Location via proxy:   [ UP ]  
[Report a bug]   [Manage cookies]                
Download as pdf or txt
Download as pdf or txt
You are on page 1of 254

Operating Instruction

TBD645

DZ02996391 en

Engine Serial Number:

Please enter the engine serial number here. In this way,


questions concerning service, repairs and spare parts
can be more easily dealt with.

In view of continuous design improvements or changes,


the technical specifications and the illustrations shown in
this manual are subject to alteration. Reprinting and
reproduction, in part or in whole, are subject to our
written approval.

Services, Wärtsilä Netherlands B.V.


Wärtsilä Deutz
TBD645

This documentation is destined for the following engine:

Engine model

Type of application

Name of installation

Power kW

Speed rpm

Date of commissioning

Please enter the relevant data here. This will facilitate you in 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.

Page II 0299 3235-0199 1012


Wärtsilä Deutz
TBD645

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
there from; 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
Wärtsilä Deutz 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.

1012 0299 3235-0199 Page III


Wärtsilä Deutz
TBD645

Dear customer,

The engines of the DEUTZ MWM 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,

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com

Page IV 0299 3235-0199 1012


Wärtsilä Deutz
TBD645

DEUTZ MWM 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.

Wärtsilä Deutz
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 Wärtsilä Deutz 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.

1012 0299 3235-0199 Page V


Quick Introduction DEUTZ MWM
Engines and Systems

QUICK INTRODUCTION (FOR TRAINED AND QUALIFIED PERSONNEL)

OPERATING INSTRUCTIONS
GETTING ➠ Chap. 1 Advice to users
STARTED

Chap. 2 Description

Chap. 3 Operation

Chap. 4 Expendables

Chap. 10 Test reports

NORMAL OPERATING INSTRUCTIONS


OPERATION ➠ Chap. 3 Operation

Chap. 4 Expendables

MAINTENANCE OPERATING INSTRUCTIONS


➠ Chap. 1 Advice to users

Chap. 4 Expendables

Chap. 5 Maintenance and
Servicing

Chap. 8 Technical data

Chap. 9 Maintenance work

SPARE PARTS CATALOGUE
Spare parts

DEUTZ Service

Page VI 0299 3232-0199 0997


DEUTZ MWM Quick Introduction
Engines and Systems

OPERATING INSTRUCTIONS
SERVICING ➠ Chap. 1 Advice to users

Chap. 5 Maintenance and
Servicing

Chap. 8 Technical data

WORKSHOP MANUAL
Servicing work

SPARE PARTS CATALOGUE
Spare parts

DEUTZ Service

MALFUNCTIONS IN OPERATING INSTRUCTIONS


OPERATION
➠ Chap. 6 Operational disturbances
causes, corrective action

Chap. 8 Technical data

Chap. 10 Test reports

⇓ ⇓
WORKSHOP MANUAL
Chap. 9 Maintenance work Servicing work
⇓ ⇓
SPARE PARTS CATALOGUE SPARE PARTS CATALOGUE
Spare parts Spare parts
⇓ ⇓
DEUTZ Service DEUTZ Service

0997 0299 3232-0199 Page VII


DEUTZ MWM
Engines and Systems

This page intentionally left blank.

Page VIII 0299 3232-0199 0997


DEUTZ MWM Contents
TBD 645

0 Introduction
Imprint, foreword, quick introduction, contents

1 Advice to users
1.1 General remarks

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

2 Description
2.1 Model
2.1.1 Explanation of types
2.1.2 Engine side designations, cylinder numbering and sense of rotation
2.2 Nomenclature for engine cylinders and components

2.3 Engine illustrations


2.3.1 Left-hand side
2.3.2 Right-hand side
2.3.3 Main dimensions
2.4 Construction and function
2.4.1 Crankcase and oil pan
2.4.2 Cylinder head
2.4.3 Drive mechanism
2.4.4 Gear train and control system
2.4.5 Fuel system
2.4.6 Governor
2.4.7 Lube oil system
2.4.8 Cooling system
2.4.9 Supercharging
2.4.10 Starting system
2.4.11 Operator control, monitoring and safety features

1197 0299 4624-0108 Page IX


Contents DEUTZ MWM
TBD 645

3 Operating
3.1 Work routines before initial start-up and after every inspection
3.1.1 General remarks
3.1.2 Monitoring
3.1.3 Coolant
3.1.4 Fuel
3.1.5 Lube oil
3.2 Work routines before start-up
3.2.1 Monitoring
3.2.2 Starting air
3.2.3 Room ventilation
3.2.4 Checking the drive mechanism
3.3 Start-up
3.3.1 Starting the engine
3.4 Operational monitoring

3.5 Shutting down the engine

3.6 Emergency operation if the turbocharger fails

3.7 Emergency operation if the operator control system fails


3.7.1 Starting procedure in emergency operation
3.8 Emergency operation if the governor fails

3.9 Emergency operation if the temperature controllers fail

3.10 Emergency operation if an injection pump fails

3.11 Heavy fuel oil operation

4 Expendables
4.1 General remarks
4.1.1 Warranty
4.1.2 Product selection
4.1.3 Mixability
4.2 Fuel

4.3 Engine lube oil

4.4 Engine coolant

Page X 0299 4624-0108 1197


DEUTZ MWM Contents
TBD 645

5 Maintenance
5.1 Maintenance plan
5.1.1 General remarks
5.1.2 Legend
5.1.3 One-off jobs
5.1.4 Maintenance plan (application-specific)
5.1.4.1 Maintenance plan in continuous operation
5.1.4.2 Maintenance plan supplement for operation with mixed fuel
5.1.4.3 Maintenance plan supplement for operation with distillate fuel
5.1.4.4 Maintenance and servicing as per instructions from component manufacturers
5.1.5 Action as necessary
5.2 Tools
5.2.1 Standard tools
5.2.1.1 Toolbox contents
5.2.1.2 Contents of toolbox
5.2.1.3 Contents of the tool chest
5.2.2 Special tools and devices
5.2.3 Other equipment
5.2.3.1 Cleaning agents
5.2.3.2 Water treatment agents

6 Operational malfunctions
6.1 Malfunction Table

7 Conservation
7.1 General remarks

7.2 Cleaning

7.3 Interior conservation


7.3.1 Lube oil system
7.3.2 Coolant system
7.3.3 Fuel system
7.3.4 Conservation run
7.3.5 Subsequent routines
7.4 Exterior conservation

7.5 Deconservation

7.6 Corrosion protection

8 Technical particulars
8.1 Engine data

8.2 Adjsutment data

8.3 Operating data

8.4 Weights

8.5 Tightening instructions

8.6 Torsional backlash

1012 0299 4624-0108 Page XI


Contents DEUTZ MWM
TBD 645

9 Job Cards
9.1 Overviews
9.1.1 Arranged alphabetically
9.1.2 Arranged by Job Card Numbers
9.1.3 Description of symbols
9.2 Job Cards arranged by Job Card Numbers

10 Sundry other instructions

Service

Page XII 0299 4624-0108 1197


DEUTZ MWM Advice to users
Engines and Systems

1 Advice to users 1
1.1 General remarks

1.2 Safety instructions / Accident prevention

1.3 Operating instructions and Workshop manual

1.4 Job cards

1.5 Spare parts

0997 0299 3245-0199 Chapter 1 - Page 1


Advice to users DEUTZ MWM
Engines and Systems

1 1 Advice to users

1.1 General remarks


The maintenance and servicing jobs specified in this manual must be carried out punctually and completely.
The maintenance and servicing staff must possess the necessary technical knowledge required for doing their
jobs properly. Any safety and protective features which had to be removed during maintenance and servicing
work must be fitted back in place after completion.
The accident prevention and safety regulations must by always be complied with throughout
all maintenance and servicing work.
Also note the special safety instructions for the various servicing groups which are listed
in detail as job cards in the Chapter „Job Cards“ see also Chapter 1.2).
The maintenance and servicing intervals are given in the maintenance and servicing schedule, which also
provides information on the jobs required.
The job cards (Chapter 9) give technical instructions on how to actually perform the jobs.

