fuel! filter Fig. 4
Fitter element 6.0541.14.0.0003
For single -stage litter 1 each
For duplex filter 2 each
Cleaning fuel pre filter (fig. 6)
1. Close fuel cocks
2. Loosen knurled nut 7 and put strap aside- Remove sight-

glass 8 and filter element 9.
3. Clean a(l parts with fuel, use a soft brush in order to

remove strong dirt.
4. Reassemble in reverse sequence. For bleeding open fuet

cocks, loosen banjo bolt 10 and operate hand fuel pump
until fuel emerges free of bubbles. Continue pumping
while tightening banjo bolt again.
Bleeding the fuel fitter
1. Open bleeding screws 11 and operate hand fuel pump

until fuel emerges free of bubbles. Continue pumping
while tightening bleeding screws 11 again.
2. Check filter for leakage during operation.
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.
Heatable container Molybdenum sulfide spray 41 - ...

Thermometer (up to 100°C) or 89 - ...
Tool set Wrench SW 27 Lithium saponified grease
Lub. oil
In order to avoid damages resulting from the malfunction of

lubrication or cooling, monitoring devices are mounted on the
engine. In case of an excessive cooling water temperature or a
too low oil pressure, warning devices (pilot lamp, siren) are
switched on or the engine is shut down via the shutdown
solenoid.
Checking and lubricating manual shutdown device Press

shutdown button 1 in direction of arrow and release again. The
shutdown device automatically returns to starting position. If
this is not the case, check rods for smooth working. Lubricate
joints 2 and tie rod 3 of the solenoid with molybdenum sulfide
or oil.
Checking oil pressure monitoring device Mole : if a timing

relay is installed the reactions of the monitoring device may delay
for 15 sec. (maximum). Switch on monitoring devic e (in case of
key-operated switch : pos. 1) and put switch "Operation - Stop"
to "Operation". The pilot lamp "oil pressure" flashes up and the
siren sounds. Operate switch "Siren off" and the siren is shut
off.
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.
Checking shutdown solenoid

Short-circuit connection on oil pressure switch or temperature
sensor 6. The shutdown solenoid is in "Stop" position. If this is
not the case, operate switch "Engine - Stop". If the shutdown
solenoid passes to position "Stop", check cable connection. If
this is of no use, renew shutdown solenoid.
89
GREAVES Job Sheet 3.2.057
5.85 2000 n TBD3
Cleaning the intercooler. read thoroughly prior Page of
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.
At the same time, the flow resistance of the air is increased

due to deposits on the air end of the cooling tubes and thus
the amount of turbo charging air diminished.
Cleaning the intercooler
1. Drain engine cooling water.
2. Remove fresh water pipes 2.
3. Loosen hose clamps 3, unscrew bolts 4 and remove inlet
pipes 8 and elbow 7
4. Remove raw water connections 5.
5. Unscrew bolts 6 and mounting bolts on intercooler frame
(Fig. 2,arrow), lift off intercooler.
6. Remove the air circulation 11
Note : The cooling fins on the air end are very delicate.
Cover flange surface with a board or the like.
7. Unscrew mounting bolts 9, remove head pieces 10.
8. Place the nest of tubes into a container with detergent
solution P3T - 1166, Henkel (concentration as per
information of the manufacturer). Foaming of the solution
characterizes the reaction. When the reaction is
completed, i.e. after 15 minutes at the latest, take the
nest of tubes off the detergent and clean the cooling
fins with a duct cleaner. The nest of tubes is then
washed out with clean water and put into a
neutralizing
agent consisting of P3-Croni (Henkel) for approx.
10
minutes. Finally, wash out the nest of tubes
thoroughly
with water.
Check the soldered connection of the nest of tubes and, if
necessary, resolder.
Reassemble in reverse sequence.
Renew gaskets.
90
Job Sheet No.
Job Sheet 3.2.060
GREAVES 5.85 2000 h TBD3
read thoroughly prior Page
to beginning 1
as required 89 - ...
Ball bearing grease Ft 1 v 34 (Messrs. Bosch)
A charging alternator is required for supplying power to the

electric loads on the engine, such as starter, indicator and
operating systems. Since the battery has a limited capacity, it
is recharged by the charging alternator which is driven by the
engine through a V-belt.
The rotor of the charging alternator has ball bearings at both

ends. These bearings must be lubricated at the intervals given
in the servicing schedule.
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.
Screw in Stauffer boxes until you strike an obstacle, then screw

in by two further rotations.
Caution!
91
GREAVES Job Sheet D3
06.86 3-3.001
TBD3
Tightening torques of main screw connections in Nm
to beginning 1 3 pages
* 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.
* 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
Set of tools
94
Job Sheet No.
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
In case of engine not installed and commissioned within a period

of 3 months, an anti -corrosion treatment is lo be carried out to
prevent corrosion.
Anti-corrosion treatment of the engine
1. Mark position of the flywheel or of the crankshaft flange.

