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RE-ASSEMBLING PROCEDURES

- 20 -

3. 

Dismantling and Assembly Procedures on the Basic Engine

3.1  Basic Requirements

−

  The aim of this Repair Manual is to pro-

vide help with carrying out repairs to the
engine.

 

The requirements for this are as follows:

−

  Trained specialist staff (of at least the

minimum legal age);

−

  and a workshop where the necessary

equipment, standard tools and special
tools are available

−

  A well-lit, unrestricted working area, free

from dirt and swarf, will make the work
considerably easier.

−

  Clean the engine thoroughly before dis-

mantling it.

−

  Attention must be paid to all the informa-

tion and warning notices which have been
affixed.

−

  Particular care is called for in the vicinity of

rotating, moving or hot parts.

ATTENTION

This symbol is used whenever failure to
comply precisely with instructions or proce-
dures may cause accidents which can result
in injuries or death.

CAUTION

This symbol is used whenever failure to
comply precisely with instructions or proce-
dures may cause damage to the engine.

Advice and tips about special features when
handling the engine.

Содержание 15W Series

Страница 1: ...1 DIESEL ENGINES 15 18 32W...

Страница 2: ...NTLING AND ASSEMBLY PROCEDURES ON THE BASIC ENGINE 20 3 1 BASIC REQUIREMENTS 20 3 2 DISMANTLING PROCEDURES 21 4 MEASUREMENT TABLE WEARING PARTS 32 4 1 CRANKCASE 32 4 2 CRANKSHAFT 33 4 3 CAMSHAFT 34 4...

Страница 3: ...OF CONTENTS 3 8 2 ENGINE STARTS BUT FIRES INTERMITTENTLY OR DIES 76 8 3 POOR ENGINE PERFORMANCE AND OR BLACK SMOKE 76 8 4 POOR ENGINE PERFORMANCE AND OR BLACK SMOKE 77 8 5 IMPERFECT OPERATING BEHAVIO...

Страница 4: ...dition and when those involved are aware of the dangers and the safety precautions In particular malfunctions which could impair safety must be rectified immediately The engine must only be used as in...

Страница 5: ...iesel engines It is assumed that all work on the engine will be carried out by competent staff who have received training Special tools must be available as described in the manual together with good...

Страница 6: ...he order number SN and the date of construction This information must always be provided when making any enquiries or complaints etc As of July 1985 the consecutive engine number is also imprinted on...

Страница 7: ...n the danger area When you have finished working on the engine always check that the safety devices have been refitted and that all tools have been removed from the engine Never carry out any work on...

Страница 8: ...pair work has been finished Before starting any work on the electrical components the power supply to all live parts must be cut off Only carry out maintenance and repair work when the engine parts ar...

Страница 9: ...DIN 6271 3 90 kW 4 70 kW 8 00 kW Max torque 14 4 Nm 16 7 Nm 30 2 Nm DIN 70020 at 2400 RPM at 2400 RPM at 2400 RPM Max speed 3600 RPM Mean piston speed at 3000 RPM 5 5 m s 5 5 m s 7 4 m s Compression r...

Страница 10: ...cooling air temperature max C 50 Permissible fuel temperature max C 80 Permissible lub oil temperature max C 130 Consumptions at IFN Output Specific fuel con sumption 3000 RPM g kWh 305 300 255 Fuel...

Страница 11: ...of delivery plunger with control edge below engines for generator and pump drive Engine RPMs min 1 1500 1800 3000 3600 1500 1800 3000 3600 1500 1800 3000 3600 Start of delivery BTDC mm 39 41 39 41 42...

Страница 12: ...ermittent duty at variable speed and load IFN ISO DIN ISO 3046 Blocked useful performance for intermittent loads ICFN ISO DIN ISO 3046 Standard performance blocked continuous useful performance for co...

Страница 13: ...L DATA 13 2 2 Output Torque Consumption 32W Leistung Output Puissance Potencia The values shown are related to the optimal load setting at the correspond ing nominal engine speed Drehmoment Torque Cou...