1.2 Safety instructions / Accident prevention


For various servicing groups, detailed safety advice has have been drawn up in the form of job cards;
they are listed before the job cards of the respective servicing groups.
The statutory accident prevention regulations have to be complied with (obtainable from professional
associations or in specialized bookshops). They depend on the installation site, the operating mode and
the expendables and auxiliary materials used.
Special protective arrangements dependent on the particular jobs are indicated and marked in the job
description.
In general, the following applies:
● for the personnel:
- Only trained personnel may operate or maintain the engine. Unauthorized persons are not
allowed to enter the machine room.
- When the engine is in operation, wear only tight-fitting clothes and ear muffs in the machine room.
- Use only professionally qualified staff for repair work.

● for the machine room:


- Ensure sufficient ventilation (do not cover air shafts).
- Provide first-aid kit and suitable fire extinguishers and check their contents and serviceability at
regular intervals.
- Only store combustible materials in the machine room if they are necessary for the operation of
the system.
- Smoking and open flames are not allowed in the machine room.

● for operation and maintenance of the engine:


- Only start the engine when all protective devices have been installed and the turning device has
been removed. Make sure that there is nobody in the danger area.
- Only carry out any cleaning, maintenance and repair work when the motor is shut down and
secured against starting.

Chapter 1 - Page 2 0299 3245-0199 0997


DEUTZ MWM Advice to users
Engines and Systems

1.3 Operating instructions and Workshop manual 1


In order to provide a user-specific information structure, the service documentation has been divided into the
Operating Instructions and the Workshop Manual.
The Operating Instructions include a general description as well as instructions for all necessary maintenance
jobs.
In detail, they contain the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Engine description
3 Operating the engine, with
- Work routines before initial start-up and after every inspection
- Work routines before start-up
- Start-up
- Operational monitoring
- Shutting down the engine
- Emergency operation if components fail (if necessary and possible).
4 Instructions for expendables
5 Maintenance and servicing, with
- Tools and equipment overview
- Maintenance and servicing schedules
6 Operational malfunctions, their causes and how to correct them
7 Engine conservation
8 Technical particulars
9 Job Cards, arranged by Job Card Numbers
10 Sundry other instructions (if not included in the appendix or in separate files)
After-sales service
• Global service directory.

The Workshop Manual presopposes knowledge of the contents of the Operating Instructions. This particularly
applies to the safety instructions. It describes easy repair jobs and emergency measures on components, which
are more elaborate to peform, and require appropriately qualified professional staff.
It contains the following chapters:
0 General remarks, Getting started, Contents
1 Advice for the user
2 Job Cards, arranged by Job Card Numbers
After-sales service
• Global service directory.

1.4 Job cards


The Job cards are divided into maintenance Job Cards of Operating instructions, for example B 1-1-1 and
servicing Job Cards of the Workshop Manual, for example W 4-5-1.
For the numbering please refer to Fig. 101.
The structure of a Job Card is shown in Fig. 102.

0997 0299 3245-0199 Chapter 1 - Page 3


Advice to users DEUTZ MWM
Engines and Systems

1
Type of documentation
• The letter at the front signifies the type of documentation involved.
➠ B = Operating Instructions
W = Workshop Manual

Maintenance Group (the same for all engines)


➠ 0 General remarks / cross-category jobs 8 Lube oil system
1 Cylinder head 9 Coolant system
2 Drive mechanism 10 Compressed air system
3 Crankcase 11 Monitoring system
4 Engine control 12 Other components
5 Governor 13 Electrical system
6 Exhaust gas system / Charging
7 Fuel system

Subsystem (component)
• The subsystems are distinguished by maintenance groups.
• Generally valid:
➠ 0 Cross-subsystem or Safety Regulations
1 System parameters or general checks

Serial Number
• Counting per subsystem (component)
• Various jobs per subsystem (component)
• Version differences

B 3-3-3 80307 0

Fig. 101 Numbering of the Job Cards

Chapter 1 - Page 4 0299 3245-0199 0997


DEUTZ MWM Advice to users
Engines and Systems

80300 1

Fig. 102 Structure of the Job Cards

1 DEUTZ AG, 10 Date of issue of the Job Cards


editor of the service documentation
11 Sequence of operations, work procedure
2 DEUTZ MWM, manufacturer, and
12 Safety instructions and general hints
engine type to which the Job Card refers
13 Full title of the Job Card
3 Short title of the Job Card
If you have any questions on the Job Card,
4 Number of the Job Card
please always state the engine type (2), the
5 Necessary tools, equipment, and number (4), the page (8), the date of issue
spare parts (10) or, as an alternative, the Internal part
number (9).
6 Reference to further Job Cards,
instructions, etc.
7 Explanatory diagrams
8 Present page of total number of pages
9 Internal part number of the Job Card

0997 0299 3245-0199 Chapter 1 - Page 5


Advice to users DEUTZ MWM
Engines and Systems

1 1.5 Spare parts


You will receive spare parts from Wärtsilä Netherlands B.V..
You will find a list of the spare parts in the engine’s
spare parts list.

Chapter 1 - Page 6 0299 3245-0199 0997


DEUTZ MWM Description
TBD 645

2 Description 2
2.1 Model
2.1.1 Explanation of types
2.1.2 Engine side designations, cylinder numbering and sense of
rotation
2.2 Nomenclature for engine cylinders and components

2.3 Engine illustrations


2.3.1 Left-hand side
2.3.2 Right-hand side
2.3.3 Main dimensions
2.4 Construction and function
2.4.1 Crankcase and oil pan
2.4.2 Cylinder head
2.4.3 Drive mechanism
2.4.4 Gear train and control system
2.4.5 Fuel system
2.4.6 Governor
2.4.7 Lube oil system
2.4.8 Cooling system
2.4.9 Supercharging
2.4.10 Starting system
2.4.11 Operator control, monitoring and safety features

1197 0299 4625-0108 Chapter 2 - Page 1


Description DEUTZ MWM
TBD 645

2 2 Description

2.1 Model
2.1.1 Explanation of types

Designation of the engine .................. T B D 645 L _

Exhaust gas turbocharger ................ T

Intercooler ........................................ B

Diesel engine ................................... D

Series ........................................... 645


with stroke in cm

Straight-type engine ......................... L

Number of cylinders .............. 6, 8 or 9

2.1.2 Engine side designations, cylinder numbering and sense of rotation


In practice, the following designations are customarily used for the 4 sides of the engine (see Fig. 201):
The designation used in these operating instructions is in each case highlighted bold type, and conforms to DIN
6265.

1 1 2 3 4 3

4
80060 0

Fig. 201 Engine side designations and cylinder numbering

Chapter 2 - Page 2 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

Engine sides: 2
1 Flywheel, drive end
2 Exhaust gas side, left-hand side
3 Front, damper, water pump, operator, non-drive end
4 Intake , receiver, control shaft, right-hand side

Cylinder numbering:
The cylinders are counted and designated from the drive end.

Sense of rotation:
Looking from the drive end (Direction 1), the following applies:
„Left“ anticlockwise
„Right“ clockwise.

2.2 Nomenclature for engine cylinders and components


The engine cylinders and certain components are numbered for identification. The numerical sequence begins
at the drive end with Cylinder 1 (compare identification in Fig. 201).
The cylinder number is punched into the following components:
- piston
- connecting rod and bearing shells

In the same way, the following components are numbered consecutively from the drive end, and identified with
punched numbers:
- Main bearing covers and bearing shells
- Control shaft bearing covers and bearing shells.