There might be first beginnings on the cylinder liners in
the height of the piston rings, therefore the position of
the piston should be changed after each anti-corrosion
treatment.
2. Fill fuel mixture consisting of 9 parts Diesel fuel and 1
part anti-corrosion oil in fuel filter.
3. Wash and/or rinse out of sump and additional devices
with own oil filling with Diesel fuel. Screw -in oi l
discharging screw No. 1 and tighten it.
4. Fill anti-corrosion oil in the engine (inlet connection 2)
and/or spray it in the additional devices.
5. In case of engines equipped with a hand pump, pump
the 'filed in anti-corrosion oil through the engine by
means of a hand pump and race the crankshaft by hand
so that all bearings and liners are slightly wet.
In case of engines not equipped with a hand pump, the
anti -corrosion oil has to be passed through the oil system
by means of the mounted lubricating oil pump, in the
following manner.
Remove blind flange on intake - and exhaust pipe. If
the starter is mounted and a battery is available, turn
the crankshaft by the starter.
Attention: Ignition of the engine is allowed, but only
with minima! speed until the oil pressure is built up. If
the engine is not equipped with a starter, race the
crankshaft serveral times by truning. In case of super-
charged engines the turbine wheel must be raced several
times by hand.
6. Remove cylinder head cover 3, spray in valve springs
and rocker arms with anti-corrosion oil, install cylinder
head cover.
7 Remove injection nozzles 4 and bring the corresponding
piston to BDC. Spray anti-corrosion oil in the combustion
rooms through the opening on the cylinder head. Re
install injection nozzles.
8. In case of engi/ies equipped with a compressed air start,
remove starling star and starting line on the cylinder
head. Spray in starting star and openings of the starting
line in the cylinder head with anti-corrosion oil. Reinstall
removed parts .
9. Unscrew oil discharging screw 1 and drain anti -corrosion
oil. Tighten oil dischrging screws 1. The fuel mixture can
remain in the system.
10. Fill cooling water mixture consisting of 20 parts cooling
water and 1 part anti-corrosion agent in the engine and
circulate the cooling water mixture in the engine by a
separate pump. Then drain the cooling water mixture
and let the draining cocks 5 opened.
11. The intake and exhaust openings are to be closed so
that external weather influences are kept away from the
engine inside.
95
Job Sheet No.
GREAVES Job Sheet 3.3.003 A
5.85 TBD3
read thoroughly prior Page of page

Anti-corrosion treatment for engines not yet installed 1 2
to beginning
Protective grease e.g. Messrs, Fuchs KG;
Set of tools Antikorit-MV
Spray gun Anti-corrosion oil for lubricating oil system,
Tilt (waterproof) e.g. Messrs. Fina; Rusan 20 W 20 Anti-
corrosion oil for fuel system, e.g. Messrs.
Castrol : Rustillo DWX 32 Anti-corrosion
agent cooling water, e.g. Messrs. Khubier-
Chemie : Purrton 4110 Talcum powder.
Representing the outer parts of engine
1. Degrease all bright outer parts of engine and clean with

fuel,
2. Coat the bright items, e.g. linkage 6 with protecting

grease.
3. Dust all rubber items (hoses, anti-vibration mounting

pads) with talcum powder.
4. Check paintwork for damage and, if necessary repair
5. If possible locate engine in storage area, spray with

preserving oil (spray gun) and cover with tarpaulin.
6. Note date of preservation and fix message "do not turn

crankshaft" at a prominent point on the engine.
96
Job Sheet No.
GREAVES Job Sheet 3.3.003 B
5.85 TBD3
Treating the installed engines against corrosion for lengthy standstill periods to beginning 1 2 pages
Protective grease e.g. Messrs, Fuchs KG; Antikorit-MV
eg. Messrs. Fina; Rusan 20 W 20
Spray gun Anti- corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs. Castrol: Rustilk) DWX 32
Talcum powder
If the engine is kept out of operation for a fairly long period of

time, an appropriate treatment against corrosion should be done.
Treating the engine against corrosion
1. Drain engine oil (drain plugs 1), then screw in and

tighten drain plugs again.
2. Unscrew, drain and reattach oil-filter cartridge 2.

