Инструкция по эксплуатации судового deutz sbv 8m 628

Chapters

S/BV 6/8/9 M 628

This Operation Manual is destined for the following engine:

Please enter the relevant data here. This you will facilitate dealing with questions concerning customer service, repairs and spare parts.

Give these data to the respective SERVICE dealership whenever you are asking for service performance.

DEUTZ AG

Service engineering

Service documentation

Deutz-Mülheimer Straße 147-149

D — 51057 Köln

http://www.deutz.de

Printed in Germany All rights reserved 3st edition, 10/2001

Order No.: 0297 7945 en

Medium-sized and large engines

●Please read all the information contained in this manual, and follow the instructions carefully. You will avoid accidents, retain the manufacturer’s warranty, and will be able to use a fully functional and operational engine.

●This engine has been built solely for the purpose appropriate to the scope of delivery concerned, as defined by the equipment manufacturer (intended use). Any other use shall be construed as not intended. The manufacturer shall not be liable for any damage resulting therefrom; all risks involved shall be borne solely by the user.

●The term „intended use“ shall also include compliance with the operating, maintenance and repair conditions specified by the manufacturer. The engine may be used, maintained and repaired only by persons who are familiar with the work concerned and who have been properly informed of the risks involved.

●Make sure that these operating instructions are available to everyone involved in operating, maintaining, and repairing the engine, and that they have all understood the contents.

●Non-compliance with these operating instructions may result in engine malfunctions and even damage or injury to persons; the manufacturer will accept no liability in such cases.

●Proper maintenance and repair work depends on the availability of all requisite equipment, tools and special implements, all of which must be in perfect condition.

●Engine parts like springs, brackets, elastic holding rings, etc., involve increased risk of injury if not handled properly.

●The relevant accident prevention regulations and other generally recognized rules relating to safety engineering and health and safety at work must all be complied with.

●Maximized cost-efficiency, reliability and long lifetime are assured only if original parts from DEUTZ AG are used.

●Engine repairs must correspond to the intended use. In the event of modification work, only parts approved by the manufacturer for the purpose concerned may be used. Unauthorized changes to the engine will preclude any liability of the manufacturer for resultant damage.

The warranty expires in case of nonobservance of these regulations!

Dear customer,

The engines of the DEUTZ brand have been developed for a broad spectrum of applications. A comprehensive range of different variants ensures that special requirements can be met for the individual case involved.

Your engine has been equipped to suit your own particular installation, and accordingly not all of the devices and components described in these operating instructions will actually be fitted to your engine.

We have endeavoured to present the differences involved as clearly as possible, to make it easier for you to find the operating and maintenance instructions you need for your own particular engine.

Please read this manual before you start up your engine, and follow the operating and maintenance instructions meticulously.

If you have any questions, just get in touch with us, and we will be pleased to answer them for you.

Yours sincerely,

DEUTZ AG

DEUTZ engines

are the culmination of long years filled with research and development work. The in-depth know-how thus acquired, in conjunction with high standards of quality, is your guarantee for engines manufactured for long lifetime, high reliability and low fuel consumption. And of course, stringent criteria of environment-friendliness are met as well.

Care and maintenance

are crucial factors in ensuring that your engine satisfactorily meets the requirements involved. Compliance with the specified maintenance intervals and meticulous performance of care and maintenance work are therefore absolutely essential. Special attention must be paid to any more critical operating conditions deviating from the norm.

DEUTZ AG

In the event of malfunctions, or if you need spare parts, please contact one of our responsible service agencies. Our trained and qualified staff will ensure fast, professional rectification of any damage, using original parts. Original parts from DEUTZ AG have always been manufactured to the very latest state-of-the-art.

You will find details of our after-sales service at the end of these operating instructions.

Careful when the engine is running!

Carry out maintenance or repair jobs only when the engine is at a standstill. If you remove any protective features, fit them back in position after completing your work. Always wear tight-fitting clothing if you are working on the engine while it is running.

Safety

!You will find this symbol next to all safety instructions. Follow these meticulously. Pass on all safety instructions to your operating staff as well. In addition, comply with the statutory general safety and accident prevention regulations applying in your country.