1197 0299 4625-0108 Chapter 2 - Page 3


Description DEUTZ MWM
TBD 645

2 2.3 Engine illustrations


2.3.1 Left-hand side

5 4 3
80120 0

Fig. 202 Engine, left-hand side

1 Coolant collecting pipe


2 Inspection hole cover with safety valve
3 Oil cooler
4 Backwash filter with integrated oil pressure
control valve (automatic filter)
5 Oil pump
6 Turbocharger
7 Air starter

Chapter 2 - Page 4 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2
2.3.2 Right-hand side

1 2 3

7
10

80119 0

Fig. 203 Engine, right-hand side

1 Turbocharger
2 Coolant connection for high-temperature
circuit (outlet)
3 Intercooler
4 Injection pumps
5 Shutdown lever
6 Instrument and control panel
7 Start button
8 Crank compartment monitor
9 Control shaft compartment
10 Actuator (governor)

1197 0299 4625-0108 Chapter 2 - Page 5


Description DEUTZ MWM
TBD 645

2
2.3.3 Main dimensions
B1
4 2 4

H1
3
5 LL RL

H2
6

L 6 B3
B2
80022 0

Fig. 204 Main dimensions, main built-on components,


senses of rotation: LL = anticlockwise
RL = clockwise

1 Turbocharger Engine L B1 B2 B3 H1 H2
2 Intercooler 6-cylinder 5,565 2,110 1,360 870 3,690 990
3 Lube oil pump 8-cylinder 6,530 2,110 1,360 870 3,570 990
4 Exhaust gas 9-cylinder 7,020 2,150 1,360 870 3,570 990
5 Governor
6 Flywheel
7 Lube oil filter

Chapter 2 - Page 6 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4 Construction and function 2


2.4.1 Crankcase and oil pan
The crankcase is stressed by the forces occurring in the cylinder and at the drive mechanism. The gas force
produced in the cylinder acts on the cylinder head and via the piston on the connecting rod and the crankshaft.
The counterforce between the cylinder head mounting and the main bearing cover mounting is transmitted to
the crankcase.
The one-part crankcase is provided with a fitted cylinder jacket for each cylinder.
From outside, the torque reaction caused by power output is transmitted to the foundation via the drive
mechanism and the contact strips cast onto the crankcase.
The crankcase possesses high rigidity, thanks to the cross-tensioning over the main bearing covers.
The low contact collar of the inserted cylinder liners, with the coolant flowing directly around them, enables the
combustion chamber to be intensively cooled.
The lube oil flowing back into the crankcase is collected in the oil pan, and then passed into a separate lube oil
reservoir.
Compare Fig. 205 on the next page.

1197 0299 4625-0108 Chapter 2 - Page 7


Description DEUTZ MWM
TBD 645

3
2

1
5

12

10 9
13

11

80000 0

Fig. 205 Crankcase and oil pan

1 Cylinder jacket 12 Safety valve closed


2 Cylinder liner 13 Safety valve open
3 Contact collar
4 Crankcase
5 Control shaft bearing
6 Contact strip
7 Screws for cross-tensioning
8 Inspection hole cover
9 Oil pan
10 Main bearing cover
11 Inspection hole cover with safety valve

Chapter 2 - Page 8 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.2 Cylinder head 2


The cylinder heads are each secured to the crankcase with eight stud bolts.
Each cylinder head is fitted with two inlet and two exhaust valves, and one injection valve. In addition, a
connection for measuring the cylinder pressure (indexing) is provided.
The inlet and exhaust valves (each provided with a valve rotating device) are actuated by the valve lifters
mounted on the cylinder heads. The exhaust valves are installed in the valve housing, and can accordingly be
removed without dismantling the cylinder head.
The injection valves are separated from the coolant compartment by a sleeve installed in the cylinder heads.
Cooling oil feed and leakage fuel return are connected to the injection valve by a connector piece sealed with
round sealing rings. The indexing valve is located outside the cylinder head hood.
Between the cylinder liner and the cylinder head is a cylinder head gasket, which seals off the combustion
chamber against the coolant compartment. A round sealing ring installed in the centering collar of the cylinder
head seals off the coolant compartment externally between crankcase and cylinder heads. The path of the
coolant through the cylinder heads is described in Section 2.4.8.

1197 0299 4625-0108 Chapter 2 - Page 9


Description DEUTZ MWM
TBD 645

10 1
2
8

4
6

9
80023 0

Fig. 206 Cylinder head

1 Exhaust valve lifter


2 Stop rod
3 Inlet valve lifter
4 Cooling oil feed line
5 Leakage oil line
6 Exhaust valve housing
7 Injection valve
8 Indexing valve
9 Dummy insert
10 Valve rotating device

Chapter 2 - Page 10 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

16 1

15
2

14
3
13
4
12
5
11

10 6

9 7

80007 0

Fig. 207 Cylinder head, sectional view

1 Exhaust valve lifter 12 Stop rod


2 Valve rotating device 13 Valve guide, inlet valve
3 Valve spring 14 Valve spring
4 Valve guide, exhaust valve 15 Inlet valve lifter
5 Exhaust valve housing 16 Valve lifter bracket
6 Exhaust valve cone
7 Centering collar
8 Cylinder jacket
9 Round sealing ring
10 Cylinder head gasket
11 Inlet valve cone

1197 0299 4625-0108 Chapter 2 - Page 11


Description DEUTZ MWM
TBD 645

2 This page intentionally left blank.

Chapter 2 - Page 12 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.3 Drive mechanism 2


The drive mechanism consists of crankshaft, connecting rod, piston and flywheel.
The crankshaft is suspended on bearings in the crankcase.
Counterweights bolted to the crank webs ensure that the internal mass effect is reduced, and thus relieve the
stress on the crankshaft bearings. The flywheel serves to decrease the irregularity of the crankshaft’s rotary
movement.
The crankshaft is driven via the connecting rods by gas forces acting on the pistons. Connecting rods divided
at an angle enable connecting rod and piston to be removed upwards through the cylinder liner.
An angled bore in the connecting rod shaft enables lube oil to penetrate to the piston pin bearing and the piston
cooling compartment.
The assembled piston consists of a forged steel upper section and a forged aluminium lower section.
The piston ring set consists of 3 compression rings in the upper section in tempered grooves, and 1 oil stripper
ring in the lower section.

Fig. 208 Piston and connecting rod

6 7 1 Connecting rod bearing shell


2 Connecting rod
3 Piston lower section
5 4 Piston pin
5 Piston rings
6 Cooling compartments
4 7 Piston upper section

80024 0

1197 0299 4625-0108 Chapter 2 - Page 13


Description DEUTZ MWM
TBD 645

2
1 2

4 3
80026 0

Fig. 209 Crankshaft

1 Crankshaft toothed gear


2 Counterweights
3 Oil splash ring
4 Flywheel flange

Chapter 2 - Page 14 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.4 Gear train and control system 2


The control shaft is driven from the crankshaft at the flywheel side via a gear train. The individual cams mounted
on the cam shaft with pressurized-oil bands control the inlet and exhaust valves via roller tappet, stop rod and
valve lifter. Individual cams likewise mounted with a pressurized-oil band actuate the injection pumps. The
governor is driven by the gear train’s idler gear via helical gearing.
For lubrication purposes, valve lifter, roller tappet, idler gear hub, injection pump drive and control shaft bearings
are connected to the engine lubrication system via distributor lines.
On the operator side, a toothed gear is likewise mounted on the crankshaft. This gear drives the lube oil pump,
and (if fitted) the scavenge pump and the coolant pumps.

7 3

8 6

80027 0

Fig. 210 Gear train

1 Control shaft 5 Idler gear, z = 112


2 Spur toothed gear (control shaft), z = 99 6 Spur toothed gear (crankshaft), z = 88
3 Idler gear, z = 63 7 Adjustment markings
4 Drive gear for governor 8 Idler gear hub
(see also 2.4.6)
1197 0299 4625-0108 Chapter 2 - Page 15
Description DEUTZ MWM
TBD 645

3
4 12

5
1

11 6 8 7 5 9 6 7

11 10 8
80008 1

Fig. 211 Valve mechanism

1 Roller tappet 11 Fuel pump cam


2 Tappet guide 12 Distributor line (lube oil)
3 Stop rod
4 Leakage fuel from injection pump and
injection nozzle
5 Tappet roller for injection pump
6 Tappet roller for inlet valve
7 Tappet roller for exhaust valve
8 Gas change cam
9 Lube oil line to control shaft bearing
10 Control shaft

Chapter 2 - Page 16 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.5 Fuel system 2


In accordance with the four-stroke principle, fuel is injected into the cylinder at every second rotation of the
crankshaft. The fuel is ignited in the air heated by compression, and combusts.
For this purpose, the fuel is taken from the day tank by a delivery pump, and passed through the fuel filter to
the injection pumps. The fuel filter’s job is to keep dirt away from the pump cylinders and the injection nozzles,
so as to avoid damage to their precisely machined parts. The fuel is injected under high pressure (at full load
over 1000 bar) by the injection pumps through the injection nozzles into the combustion chamber. The leakage
fuel exiting due to the high pressure between nozzle body and nozzle needle in the injection valve is fed back
into the tank. The narrow nozzle bores and the high injection pressure ensure that the fuel is finely atomized
in the combustion chamber, thus causing the fuel to be thoroughly mixed with the combustion air.
In order to maintain the operating temperature in the injection pumps at a constant level, more fuel is fed in than
is actually needed for combustion. The superfluous fuel is fed into the day tank through an overflow valve. In
heavy-fuel engines, the injection nozzles are cooled with lube oil, which is taken from the valve lifter lubrication
system.
In heavy fuel operation, the high soiling and viscosity of the fuel involved necessitate a special treatment system.
The heavy fuel is cleaned by special filters and separators, and warmed up to reduce its viscosity.
Please consult the supplement for details of your own particular engine’s fuel system and the individual parts
it contains.