Tightening procedure for filter cartridge : screw in filter
cartridge until gasket touches slightly, then, tighten,
turning by approx. half a turn manually and using no
tool.
3. Fill engine with anticorrosion oil (filling neck 3).
4. Drain cooling water (drain cock 5) and fill engine with

mixture composed of 20 parts of cooling water and 1
part of anticorrosion agent. Vent at venting screws 6
and fill in with mixture through filling neck up to lower
mark.
5. Drain fuel out of tank, make a mixture composed of 9
parts of fuel and 1 part of anticorros ion oil and fill it into
tank.
6. Start engine, wait until oil pressure gauge indicates

pressure and then, increase speed to approx. 2/3 of
nominal speed. Allow engine to run for about 15 minutes
without load.
7. Stop engine
8. Remove air filter.
9. If the engine is equipped with Nova starting appliances,

close starting air receiver, remove starting-air line up
stream of main valve and fill approx. 0.25 dm 3 o f
anticorrosion oil into starting line. Connect starting line
again.
10. Crank engine using starting appliances while holding stop

lever 4 on stop position. Spray anticorrosion oil into open
air-intake pipes, using a spraying gun, during the starting
process.
11. Attach air filter.
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
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
Protective grease e.g. Messrs, Fucfis KG; Antikorit-MV

Spray gun e.g. Messrs. Fina; Rusan 20 W 20
Anti-corrosion oil for fuel system, e.g.
Tilt (waterproof) Messrs- Castrol : Rustillo DWX 32
Talcum powder.
Preserving the outer parts
1. Coat all bright items, e.g. control linkages (Fig. 4} with

protecting grease.
2. Dust all rubber items (hoses, anti-vibration mounting

pads) with talcum powder.
3. Check paintwork for damage and, if necessary, repair.
4. Locate engine in storage area, spray with preserving oil

(spray gun) and cover with tarpaulin.
5. Note date of preservation and fix message "do not turn

crankshaft" at a prominent point on the engine.
Caution! Repeat preservation after at least 3 months
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
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
For the protection of the engine, the cooling system is divided

into a raw water circuit and a fresh water circuit. The fresh
water absorbs the heat given off by the engine and passes it
on to the raw water in the heat exchanger. Efficient exchange
of heat is only ensured when the walls of the tube bundle in
the heat exchanger are free of dirt and scale.
Removing and cleaning the tube bundle
1. Close the raw water cocks.

2. Drain cooling water at drain cocks (Fig. 1, item 1 for
fresh water, item 2 for raw water). Collect the fresh water
for reuse.
3. Remove fuel filter (Fig. 2) with mounting bracket and
place on engine.
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
GREAVES Job Sheet D3
9.84 TBD3
3.3.007 A

Cleaning fresh water recooler (indirect cooling) to beginning 2 2 pages
Tool set 4 O-rings 6.0493.10.4.1405

2 O-rings 6.0493.10.4.1655 63 -
Brush 1 O-ring 6.0493.10.5.0803
Stud, min. 100 mm long, M 8 1 Sealing ring 6.0492.01.0.1418
1 Sealing ring 6.232.0.850.004.4
Wevolic 2 Sealing compound 6.0153.70.1.0205
Fuel
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)
12. Unscrew stud and fit adjusting screw.
13. Coat sealing surface (Fig. 7, arrow) of the header with

sealing compound, place tube bundle in shell (Fig. 7)
and screw in the mounting bolts loosely.
Note :
The sealing compound is necessary for heat insulating

purposes, since greatly differing temperatures arise in
the shell and header.
14. Coat the sealing surface of the second header with

sealing compound and fit header.
15. Fit flange connector, ensuring proper location of gasket.