Instruction

You will find this symbol next to instructions of a general nature. Follow these instructions carefully.

Asbestos

The seals and gaskets used in this engine are asbestos-free. Please use the appropriate spare parts for maintenance and repair jobs.

Medium-sized and large engines

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Inhaltsverzeichnis Indice

Table des matières Indice Inhoudsopgave

й„О‡‚ОВМЛВ

Table of contents

1 Guide to this Manual

1.1General

1.2Trouble — shooting

1.3Planned Mainenance

1.4Identification of Spare Parts

1.5Specification Data

1.6Job Card No.

1.7Standard Tools

1.8Special Tools

1.9Index of DEUTZ Assembly Groups

2 Layout and Description of Engine

2.101 Cylinder Head

2.202 Crankshaft System

2.303 Engine Frame

2.404 Timing System

2.505 Speed Control System

2.606 Exhaust / Turbocharging System

2.707 Fuel System

2.808 Lubricating Oil System

2.909 Cooling Water System

2.1010 Pneumatic System

2.1111 Engine Protective System

2.1212 Engine Auxiliaries

2.1313 Engine Assemblies and Subassemblies

2.1414 Cutaway View of Engine

3 Specification Data

3.1Model Designation

3.2Designation of Engine Ends and Sides and Related Definitions

3.3Basic Data

3.3.1Design Data

3.3.2Operating Data

3.3.3Setting Data for Saftey Switches

3.4Weights of Main Engine Components

3.5Tightening Specification for Heavy — duty Screwed Joints

3.5.1Tightening Schedule

3.5.2/3. Tightening Instructions

3.5.4Hydraulic Tool for Annular Nuts

3.6List of Compounds ( Sealing, Locking, Lubricating, Heat Conduction )

3.7Use of Liquid Nitrogen

3.8Dye Checking of Metal Surfaces with Distillate Fuel

4 Operating the Engine

4.1Preparatory Work before Operating the Engine with Distillate Fuel

4.1.1Preparatory Work before Operating the Engine with Heavy Fuel or MDF Blend

4.2Running the Engine with Destillate Fuel

4.2.1Running the Engine with Heavy Fuel or MDF Blend

4.3Attendance in Service

4.4Stopping the Engine Running on Destillate Fuel

4.4.1Stopping the Engine Running on Heavy Fuel or MDF Blend

5.1Fuel System

5.2Lubrication Oil System

5.3Cooling Water System

5.4Pneumatic System

5.5Injection Pump Plunger Sealing System

5.6Injection Nozzle Cooling

5.7Symbols Used in Piping Diagrams 0

6Engine Operating Media

7Trouble — shooting

7.1Summary of Potential Troubles

7.2General

7.3Trouble Chart

8 Maintenance Schedules, List of Job Cards and Job Cards

8.1Summary of Maintenance Schedules

8.1.1Initial Maintenance jobs

8.1.1.1— Engines running in countinuos operation, e.g. marine engines, >300 hour / year

8.1.1.2— Engines running in standby operation, e.g. emrgency generating sets,

<300 hours / year

8.1.2Daily maintenance jobs

These jobs are described in Section 4.3, as well as in the Brief instructions under Section * ”Monitoring of Engine Operation”.

8.1.3Periodic maintenance jobs for engines running in continuous operation > 300 hours / year, e.g. marine engines.

This schedule forms part of Brief Instructions*

8.1.4Periodic maintenance jobs for engines running in continuous operation < 300 hour / year, wich are exclusively or most of the time in standby mode, e.g. emergency generating

sets.

This schedule forms part of Brief Instructions*.