Страница 14: ...TECHNICAL DATA 14 Verbrauch Consumption Consommation Consumo...

Страница 15: ...dth Nm mm 30 33 13 30 33 13 52 56 17 Nozzle holder torque wrench width Nm mm 20 23 13 20 23 13 20 23 13 Injection pump torque wrench width Nm mm 8 12 10 8 12 10 20 23 13 Delivery valve torque wrench w...

Страница 16: ...cial screw driver to adjust governor spring nuts 748 132 6 Crankshaft race puller use with part no 748 136 2 to pull off main bearing race from crankshaft 748 137 2 Crankshaft gear wheel puller use wi...

Страница 17: ...ut the crank shaft roller bearing 748 173 2 Oil filter wrench to remove the full flow oil filter 748 172 4 Bearing driver to press the little end bearing bush in and out connecting rod 748 129 4 Beari...

Страница 18: ...TECHNICAL DATA 18 2 4 Tools 748 126 2 Oil pressure gauge to measure the oil pressure 748 131 5 Valve spring lifter to remove and fit the valve springs...

Страница 19: ...fuel system is driven directly while the valves are driven by push rods and rockers An electric starter and a manual starting device are provided to start the engine The engines are equipped with an...

Страница 20: ...e from dirt and swarf will make the work considerably easier Clean the engine thoroughly before dis mantling it Attention must be paid to all the informa tion and warning notices which have been affix...

Страница 21: ...ow instructions of the operating man ual Marine propulsion engines There are different versions of aircleaner and noise damper in use In each case remove the 2 selflocking nuts and pull of the assy Di...

Страница 22: ...injector If existing remove fuel filter bracket setscrews and spring washers Close ports of injection pump and injector with banjo bolts to prevent dirt Caution Use only original fuel filter and fuel...

Страница 23: ...the same way Caution Check taper ends of the high pressure line for damage or wear Replace if necessary 6 Fuel injector Remove hex nuts and lock washer from injector clamp Pull out injector Caution S...

Страница 24: ...drift pin and a hammer Remove rocker arms and push rods Check rocker arm bushings for wear Replace bushings if necessary Check push rods for bending and wear at the taper ends Replace if necessary Re...

Страница 25: ...With missing guide pin shaft will move out when engine is in operation 9 Cylinder Rotate the flywheel until the piston the bottom of ist stroke Carefully slide the cylinder up of the studs Check o sea...

Страница 26: ...work bench 11 Conrod Turn the flywheel untol piston is in BTC posi tion Put the engine down on flywheel side Re move the crankcase bottom plate by unscrewing the 6 head screws Discard gasket Caution...

Страница 27: ...ion 13 Gear end cover Remove the 6 allen screws and pull off the gear end cover If necessary tap with a soft faced hammer Caution While removing the gear end cover the gear of the camshaft could stick...

Страница 28: ...lock washers on their studs To remove the injection pump camfollower un screw fixing screw arrow through oil filling bore 15 Camshaft Remove the circlip lock ring fixing the camshaft in the gear end...

Страница 29: ...use a pliers and watch out for your fin gers Hold the inner control lever and twist ac celeration lever down to stop position till the inner torsion spring is without tension Then pull eccenter shaft...

Страница 30: ...the 3 mounting screws Discard gasket Leave the flywheel nut on the shaft Install fly wheel puller and turn the screws until the fly wheel breaks loose from the crankshaft tapper Remove the puller fly...

Страница 31: ...r on the main bearing bushing Use a puller to pull of the crankshaft gear In case the roller bearing needs replacement replace also the inner race which is shrunk fit on to the crankshaft Use race pul...

Страница 32: ...MEASUREMENT TABLE WEAR 32 4 MEASUREMENT TABLE WEARING PARTS 4 1 CRANKCASE...

Страница 33: ...MEASUREMENT TABLE WEAR 33 4 2 CRANKSHAFT...