If required, realign tube bundle by turning the header
(Fig. 7)
16. Tighten the headers.
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
Set of tools 1 set of gaskets 6.234.0.013.005.7 63 -

Brush (Nylon) Fuel
Round iron 150 mm long, 5 mm
Rubber arch
The cooling system of the engine is divided into a raw water

circuit and a fresh water circuit. The fresh water absorbs the
heat given off by the engine and passes it on to the raw water
in the heat exchanger. Efficient exchange of heat is only ensured
when the walls of the tube bundle in the heat exchanger are
free of dirt and scale.
Removing and cleaning the tube bundle
1. Close the raw water cocks.

2. Drain cooling water at drain cocks (Fig. 1 for fresh water,
Item 2 for raw water). Collect the fresh water for reuse.
3. Remove fuel filter (Fig. 2) with mounting bracket and
place on engine.
Caution!
Do not kink the hoses!
4. Remove raw -water connections (item 3)

5. Unscrew fastening screws (Item 4) from both head
pieces (Item 5) and take down head pieces.
6. Insert 2 rods irons (5mm dia.) on left-hand and right
hand side of the tube nest (bracket)
7. Extract tube nest from its seat by knocking gently (mallet)
and lift it off the housing at rod irons.
8. Clean tube nest in fuel, using a nylon brush (inside the
tubes), then rinse with pure water. Check soldering joints
of jacket (Item 6) and re solder, if necessary. Clean head
pieces and screws in fuel as well.
9. Check cooling-water lines for contamination and clean,
if necessary.
NOTE :
Replace all seals and O-rings. Coat O-rings with grease.

Pay attention to proper attachment when mounting tube
nest (Item 9)
10. Assemble in reverse sequence.
11. Filter fresh water through cloth and fill up again; vent at
venting screws (Item 7) and top up with fresh water up
to bottom mark (Item 8)
12. Open the raw water cocks. Fill the raw water pump.
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.

Manual d3 Engine 30 08 08

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GREAVES COTTON LTD

Please read prior to putting Generating set into service

This User's Manual is prepared for use by the Operating Personnel,

AUXILIARY POWER DIV.

Should any information be required our Service Department and Agents

Part 1; ENGINE DATA AND DESCRIPTION

Part 2 : OPERATION AND POL PRODUCTS

2.1 Preparation for First-Time Operation

3. 1.1 Other Additives

01.1 General Remarks

01,2 Assembly Breakdown

1 of these Operating Instructions are broken down in the following assemblies

1 these assemblies are shown in (he engine sectional drawings.

01.4 Warranty claims

01.5 Measuring Units

Symbol Value Unit Denomination Further units Remarks/conversions

a Plane angle rad Radian * Degree 1 rad = 1 m/m=360

m Mass Kg Kilogram g (Grams)

f Frequency Hz Hertz 1 Hz= 1/S

P Force of liquids bar Pa (Pascal) 1pa=1N/m2

E Energy J joule Ws (watt second) 1J = 1 Ws = 1Nm

W Work KW/h (kilowatt hour) 1kwh=3600 KJ

T Temperature K kelvin 'C (degrees Celsius) O c =273.15K

Prefix Abbrevation Value

Mega M 105 = 1000000

Equations for engine characteristic values:

1- Mean piston speed

4 Specific fuel consumption

(calculated witn a lower cal. valuo ol J2 7 hJ/g)

n t/ mm revolutions per minute

Vh dm3 Total swept volume

B g/h fuel consumption per hour

1/1Part 1 ENGINE DATA AND DESCRIPTION

1.0 Views of Engine

1.1 Engine Data

1.1.2 Cylinder Numbering

1.1.3 Construction Data

1.1.4 Adjusting Data

1.1.5 Performance Data

1.1.6 Filling Quantities

1.2 OVERALL DIMENSIONS AND WEIGHTS

1.3 DESCRIPTION OF ENGINE

1.3.0 Function of Engine

1.3.1 Cylinder Crankcase and Oil Pan

1.3.2 Cylinder Heads

1.3.3 Crank Assembly

1.3.4 Gear Drive and Camshaft

1.3.5 Fuel System

1.3.6 Lube. Oil System

1.3.7 Cooling System

1.3.8 Turbo charging System

1.3.9 Starting System

1.3.10 Control Pane!

1.3.11 Engine Monitoring

1 Engine Data and Description

1.0 Views of Engine

Fig. 1 Engine TBD 3,

1 Radiator fan 7 Injector