8.2List of Job Cards

by maintenance groups

8.3Job Cards

by maintenance groups

01.00.00Cylinder Head

02.00.00Crankshaft System

03.00.00Engine Frame

04.00.00Timing System

05.00.00Speed Control System

06.00.00Exhaust and Turbocharging System

07.00.00Fuel System

08.00.00Lubricating Oil System

09.00.00Cooling Water System

10.00.00Pneumatic System

11.00.00Engine Protective system

12.00.00Engine Auxiliaries

9 Appendix

Brief Instructions

* The Brief Instructions are attached to this Operating Manual

1 Guide to this Manual

1.1General

Surely you expect high degrees of reliability and availibility of your DEUTZ engine as prerequisites for its economical application. Great importance was attached to these properties in the course of the engine’s development. However, these properties can be upheld during the engine’s entire lifespan only, if the maintenance and servicing jobs described in this Manual are carried out punctually and fully.

It is therefore essential that you become well acquainted with the contents of this Manual not only before commissioning the new engine, but also to use it as a source of information for maintaining the high value of the machine.

All safety precautions and regulations have been observed in the design, choice of materials, and manufacture of your engine. This high degree of safety and reliability will be maintained, if the servicing jobs are fully performed according to schedule by properly trained personnel, and if all guards and protective devices removed for carrying out work on the engine are afterwards refitted.

When servicing, it is essential to observe the relevant regulations regarding accident prevention and general safety.

The Maintenance Schedules give information concerning the work involved at the prescribed intervals.

The Job Cards (Section give detailed instructions for carrying out the work. The Job Cards are arranged in accordance with Maintenance Groups as per the PLanned Maintenance System 333*. On Page 1-0-05 is an alphabetical Index of DEUTZ Assembly Groups together with the relevant Job Card Nos. and Maintenance Groups.

*Institut für Schiffsbetriebsforschung, Flensburg

1.2Trouble-shooting

Should troubles and faults of any kind arise on the engine, please refer to Section 7, «Troubleshooting».

The Trouble Chart lists various potential causes for a certain fault, gives brief instructions for providing possible remedies, and refers to the Manual Section concerned and the Job Cards containing further details for carrying out the work involved.

1.3Planned Maintenance

Keep a regular record of the engine’s running hours and observe the schedule for maintenance and servicing accordingly

The Maintenance Schedule contains details of the maintenance work involved and the relevant Job Card Nos.

Carry out the work detailed on the Job Card.

1.4Ordering of Spare Parts

The Spare Parts Catalogue associated with this Instruction Manual contains the Part Nos. for the ordering of parts, and also design details , where necessary.

The Spare Parts Catalogue is arranged in accordance with DEUTZ Assembly Group Nos. These DEUTZ Assembly Group Nos. are also to be found in the Filing No. (not Job Card No.!) in the heading of the Job Cards. The number appearing between the hyphens, for example in the case of 0178-08- 501 1110, the -08-, is the DEUTZ Assembly Group No.

For detailed information on spare parts identification, please refer to the introductory lines of the Spare Parts Catalogue.

1.5Specification Data

Design data, operating data, and setting data for monitoring equipment are not given in the Job Cards. Please refer to Section 3, «Specification Data».

1.6Job Card No.

In addition to the Filing No., each card is provided with a Job Card No.

Typical Job Card No.: 01.02.03, where:

01 = Maintenance Group = cylinder head

03 = Serial No. of card

1.7Standard Tools

Standard tools are those tools which are normally included in a workshop tool box.

1.8Special Tools

Special fitting tools and devices, normally supplied along with the engine, are listed in the associated Spare Parts Catalogue under the Assembly Group No. 49.

1.8.1These tools are available from your local Deutz distributor.

1.9Index of DEUTZ Assembly Groups as Incorporated in System 333 — Job Cards, Maintenance Groups

Aufbau und Funktion des Motors Struttura e funzioni del motore Constitution et fonctionnement du moteur

Construcción y funciones de partes del motor Samenstelling en werkwijze van de motor

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Layout and Description

of Engine

2 Layout and Description of Engine

2.101 Cylinder Head

The Head iß held down on the crankcase through 4 hydraulically tightened studs.

Fitted in the head are 2 inlet valves, 2 exhaust valves, one fuel injector, a starting valve, an indicator valve and, if required, a relief valve.

The exhaust valves are equipped with rotators, the inlet valves with a seat lubrication to reduce wear. In fact, oil is injected in a metered amount into the charge air, so this seat lubrication requires no servicing. Injector and inlet/exhaust valves plus drive are protected by a rocker chamber cover. Coolant transfer from crankcase to head is made through plugged pipes within the head contour.