Страница 34: ...MEASUREMENT TABLE WEAR 34 4 3 CAMSHAFT...

Страница 35: ...MEASUREMENT TABLE WEAR 35 4 4 GEAR COVER...

Страница 36: ...MEASUREMENT TABLE WEAR 36 4 5 SHAFTS BEARINGS...

Страница 37: ...MEASUREMENT TABLE WEAR 37 4 6 CONNECTING ROD...

Страница 38: ...NER Dimensions 15W 18W 32W A 92 0 05 92 0 05 109 2 0 1 B 75 050 75 030 82 050 82 030 95 040 95 020 C 78 8 0 1 85 0 0 2 100 5 0 2 D 95 0 036 0 071 95 0 036 0 071 117 0 1 0 15 E 86 75 0 025 86 75 0 025...

Страница 39: ...MEASUREMENT TABLE WEAR 39 4 8 PISTON 15 18W...

Страница 40: ...MEASUREMENT TABLE WEAR 40 4 9 PISTON 32W...

Страница 41: ...MEASUREMENT TABLE WEAR 41 4 10 CYLINDER HEAD 15 18W Cylinder head 15W Cylinder head 18W...

Страница 42: ...MEASUREMENT TABLE WEAR 42 4 11 CYLINDER HEAD 32W Cylinder head 32W Rocker arm 15 18 32W...

Страница 43: ...and that the oil holes in the bushing and in the crankcase bore are properly linedup 2 Crankshaft To install the crankshaft gear and the inner race of the roller bearing heat up the parts to a temp O...

Страница 44: ...onto studs Caution Bearing housing can only be fitted in one posi tion Tap lightly with a soft faced hammer to seat the cover Torque down the fastening nuts crosswise Assemble the thrust washer 1 and...

Страница 45: ...governor and crankshaft threads are free of oil and grease Apply a couple of trops of Loctite 270 or similar on the governor thread Torque the governor down according the torque table Attention Gover...

Страница 46: ...numbers must be aligned on the same side of the rod but it is not important which engine side the numbers face Thighten the con rod nuts to the specified torque and reinstall crankcase cover 8 Camsha...

Страница 47: ...ed pin and spring into the hole in the gear end housing Put the return spring 1 into small hole of the control lever Move the torsion spring 2 over the eccentric shaft and hook spring leg in the space...

Страница 48: ...lever from the stop position back into idle position Speed control Vehicle Bowden cable The outer torsion spring pulls the acceleration lever into stop position Speed control Generator The outer torsi...

Страница 49: ...cylinder Slide the piston and cylinder over the studs For 18W 32W only The arrow sign or crankshaft sign stamped on the piston top must point towards the fly wheel Align the piston and conecting rod...

Страница 50: ...hard movement replace NOTE 32W engine There s no difference between inlet and exhaust valve spring Fit cylinder head gasket and slide cylinder head down onto the cylinder Fit spring washers and cylin...

Страница 51: ...cover onto the crankcase being careful not to move the camshaft gear Remember to place the gasket After the cover is installed check the timing marks on the flywheel side If both marks are within 2mm...

Страница 52: ...of the crankhandle support Lubricate the camshaft and the sealing lips of the oil sealing ring Don t push the guide straight onto the gear end cover Instead use a light twisting motion until the guide...

Страница 53: ...in the joint set Carry out the two measurements again If the tolerance is more than 1 0 mm replace the 0 4 mm gasket with a 0 3 mm gasket Carry out the two measurements 14 Push rods and protection tub...

Страница 54: ...ical position again Check and reset the valves 17 Oil filter 32W engine only Fill up oilfilter with new oil Oil the rubber gasket and screw on oilfilter Attention Hand tighten oilfilter only Don t use...

Страница 55: ...First install the paper gasket in any case Attention To check correct assembly of the fuel injection pump turn the acceleration lever to stop position Excess fuel button must push back to normal oper...

Страница 56: ...min idle speed for cooling down During test run check for proper function un usual noise and leakages 2 Lubrication system basic info 32W engines A gear pump sucks the oil from the sump and conveys th...