Fig. 212 Fuel system

1 Leakage oil line to supply tank


2 Injection valve
3 Nozzle cooling oil outlet
1 4 Injection pump
5 Overflow line
8 6 From fuel filter
7 Pressure line
7 2 8 Nozzle cooling oil feed

1 3

80034 0

1197 0299 4625-0108 Chapter 2 - Page 17


Description DEUTZ MWM
TBD 645

2 Fig. 213/214 Injection pump and pump drive

1 Connector piece
2 Constant-pressure relief valve
3 Pressure valve
4 Pump element
5 Control rod
6 Regulating sleeve
7 Tappet spring
8 Connections (for removing leakage oil from
the grooves)
9 Roller tappet
10 Tappet roller
80218 2
11 Fuel return
Fig. 213 Injection pump and pump drive
12 Fuel feed
y Diesel fuel connection for cleaning
the regulating sleeve
2 1

8
4
y

7 5

10
80009 1

Fig. 214 Injection pump and pump drive


Chapter 2 - Page 18 0299 4625-0108 1197
DEUTZ MWM Description
TBD 645

Fig. 215 Injection valve 2


1 Setscrew

1 2 Counternut
3 Nozzle holder

2 4 Coolant return (exits freely in valve lifter


compartment)
11 5 Leakage oil return (fuel)
3
6 Compression spring
7 Thrust piece
4
8 Injection nozzle
9 Fuel feed

10 5 12 10 Coolant feed
11 Connector piece for leakage oil and coolant
12 Cylinder head
13 Fuel pressure line

9 6 13

80010 0

1197 0299 4625-0108 Chapter 2 - Page 19


Description DEUTZ MWM
TBD 645

2 This page intentionally left blank.

Chapter 2 - Page 20 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.6 Governor 2
The governor’s job is to create a stable speed behaviour pattern for all operating conditions by regulating the
quantity of fuel injected. For this engine, an electronic governor has been provided, coupled to a hydraulic final
control element for adjusting the control rod 1.
The electronic speed control system consists of the proximity switch 2 (Pick-up), the control electronics 3
(electronics box) and the actuator 4 for operating the control rod. In the case of the actuator with back-up, a
mechanical control system with centrifugal weights is additionally accommodated in the final control element,
and will assume control of the hydraulic final control element if the electronics fail. In the event of the electronics
failing, the actuator will thus function as a mechanical/hydraulic controller. Depending on the requirements
involved, special accessories can be added and ancillary functions implemented, such as:
- start quantity limitation,
- charging-air-pressure-dependent filling limitation,
- actual-speed-dependent filling limitation,
- manual speed adjustment,
- shutdown solenoid.
At the electronic governor, the actual speed is measured with the proximity switch, transferred to the electronics
box, and compared with the preset setpoint speed. In the event of deviations, the injection pump filling is
corrected by the actuator activated by the electronics box.

Actuators 2221 and 2231 are supplied by the manufacturer without a filling of lube oil. Before
commissioning, fill up to the middle of the sight glass with approx. 1.5 litres of lube oil.

1197 0299 4625-0108 Chapter 2 - Page 21


Description DEUTZ MWM
TBD 645

10 4 5 6 1

10 11 8

2 7

11 3
80028 0

Fig. 216 Diagram of the electronic control circuit

1 Control rod 8 Injection pump


2 Proximity switch (pick-up) 9 Flywheel with studs
3 Control electronics (electronics box) 10 Studs for speed pulses of the proximity switch
6 cylinders: 3 studs
4 Actuator
8 cylinders: 4 studs
5 Spring element 9 cylinders: 9 studs
6 Control shaft 11 Electrical connections
7 Electrical speed adj. (setpoint specification)

Fig. 217 Actuator

1 Spring element
1 2 Lube oil sight glass
3 Actuator
4 Lube oil filter

4 2

80029 0

Chapter 2 - Page 22 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

4
1

4
3
7

4
6

80030 0

Fig. 218 Governor drive

1 Seal
2 Governor drive, complete
3 Spur-toothed gear
4 Grooved ball bearing
5 Shaft
6 Spur-toothed gear
7 Shaft
8 Spur-toothed gear

1197 0299 4625-0108 Chapter 2 - Page 23


Description DEUTZ MWM
TBD 645

2 This page intentionally left blank.

Chapter 2 - Page 24 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.7 Lube oil system 2


The lube oil reduces the friction of the components sliding on each other, and removes heat from the sliding-
contact surfaces, the upper part of the piston, and the injection nozzles. A film of lube oil on the cylinder’s contact
surfaces supports the sealing effect of the piston rings. In addition, the lube oil keeps dirt in suspension and
transports it to the lube oil filter.
The lube oil circuit is designed for pressure circulating lubrication with a dry sump.
The gear oil pump flanged onto the operator side of the engine pumps the lube oil from the lube oil reservoir
and passes it through lube oil cooler, system-side backwash filter and engine-side backwash filter (permanently
rinsing) into the engine’s lubrication circuit.
A thermostat regulates the quantity of lube oil flowing through the lube oil cooler in dependence on the lube oil
temperature. The lube oil pressure in the engine circuit is adjusted by means of a lube oil pressure control valve
integrated into the backwash filter. A safety valve fitted to the gear oil pump will open if the lube oil pressure
becomes so high that the lube oil pump is endangered.
The drive mechanism is supplied with oil via the distributor line in the oil pan. To this distributor line are connected
further distributor lines for lubricating the control shaft bearings, the tappets, valve lifters and the nozzle cooler.

1197 0299 4625-0108 Chapter 2 - Page 25


Description DEUTZ MWM
TBD 645

2
17 18 1

3 4 5 6

16

15 7

14 13 12 11 10
0 9 8

80035 0

Fig. 219 Lube oil system

1 Valve lifter 11 Return to lube oil reservoir


2 Piston 12 Crankshaft
3 Backwash filter (engine side) 13 Distributor line in the oil pan
4 Automatic filter (system side) 14 Distributor line for control shaft lubrication
5 Lube oil thermostat 15 Idler gear
6 Lube oil pump 16 Control shaft
7 Lube oil cooler 17 Distributor line for tappet lubrication
8 Safety valve 18 Tappet
9 From lube oil reservoir
10 Pressure control valve, integrated into the
backwash filter

Chapter 2 - Page 26 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

18 1 4 3 5 16

10

11

9 8 7 6 12

13

2 14

15

80036 0

Fig. 220 Lube oil pump

1 Lube oil pump 11 Valve spring


2 Safety valve 12 Valve spindle
3 Line to lube oil cooler or 13 Valve nut
lube oil filter 14 Cover
4 Drive flange 15 Cap nut
5 Drive gear shaft 16 Fixing screws
6 Housing 18 Drive gear
7 Gear axle
8 Shaft seal
9 Nut
10 Valve cone