2.202 Crankshaft System

The drop-forged crankshaft is fitted in the crankcase in underslung arrangement. Main journals and crankpins are hardened and carried in complex-metal bearing shells. As required by the rated engine spee, the shaft is fitted with balance weights to reduce mass forces.

The bearing caps are secured to the crankshaft by 2 vertical and 2 horizontal bolts, the former ones being tightened jointly by a hydraulic tool.

The flywheel is flanged to the shaft‘s driving end, the flange being fitted on the shaft by hydraulic shrinkage. Power for secundary drives can be taken off from the shaft‘s free end.

The drop-forged connecting rod big end is split in straight (horizontal) arrangement, while the small end is of the stepped type.

The two-piece pistons are fitted with 3 compression rings and one oil control ring. The former rings are located in the steel top, the oil ring in the piston skirt above the full-float piston pin.

2.303 Engine Frame

The crankcase is a single-piece casting. Large doors permit easy access to all motion parts. Some doors may optionally be provided with relief valves safeguarding the engine in the case of crankcase of explosions.

The standard deep ”wet-type” oil sump represents the engine‘s lube oil reservoir, from which oil is forced into the lubricating circuit by a special delivery pump. Where high or low-level tanks are utilized for oil reservoir, use is made of a flat ”dry-type” sump with connections for an oil drain (to the low-level tank) or a special suction pump (to the high-level tank) respectively.

The cylinder liner is located in the crankcase at top and bottom. The liner flange is seated on a highly waer-resistant ring pressed into the crankcase. The water jackets are sealed by one ”watercooled” Viton 0-seals at the bottom. The head/liner gasket is a steel ring.

2.4 04 Timing System

ILocated at the engine‘s driving end and driven from a big gear on the crankshaft, the timing gear train drives, through idler gears, the camshaft, injection pumps and governor.

As determined by the engine‘s firing order, the camshaft, carried in bearing bushes, actuates the inlet and exhaust valves as well as the starting pilot air distributor, The shaft is split in two halves and can be pulled out of the engine lengthwise. Cams and bearing points are surface-hardened.

The pump chest at the engine‘s free end can mount, besides the standard lube oil delivery pump, one oil suction pump and 2 cooling water pumps. The pumps are gear-driven, i.e. the oil pumps direct and the coolant pumps through flexible couplings.

2.5 05 Speed Control System

The Engine is controlled by hydraulic governor which, through the injection pump‘s control rod, automatically meters the amount of fuel to be injected as a function of engine load.

Overall engine control is by an engine-mounted panel or seperately installed local or remote control units.

Emergency engine shutdown is possible by an automatic system or manually on the speed governor direct.

2.6 06 Exhaust / Turbocharging System

The non-insulated exhaust manifold running along the engine is lagged by an easily removable and multisplit casing. Only the water-cooled exhaust elbows from cylinder head to manifold are located outside this casing. Being connected through sliding pieces with 0-seals, the water jackets of the exhaust elbows form the cooling water manifold for the engine.

The engines are fitted with BBC turbochargers connected to the engine‘s cooling system. The compressors of these turbochargers are cleaned by a scavenging device. The charge air is cooled by water in special units.

The charge air pipe is divided into single sections for each cylinder. These sections are likewise connected through sliding pieces with 0-seals.

This new concept of exhaust manifold with cooled elbows and integral water manifold, the division of the charge air pipe, the plug-type water transfer pipes between cylinder head and crankcase and, last not least, the use of hydraulic tools for tightening the cylinder head studs/nuts significantly improve the ease in dismantling and refitting components at the engine top.

2.707 Fuel System (see also 5.1)

The following integral in-line injection pumps are provided:

The type of pumps chosen and the connection of the injection piping to the cylinder head sideways gave the advantage of very short injection piping.

Pump lubrication is connected to the regular motor oil circuit. In the case of engines running on intermediate fuels a sealing-oil system prevents the lube oil from being diluted by fuel.