Страница 57: ...supplied quantity will flow back via return line Returning fuel carries heat away from the system Returning fuel also ensures a constant bleed in the fuel system From the injection pump fuel is fed th...

Страница 58: ...aution Keep hands away from nozzle spray The spray can penetrate deep into the flesh of your hand and destroy the tissues Diesel fuel can cause blood poisoning If injection pressure is too high or low...

Страница 59: ...nd returns to ist normal operating position Therefore it is necessary to start the engine without load in order to reach max rpm Other wise the starting fuel button will not diengage and continously o...

Страница 60: ...lever at max speed Attention Excess starting fuel button must not be pulled Open fuel supply line Slowly crank the engine rotationwise and observe the drip tube First the fuel flows free drips stops...

Страница 61: ...nd 59 1 mm 2 327 If it is not possible to set the correct injection timing via adjustment shims then most probably the alignment of the camshaft gear is not cor rect Or TDC marks is wrong Attention Th...

Страница 62: ...ed operation and idle speed relief Such as compressors freezer units 3 All speed governor variable speed Governs the complete range of speed from idle up to full speed For applications such as industr...

Страница 63: ...ine until the slot between the governor flyweights is in vertical position Move the acceleration lever to full speed posi tion Bend up the lock plate and unscrew the castle nut by holding the tapped b...

Страница 64: ...l lines if necessary Turn flywheel that the slotted nut is in front of the inj pump bore Insert the governor tool and correct speed as required of a turn speed variation of 20 rpm Max possible speed v...

Страница 65: ...ver is important The lower edge of the lever should leave one and a half notches visible If more notches are visible the shut of the engine may be hammered or in badest case it s not possible to stop...

Страница 66: ...Terminal 15 ignition lock Connection to earth is made via the assembly surface 7 2 Function Tests a Alternating voltage at the coil output Disconnect the connecting plug 4 The voltage proportional to...

Страница 67: ...um Governor is destroyed in a short time Battery is disconnected while the engine is running load shedding Governor is destroyed in a short time Charging with start aid cable when bat tery is defectiv...

Страница 68: ...Flywheel dynamo regulator GRAPHs Idling Voltage without Governor Graph A 10 15 20 25 30 35 U V 500 1000 1500 2000 2500 3000 3500 n 1 min Charging Current Graph B 0 4 8 12 16 20 I A 500 1000 1500 2000...

Страница 69: ...ELECTRICAL SYSTEM 69 7 5 WIRING DIAGRAMS 7 5 1 Diagram 1...

Страница 70: ...ELECTRICAL SYSTEM 70...

Страница 71: ...ELECTRICAL SYSTEM 71 7 5 2 DIAGRAM 2...

Страница 72: ...ELECTRICAL SYSTEM 72 7 5 3 DIAGRAM 3...

Страница 73: ...ELECTRICAL SYSTEM 73 7 5 4 DIAGRAM 4...

Страница 74: ...ELECTRICAL SYSTEM 74 7 5 5 DIAGRAM 5...

Страница 75: ...ctor pump Gasoline instead of diesel in tank Air intake blocked Fill with fuel no venting needed Set lever to full load Renew cap Check lines Renew filter Renew pipe tighten connections Cool the fuel...

Страница 76: ...intake Restricted blocked exhaust Check clean exchange intake system Check clean exchange exhaust system 8 3 Poor engine performance and or black smoke Operating conditions Engine overloaded Power red...

Страница 77: ...engine installation Drain to proper level Check repair renew nozzle Knocking Noises Oil carbon deposits on piston Injector needle sticking Advanced ignition Broken piston rings Worn piston and cylinde...

Страница 78: ...d of delivery Renew nozzle Oil pressure warning light on Oil pressure warning lamp is de fective Oil level is too low Defective oil pressure switch Exchange warning lamp Measure oil level if necessary...

Страница 79: ...NOTES 79...

Страница 80: ...NOTES 80...

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