1197 0299 4625-0108 Chapter 2 - Page 27


Description DEUTZ MWM
TBD 645

2
7 8 9

6
1
5

11 4
2
3

3 2

4 1

10 10

5
9
10

8
6
7

11
80037 0 80038 0

Fig. 221 Backwash filter Fig. 222 Pressure control valve

1 Hydraulic drive for flushing device 1 Valve cone


2 Filter monitor 2 Valve spring
3 Filter housing 3 Lube oil return
4 Pressure after filter 4 Spring cup
5 Pressure before filter 5 Sealing ring
6 From prelubrication pump 6 Round sealing ring
7 Flushing oil drain 7 Threaded piece
8 Lube oil feed 8 Counternut
9 Lube oil to engine 9 Setscrew
10 Screw-in point for temperature sensor 10 Feed from filter
11 Pressure control valve 11 Pressure line to engine

Chapter 2 - Page 28 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.8 Cooling system 2


During combustion, the chemical energy contained in the fuel is converted into thermal energy. Only part of this
can be converted into mechanical energy in the engine. The remaining heat is removed mainly with the exhaust
gas and the coolant.
The methods of cooling used are single-circuit mixed cooling and (for special cases) twin-circuit cooling.
• In single-circuit mixed cooling via a coolant recirculation pump, the high and low-temperature circuits are
connected to each other, with the permissible coolant temperature being regulated by a thermostat in each
circuit.
Heat is removed from the recooler by a separate cooling circuit.
• In twin-circuit cooling, the high and low-temperature circuits each have their own recooler. Both cooling
circuits likewise have separate coolant pumps and thermostats.
Heat is removed from the recoolers by a separate cooling circuit.
The walls of the combustion chamber are cooled by the high-temperature circuit. The coolant is passed through
the coolant compartments between crankcase and cylinder liners. From there, the coolant is passed via bores
in the cylinder jacket past the cylinder liner support to the combustion chamber area of the cylinder liners and
to the cylinder heads. Channels in the cylinder heads and exhaust valve housings lead the coolant to the bottom
of the cylinder head and the valve seatings. Ball valves installed in the cylinder head enable the exhaust valve
housings to be removed without draining the water from the engine.
Parallel to the cylinder heads, the coolant flows around the exhaust gas compartments of the turbocharger. The
coolant exiting from cylinder heads and turbocharger is passed through the collecting pipe to the high-
temperature stage of the intercooler, and from there into the system’s cooling circuit. Pistons, injection nozzles
and bearings are cooled by lube oil. The lube oil gives up the heat thus absorbed in the lube oil cooler. Lube
oil cooler and low-temperature stage of the intercooler are connected to the low-temperature circuit of the
cooling system. In heavy-fuel operation, the charging air is preheated in partial-load operation. For this purpose,
on the system side, a charging-pressure-controlled 3-way valve is provided, which in dependence on the engine
output blocks the coolant flow to the low-temperature stage of the intercooler, thus causing the charging air in
the high-temperature stage of the intercooler to warm up, due to the coolant of the high-temperature circuit.
Please consult the supplement for details of your own particular engine’s cooling system and the individual
components it contains.

1197 0299 4625-0108 Chapter 2 - Page 29


Description DEUTZ MWM
TBD 645

8 9

10
6

2 11
3
12

1 6

80039 0

Fig. 223 Coolant flow through the engine Fig. 224 Charging-pressure-controlled three-
way valve ➤
1 Lube oil cooler
1 Coolant inlet, high-temperature circuit
2 Setscrew
2 Coolant inlet, low-temperature circuit
3 Compression spring
3 Control line
4 Valve cone
4 Charging-pressure-controlled three-way valve
(heavy-fuel engine) 5 Spool valve
5 To intercooler 6 Thrust piece
6 To lube oil cooler 7 Housing for control diaphragm
7 Coolant outlet, high-temperature circuit 8 Control line
8 Exhaust valve 9 Intercooler
9 Coolant collecting line A Coolant inlet
10 From turbocharger B Coolant to lube oil cooler
11 To turbocharger C Coolant to intercooler
(closed at low charging air pressure)
12 Cylinder liner

Chapter 2 - Page 30 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

3 4 C 5 B 6 7 8

80040 0

Fig. 224 Charging-pressure-controlled three-way valve, LT cooling circuit

1197 0299 4625-0108 Chapter 2 - Page 31


Description DEUTZ MWM
TBD 645

2 This page intentionally left blank.

Chapter 2 - Page 32 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.9 Supercharging 2
In order to achieve cost-efficient performance per litre of swept volume, more fuel has to be burnt in the engine
per cylinder filling. For this purpose, a larger quantity of combustion air is likewise required.
This additional quantity of combustion air is supplied by the exhaust gas turbocharger. Compressor and turbine
of the exhaust gas turbocharger are mounted on a common shaft. The turbine is driven by the engine exhaust
gases.
Since the air warms up when compressed, it is recooled in the intercooler. This further increases the quantity
of combustion air fed to the cylinder, and reduces the temperature level in the combustion chamber.

8 9 1 2 3

7 6 5 4
80031 0

Fig. 225 Diagram of the supercharging system

1 Compressor 6 Exhaust valve


2 Intake air filter 7 Exhaust gas pipe
3 Intercooler 8 Exhaust gas turbine
4 Intake pipe 9 To sound absorber
5 Inlet valve

1197 0299 4625-0108 Chapter 2 - Page 33


Description DEUTZ MWM
TBD 645

2 Fig. 226 Exhaust gas turbocharger


3
1 Air filter
2 Compressor
3 Turbine
4 Return line for turbine washing system
5 Feed line for turbine washing system
6 Reservoir for compressor cleaning system

1 2 6 5
80032 0

Fig. 227 Intercooler


1 2 3
1 Coolant connections, high-temperature
circuit
2 Intercooler
3 Intake pipe
4 Coolant connections, low-temperature
circuit

80033 0

Chapter 2 - Page 34 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.10 Starting system 2


Engines of this size are started by means of compressed air. Compressed-air starters generate, over the
flywheel, a sufficiently high starting speed for self-ignition.
Triggered by the mechanical button (item 21 in Fig. 229) or by remote control, control air at 7 bar forces starting
pinion 2 into the flywheel ring gear 3, after which the working air at 11 bar causes the engine to run up to the
starting speed. When the engine has ignited, the monitoring system disables the starter, and blocks any further
starts while the machine is running.
Larger starting torques require 2 starters, the pinions of which are enabled one after the other.

Fig. 228 Compressed-air starter at the engine

10 2 Starter pinion
3 3 Flywheel ring gear
15
8 Working air, inlet
9 Control air to the main starting valve
15 Working air, outlet
2

8 9
80140 1

1197 0299 4625-0108 Chapter 2 - Page 35


Description DEUTZ MWM
TBD 645

2
1 2 3

7 bar
22

21

24 P
E
P
E
4
20
23

19 7

18 8

17 11 bar 14

max. 30 bar
9
> 12 bar
10

16 15 13 12 11
80164 1

Fig. 229 Pneumatics diagram for the engine

1 Pressure reducing station 13 Quick-release valve


2 To oil mist detector 14 „STOP“ solenoid
3 Pressure transmitter panel 15 Quick-release valve
starting control air pressure
16 Pressure reducing valve with safety valve
4 Overspeed emergency stop
17 Machine room
5 Filling booster control
18 Engine start, electrical
6 Stop cylinder
19 Instrument panel
7 Control shaft
20 Turning machine
8 Filling booster
21 Pushbutton for pneumatic start
9 Actuator
22 Start blocker
10 Booster
23 Start disable
11 Starter I
24 Turning device „ON“
12 Starter II

Chapter 2 - Page 36 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2
1 2 3

7 bar
22

21

24 P
E
P
E
4
20 START STOP
23

19 7

18 8

25 5

17 11 bar 14

max. 30 bar
9
> 12 bar
10

16 15 13 12 11
80205 1

Fig. 230 Pneumatics diagram for remote control

1 Pressure reducing station 13 Quick-release valve


2 To oil mist detector 14 „STOP“ solenoid
3 Pressure transmitter panel 15 Quick-release valve
starting control air pressure 16 Pressure reducing valve with safety valve
4 Overspeed emergency stop 17 Engine room
5 Filling booster control 18 Engine start, electrical
6 Stop cylinder 19 Instrument panel
7 Control shaft 20 Turning machine
8 Filling booster 21 Remote start
9 Actuator 22 Start blocker
10 Booster 23 Start disable
11 Starter I 24 Turning device „ON“
12 Starter II 25 Emergency start