The multi-orifice injection nozzle is located in the middle of the cylinder head and connected to the latter by a lateral injection line.

The fuel feed pump is mounted on one injection pump. Fuel cleaning is through a change-over type duplex filter.

In the case of engines running on heavy fuel, the feed pump is installed seperately. The changeover duplex filter can be preheated by having the transferred, preheated fuel flow through the filter. If available, the injection nozzles are cooled with engine lube oil or gas oil or — in exceptional cases

— even with engine coolant.

2.808 Lubricating Oil System (see also 5.2)

From the oil sump, or the lowor high-level oil tank, as provided, the engine mounted delivery-type oil pump forces the oil through the oil-cooler, usually also engine-mounted, and the combined oil filter (paper filter followed by edge filter) into the oil gallery integrally cast inside the crankcase.

From this gallery the oil flows on through passages in the crankcase wall to crankshaft journals and crankpins and to the nozzles provided for cooling the pistons. Passages in the crankcase front, wich are connected to the oil gallery, supply the timing gear train.

Additional bypass oil filtration is by two centrifuges attached to the crankcase doors.

Connections are also available for standby oil pumps and the electric priming pump.

2.909 Cooling Water System (see also 5.3)

As requiered by the particular engine application, the following standard systems can be provided:

Optionally available are various versions of the above two systems

2.12 12 Engine Auxiliaries

Provided for this engine family is an external vibration damper either of the viscous or rubber type. The 6-cylinder model is also available without this damper.

Section: 2

Layout and description of engine

Page: 2-1-01

Engine: S/BV 6/8/9 M 628

2.13Engine Assemblies and Subassemblies (as for the relevant location, please refer

to Section 2.14)

09Lube oil filter

10Lube oil filter combination

11Fuel injection pump

12Vibration damper

13Cylinder liner

14Oil dipstick

15Connecting rod

16Crankshaft

17Speed governor drive

18Oil pan

19Flywheel

20Timing gear train

21Piston

22Starting pilot air distributor

23Camshaft

24Air intake silencer

25Exhaust valve

26Pushrods

27Exhaust turbocharger

28Injector

29Cylinder head

30Valve drive

Technische Angaben Indicazioni tecniche Données techniques Datos técnicos Technische gegevens

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Specification Data

3 Specification Data

3.1Model Designation: S/BV 6/8/9 M 628

3.2Designations of engine sides, cylinders and rotation direction

Viewed towards the drive-side coupling flange of the engine.

Specification Data

3.3.1Design Data

Section: 3.3

Engine: S/BV 6/8/9M 628

06 Exhaust / Turbocharging System

Charge air cooler see acceptance test sheet

Exhaust System

On the 8- and 9-cylinder models, the cylinder next to the turbocharger goes to the multi-pulse unit direct, so the exhaust temperatures of this cylinder are somewhat lower (see acceptance test sheet).

Specification Data

Oil Sump Inclinations and Capacities

*1) Where sump inclinations α ± are below 10°, the oil level can be kept at a corresponding level between the top and medium dipstick mark to ensure maximum oil supply to the engine and hence increase oil change intervals . (1° less inclination allows for approx. 10 mm higher level above medium mark.)

*2) Sump lubrication for heavy fuel requires min. 0,82 lit/kW

*3) Due to inclined dipstick, correct maximum distance can be obtained only with β = 0°.

Specification Data

Oil Delivery Rate for Valve Seat Lubrication

Specification Data

3.3.3Setting data for monitoring equipment

Further setting data may be obtained from the gauge point list which is included in the engine documentation.

Specification Data

3.3.4Arrangement of Electrical Equipment

Section: 3.3

Engine: S/BV 6/8/9 M 628

Specification Data

3.3.4.1Exhaust Turbocharger at Driving End

25 437 2 ©

Section: 3.3

Engine: S/BV 6/8/9 M 628

25 438 2 ©

Specification Data

3.3.4.2Exhaust Turbocharger at Free End

25 439 2 ©

Section: 3.3

Engine: S/BV 6/8/9 M 628

25 440 2 ©

Specification Data

3.4Weight of Engine Components

(approx. kg per unit)