1197 0299 4625-0108 Chapter 2 - Page 37


Description DEUTZ MWM
TBD 645

2 This page intentionally left blank.

Chapter 2 - Page 38 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

2.4.11 Operator control, monitoring and safety features 2


Operator control
Controls for starting the engine, adjusting the speed and shutting the engine down are provided directly at the
engine itself. For remote control, electrical switching devices are generally used, for switching appropriate
control devices at the engine.
For starting, the control current is passed either directly to the engine starting valve or to an electrically controlled
valve. This valve releases the control air to the engine starting valve.
Speed is adjusted at the engine operating console by means of a changeover button (increase or reduce speed)
and under remote control by an electric signal (4 to 20 mA) proportional to the setpoint value and provided by
the remote control system.
When the engine is shut down by remote control, the stop cylinder is pressurized via a solenoid valve. A latching
feature ensures that this solenoid valve remains actuated until the latching is cancelled by a remote start or a
command switchover to the machine. The stop cylinder is pressed into its original position by the built-in spring.

80042 1 80043 1

Fig. 231 Operating lever at the engine Fig. 232 Filling stop screw

1 Shutdown lever 1 Stop screw


2 Filling indicator 2 Lever

1197 0299 4625-0108 Chapter 2 - Page 39


Description DEUTZ MWM
TBD 645

2
Monitoring system
The engine’s monitoring system is designed to prevent operational malfunctions resulting in major damage to
the engine and the system as a whole. When a defined limit value is reached, an alarm is given, or the engine
is shut down by the KN 1140 safety system.
● Monitoring the operating pressures
Pressure sensors mounted on the engine are used to monitor the limit values. The operating pressure
detected at the pressure sensor’s input is converted into an electric voltage. Corresponding to the importance
of the variable being monitored, 2 VD 61 pressure sensors are provided for each of the following
the lube oil
the charging air
the coolant I (high-temperature circuit)
the coolant II (low-temperature circuit) and
the starting/control air.
The electric pulse from the first pressure sensor is used for the indicator or the alarm signal. The second
pressure sensor belongs to the safety system, which controls alarm processing, e.g. immediate engine stop,
output reduction, or activation of auxiliary pumps, etc.
Alarm system
The pressure transmitter at Measuring Point 2.6.11 is used for the indicator units as well as for alarm contacts.
The functioning of the pressure transmitter can accordingly be checked at the indicator unit (instrument box).
Safety system
The pressure transmitter at Measuring Point 2.6.11/1 is wired directly to the KN 1140 safety system. The entire
circuit is monitored for open circuit.
Only one pressure sensor is provided for the fuel admission pressure.
● Main bearing temperature monitoring
In every main bearing cover, a temperature sensor is pressed by a spring against the rear of the bearing,
and fixed in position with a threaded joint. The sensor cable laid inside a conduit passes through the
crankcase to a separate evaluation unit. If the bearing temperature increases above the normal operating
temperature to a defined maximum value, the engine will be automatically shut down.
When you replace temperature sensors, you must prebend the new ones to match the old ones you have
removed. After installing them, check that the crank web is free, and if necessary, rebend the support pipe,
and fasten it to the bearing cover with a pipe clip.
The temperatures for lube oil, coolant and exhaust gas can likewise be incorporated in the engine’s monitoring
system.
● Speed monitoring by safety system
Overspeed shutdown by the KN 1140 safety system
The speed is evaluated in two mutually independent systems, each consisting of a proximity-type speed pick-
up and a speed withdrawable module. Both systems are monitored for sensor failure / open circuit; the stopping
device is likewise monitored for open circuit. Even if only one of the systems signals overspeed, the engine will
be shut down. In the event of discrepancies between the two systems, „Sa.Sy malfunction“ (safety system
malfunction) is signalled. Each time a shut-down command is received - overspeed, lube oil deficiency,
overtemperature at main bearing, and emergency stop from bridge -, the KN 1140 will go to self-holding mode.
It is only possible to resume operation after the malfunction has been corrected and acknowledged with the reset
button.
Speed indication system
The speed is evaluated and indicated by proximity-type speed pick-ups and a VV41 measuring transducer.
A green LED at the VV41 is located in the supply circuit for the speed pick-up, and will light up when the pick-
up is connected and its circuit is closed. If there is an open circuit or the unit is destroyed, the LED will go out.
Classification societies specify what operating values must be incorporated in the engine’s monitoring system
for the application concerned.

Chapter 2 - Page 40 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

7 3

6 5

80044 0

Fig. 233 Attachment points for monitoring devices

1 Charging air temperature sensor


2 Coolant temperature sensor
3 Instrument and control panel
4 Lube oil temperature sensor
5 Crank compartment monitor
6 Leakage fuel monitor
7 Pick-Up

1197 0299 4625-0108 Chapter 2 - Page 41


Description DEUTZ MWM
TBD 645

2 Fig. 234 Pressure sensor

1 Pressure sensor (indication, alarm)


2 Pressure sensor (safety system)
3 Three-way cock
4 Operating pressure
5 Electric cable to monitoring cubicle 1
3
2
4
5
5
80045 0

Fig. 235 Pressure sensor

1 Pressure sensor (indication, alarm)


3 Three-way cock
4 Operating pressure
5 Electric cable to monitoring cubicle

4 1

5
80157 0

Fig. 236 Instrument and control panel

1 Engine/turbocharger rpm
2 Exhaust gas temperature 1 2
3 Charging air temperature
13 3
4 Fuel admission pressure
5 Charging air pressure 12 4
6 Coolant pressure II
11 5
7 Starting air pressure
8 Controls 6
10
9 Hours counter
10 Lube oil pressure after filter 9 7
11 Coolant pressure I 8
12 Lube oil temperature 80046 0

13 Coolant temperature I

Chapter 2 - Page 42 0299 4625-0108 1197


DEUTZ MWM Description
TBD 645

Fig. 237 Engine shutdown diagram 2


(stationary system)
1 2 3 4 5 6

1 Electrical circuit
2 Monitor unit or stop switch
3 Solenoid valve
4 Shutdown cylinder
5 Lever
8 7
6 Regulating shaft
7 Control rod of injection pump
8 Control air feed

80047 0

Fig. 238 Shutdown cylinder (marine operation)

1 Control air line


2 Shutdown cylinder
3 Lever at the regulating shaft

1 2 3

80048 0

1197 0299 4625-0108 Chapter 2 - Page 43


Description DEUTZ MWM
TBD 645

2 Safety features
● Crank compartment monitoring by oil mist detectors.
Through branch lines for each cylinder to two collecting pipes at the longitudinal sides of the engine, the oil
mist detector continuously extracts crank-compartment atmosphere from the crank compartment, and
passes it to a measuring section, which uses infra-red light to detect the cloudiness. Evaluation is performed
in an electronics measuring add-on. If the permissible values for oil mist concentration in the crank
compartment are exceeded, the engine will be stopped. The underpressure for extraction from the crank
compartment is generated by an associated air-jet pump.
● Inspection hole cover with safety valve.
If drive mechanism components run hot, then the air/oil vapour mixture in the crank compartment may lead
to detonation at certain concentrations. The classification societies accordingly insist that the crankcase be
fitted with anti-explosion valves (all inspection hole covers on the exhaust gas side), which will open without
delay if the pressure increases by approx. 0.1 bar, bleed off the pressure, and then close again immediately.

Chapter 2 - Page 44 0299 4625-0108 1197


DEUTZ MWM Operating
TBD 645

3 Operating 3
3.1 Work routines before initial start-up and after every
inspection
3.1.1 General remarks
3.1.2 Monitoring
3.1.3 Coolant
3.1.4 Fuel
3.1.5 Lube oil
3.2 Work routines before start-up
3.2.1 Monitoring
3.2.2 Starting air
3.2.3 Room ventilation
3.2.4 Checking the drive mechanism
3.3 Start-up
3.3.1 Starting the engine
3.4 Operational monitoring

3.5 Shutting down the engine

3.6 Emergency operation if the turbocharger fails

3.7 Emergency operation if the operator control system fails


3.7.1 Starting procedure in emergency operation
3.8 Emergency operation if the governor fails

3.9 Emergency operation if the temperature controllers fail

3.10 Emergency operation if an injection pump fails

3.11 Heavy fuel oil operation

1197 0299 4626-0108 Chapter 3 - Page 1


Operating DEUTZ MWM
TBD 645

3 3 Operating

3.1 Work routines before initial start-up and after every inspection
3.1.1 General remarks
The work and check routines described in this section are necessary to make your engine function properly and
to prevent accidents. Above all, proper functioning of the drive mechanism and the governor is essential for
trouble-free operation.
● Before filling, clean new lines and tanks for fuel, coolant and lube oil.
● Align the engine, and check that the foundation attachment is as per specification (see also Leaflet
6.000.9.000.3314 or 6.000.9.000.3304 in the supplement).
● Clean the engine, and remove any objects deposited on the engine.
Objects deposited on the engine (especially on moving parts like flywheels) may cause serious
damage or even accidents.

Make sure the expendables detailed below are of the requisite quality as specified in Chapter 4.

3.1.2 Monitoring
● Check the monitoring functions (Job Cards from Servicing Group 11).

3.1.3 Coolant
● Before initial start-up, clean shipyard’s coolant lines.
● Fill the engine’s cooling system with prepared coolant, as detailed in chapter 4.4.
● Open valves in coolant lines, and check switching positions.
● Vent cooling system (see Fig. 301 ➤);
HT: Coolant collecting line,
NT: Lube oil coolant, intercooler.
● Check the coolant level in the expansion tank,
setting level at room temperature: approx. 75 %.
● After filling, check for any leaks in lines and engine.
● Remove inspection hole covers and check whether there are any leaks in the cylinder liner seals.

3.1.4 Fuel
● Fill supply tank and day tank with fuel.
● Vent fuel system, and check for leaks.

When operating with heavy fuel oil:


● Start up fuel processing system.
● Preheat engine and system. Determine the requisite fuel temperature for pure heavy fuel oil operation
according to chapter 4.

Chapter 3 - Page 2 0299 4626-0108 1197


DEUTZ MWM Operating
TBD 645

3.1.5 Lube oil 3


● Before initial start-up, fill actuators 2221 and 2231 with approx. 1.5 litres of lube oil, up to the middle of the
sight glass.
● Check the lube oil level in the governor and the turbocharger, and top up if necessary.

Use only turbine oil in the turbocharger.

● Quantity of lube oil in the system approx. 1,3 dm3/kW.


● Fill the lube oil reservoir with lube oil, and prime with the prelubrication pump or the reserve lube oil pump
(until pressure is indicated / shown).
● At initial start-up and after removing or installing cylinder heads or control shafts, turn the engine to check
for free movement of the drive mechanism immediately after priming. This priming routine prevents the
bearings running dry. Use the turning device to rotate the engine by at least two revolutions, then remove
the turning device (decouple the turning motor). Top up the lube oil level in the operating tank until it has
reached the upper marking.

80049 0

Fig. 301 Venting screws


1197 0299 4626-0108 Chapter 3 - Page 3
Operating DEUTZ MWM
TBD 645

3 3.2 Work routines before start-up


3.2.1 Monitoring
● Check power supply to the monitoring equipment (battery).
● Switch on the monitor.

3.2.2 Starting air


● Fill the starting air to 30 bar using the starting air compressor or carbon dioxide (CO2) from the pressurized
tank, and drain off any water.
Due to the explosion risk involved, it is fatally dangerous to fill the starting air tank with oxygen or
flammable gases like hydrogen!

3.2.3 Room ventilation


● Switch on the room ventilation system, in order to remove radiated heat and oil vapours. The room ventilation
system also has the job of supplying the engine with combustion air if the intake comes from the engine room.

3.2.4 Checking the drive mechanism


● Prime with lube oil (keep the pressure at not less than 0.2 bar after the filter for 2 to 3 minutes), and open
indicator cocks.
● Set the stop lever to „Stop“, and turn the engine with the compressed-air starter. If coolant exits at one or
more indicator cocks, correct the cause of the coolant escape.
● Close indicator cocks.
● Press the governor outler lever by hand to „Filling“, and set the stop lever to „Operation“. The control rodding
must go to „Filling“ automatically. If this is not the case, ensure that the control rodding moves freely.

3.3 Start-up
3.3.1 Starting the engine
For initial start-up and after inspections, perform the work routines detailed under Section 3.1.
● After lengthy interruptions in operation (cold engine), perform the work routines detailed in Section 3.2.
● If the engine is to be started up for operation with heavy fuel oil, preheat the engine and the fuel processing
system.
● Open coolant and fuel cocks. If present, switch on pump.
● Remove the turning device (decouple the turning motor).
● Open the main valve at the starting air tank, and drain the water out of the piping upstream of the engine.
● Switch on the monitor.
● Set a low engine rpm.
● Prime with lube oil (keep pressure after the filter at not less than 0.2 bar for 2 to 3 minutes).
● Use the operator control system to start up the engine.
● Slowly increase the load and the speed (up to full load within approx. 15 minutes).

Chapter 3 - Page 4 0299 4626-0108 1197


DEUTZ MWM Operating
TBD 645

3.4 Operational monitoring 3


During engine operation, check the monitoring equipment and make sure the readings the instruments are
giving are correct.

3.5 Shutting down the engine


● Avoid shutting down the engine from full load.
Before shutting down, run the engine for about another 5 minutes at low speed, in order to avoid heat
accumulation at cylinder liners and cylinder heads.
● Use the operator control system to shut down the engine.
● After shutdown, run any coolant pump units for a few more minutes.
● If the engine is going to be shut down for a lengthy period, close raw water, fuel and starting air cocks.

3.6 Emergency operation if the turbocharger fails


If the turbocharger fails, you can continue to run the engine at reduced output.
● If possible, use gas oil as fuel.
● Block or remove the turbocharger’s rotor (see „Instructions for Operation and Maintenance“ from the
turbocharger manufacturer). Due to the reduced flow impedances involved, it is better to remove the rotor.
● Guideline figures for operating data in emergency mode are given in the table below:

Speed in rpm Control shaft Maximum output (kW)


(min-1) (Skalenteile) 6-cyl. engine 8-cyl. engine 9-cyl. engine
315 9 370 495 554 Fixed-pitch prop.
600 8 430 575 645 n = constant

● The exhaust gas temperatures have to be checked continuously.


The exhaust gas temperatures must not exceed the limit specified on the type identification plate of the
turbocharger. If this is the case or if there is any smoke in the exhaust, further reduce the engine output.

If the permissible exhaust gas temperature is observed, you can increase the engine output even above
the reference values given in the above mentioned table.

1197 0299 4626-0108 Chapter 3 - Page 5


Operating DEUTZ MWM
TBD 645

3 3.7 Emergency operation if the operator control system fails


If the operator control system (instrument box at the engine) fails, you can start up your engine using a separate
starting lever 1 fitted to bracket 2 of the starter device.
3.7.1 Starting procedure in emergency operation
For another starting routine without the control panel, the following electrical conditions have to be satisfied.
● Before you begin to repeat any start-up routine, the reset button for the governor must be pressed in the event
of an unsuccessful start or error message (“Pick-up fault“ and “Backup active“).
● Relays K5 and K5.1 in the instrument box must be de-energized, since otherwise a 24-volt DC voltage signal
will be received at the governor input, Terminal 39 “Stop” through contacts K5.1-11/14.
● Nor must there be any stop or emergency stop signals from the KN 1140 safety system being received at
the shutdown functions.
When all the criteria for an emergency start have been met, the mechanical starting procedure can be executed
by releasing the locking mechanism 3 and shifting the starter lever 1.

Setting the speed:


● directly at the actuator (see Fig. 306).

82131 0

Fig. 302 Starter leve

For normal operation, reset lever 3 to its original position!

3.8 Emergency operation if the governor fails


If the governor fails, you can adjust the fuel injection, and thus the speed, by hand.
● Disengage the control rodding (Unscrew screw 1 - Fig. 304).
● Regulate manually using lever 1 or stop screw 2 (Fig. 305).

Keep the speed indicator under continuous observation, since the engine speed will rise rapidly in the
event of load-shedding.

If the electronics fail, you can adjust the speed at the actuator. To do this, open lead seal 1, unscrew counternut
2, and use knurled screw 3 to adjust the speed (Fig. 306).
Increasing speed: turn clockwise
Reducing speed: turn anticlockwise

Chapter 3 - Page 6 0299 4626-0108 1197


DEUTZ MWM Operating
TBD 645

80052 0

Fig. 304 Control rodding

1 Screw

Fig. 305 Emergency operation without governor

1 Lever 1 2
80053 0
2 Stop screw
Fig. 305 Emergency operation without governor

Fig. 306 Emergency operation at the actuator

1 Lead seal
2 Counternut
3 Knurled screw 3 1 2
4 Speed reduction
5 Speed increase 80158 0

Fig. 306 Emergency operation at the actuator

1197 0299 4626-0108 Chapter 3 - Page 7


Operating DEUTZ MWM
TBD 645

3 3.9 Emergency operation if the temperature controllers fail


Adjuster devices are fitted at the temperature controllers, enabling you to alter the flow by hand in the event of
malfunctions. The requisite procedures are described below.
Keep the temperature involved under continuous observation during emergency operation, since any changes
in temperature will not be automatically corrected.

Temperature controller, coolant


Messrs. Amot 1

● Move adjuster lever 1 to the other side. If there is


more than one adjuster lever 1 provided, move
only as many as are necessary to ensure that the
temperature adjusts to a level below the operating
temperature.

80054 0

Fig. 307 Temperature controller, coolant

Temperature controller, coolant


Messrs. AKO 2 2

● Unscrew counternut 1. 1 1
● At adjuster screws 2, adjust temperature to test
report value (screw in the screws: the coolant
temperature falls).
● Tighten counternut 1.

80055 0

Fig. 308 Temperature controller, coolant


Chapter 3 - Page 8 0299 4626-0108 1197
DEUTZ MWM Operating
TBD 645

Charging-pressure-dependent three-way valve,


only with heavy fuel oil version; flow control for inter-
cooler
Messrs. AKO

● Remove charging air connection at the intake line.


Insert a dummy cap in the connection.
● Remove charging air connection 1 at the three-
way valve, and screw adjuster screw 2 with
counternut 3 into the thread of connection 1.
1 2 3 ● Adjust charging air temperature at adjuster screw
2 to test report value (screw in adjuster screw 2:
charging air temperature falls).
● Tighten counternut 3.
80056 0

Fig. 309 Charging-pressure-dependent three-way valve

Temperature controller, lube oil


3 2 Messrs. Behr-Thomson

3 2
● Remove lead seal 1.
● Unscrew counternut 3.
● Screw in adjuster screw 2 by 5 turns.
● Tighten counternut 3. (Entire lube oil flow is then
passed through the oil cooler.)
● Check the position of the control slide at indicator
4.
4 1
1
80057 0

Fig. 310 Temperature controller, lube oil


1197 0299 4626-0108 Chapter 3 - Page 9
Operating DEUTZ MWM
TBD 645

3 3.10 Emergency operation if an injection pump fails


If an injection pump fails, the roller tappet of the injection pump drive must be kept fixed above the TDC with
the set-up device, so that the engine can continue to be run for a short period while switching off the cylinder
concerned.
See Job Card B 7-2-1.

3.11 Heavy fuel oil operation


In the upper load range, the engine can be run continuously with heavy fuel oil. To start up with heavy fuel oil,
you must first preheat the engine and the fuel processing system.
Partial-load operation is possible only to a limited extent, since due to the poorer combustion conditions residues
are produced. In order to avoid damage due to deposits on combustion chamber walls, valves and exhaust gas
ducts, the engine must be run at not less than 60 % of full load after the partial-load operating times shown in
the diagram. This increased load should be run every day for at least one hour (See Chapter 4).

Chapter 3 - Page 10 0299 4626-0108 1197


Wärtsilä Deutz
Expendables
TBD645

4 Expendables 4
4.1 General remarks
4.1.1 Warranty
4.1.2 Product selection
4.1.3 Mixability

4.2 Fuel

4.3 Engine lube oil

4.4 Engine coolant

1012 0299 4627-0108 Chapter 4 Page 1 of 6


Wärtsilä Deutz
Expendables
TBD645

4.1 General remarks


4.1.1 Warranty
If unsuitable expendables are used, or if it cannot be documented that the expendables used
conform to requirements, no warranty will be accepted by the engine’s manufacturer for
trouble-free operation. This also applies for inadequate care and maintenance of the engines
and the expendables.

4.1.2 Product selection


Due to the large number of products available nationally and internationally and the wide
variety of qualities involved, plus continual improvements as well, it is impossible for us to
check all suitable products and name them, and accordingly we cannot accept any
responsibility for these products.

The supply of the expendables concerned bears sole responsibility for globally consistent
quality of the products named here, and in the case of products not named additionally for
compliance with the specified requirements for the expendables and their operational
reliability. This shall also apply in the event that the producer concerned improves the
products named here.

The expendables named here (reference products) are only a selection from certain
producers and their products. Other expendables not listed here may also be used, provided
they conform to the requirements involved, i.e. are at least equivalent in terms of all criteria.
The expendables named in this specification shall be used as reference products for
purposes of comparison. The expendables suppliers involved can supply the requisite
information, and should also confirm the suitability of their products correspondingly.

4.1.3 Mixability
Mixing different expendable types together, .e.g. different lube oils with each other, different
coolant additives with each other, may lead to malfunctions.

In every such case, before any mixing is performed, permission must be obtained from the
suppliers of the products involved, who shall then bear the responsibility for any such mixing.
This shall also apply to putting any further additives in the expendables.

4.2 Fuel
See Technical Bulletin TB00/99/2089.

For this engine, the values and particulars for the BVM 628 engine apply analogously.

Chapter 4 Page 2 of 6 0299 4627-0108 1012


TECHNICAL
BULLETIN
Services, Wärtsilä Netherlands B.V.
Engine section Engine type Ref. Date Issue Document No. Page
99 Service information See below Services 10.08.2 010 03 TB00/99/2089 1(8) + encl.

Fuels, fuel preparation


Engine types This bulletin applies to all D232, D234, D518, D601, D602, D603, D604(B),
D616, D618, D620, D628, D640, D645 D716, D816 and D18/22 engines.
It applies in part to older engines which are no longer in the model range.
Please contact your Wärtsilä Services Network Company if you have any
questions.

Contents 1 Fuel types


1.1 Distillate fuel
1.2 Intermediate fuel
1.3 Residual oil
2 Notes on fuel
2.1 Ignition quality
2.2 Fuel mixtures
2.3 Influence of fuel on performance
2.4 Fuel temperature
2.4.1 Temperature required for fuel pumping
2.4.2 Separating temperature
2.4.3 Fuel temperature at injection pump inlet
2.5 Separation of fuels
2.6 Injector cooling system
2.7 Low-load operation with residual fuels
2.8 Shutting down and starting the engine for operation with residual fuel

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 2(8)
1 Fuel types

The following table lists those fuels which are approved for Wärtsilä Deutz marine engines.

Approved for engines

see enclosure
Permissible fuels D601
D518 D232 D602
D716
D618 D234 D603 D628 D640 D645
D816
D18/22 D616 D604(B)
D620
Diesel fuels to:
EN 590 4
Distil-
late Marine distillate fuels to:
fuels ISO 8217:2005 DMA 5
ISO 8217:2005 DMX 5

MDF mixed-fuel oil to: Only constant


Inter- speed engines
ISO 8217:2005 DMB 5
mediat
MDF mixed-fuel oil to:
e fuels
ISO 8217:2005 DMC 5
Residual oil to:
ISO 8217:2005
Resi- RMA30 / RMB30
dual oil RMD80
(heavy RME180 / RMF180 6
oil) RMG380/RMH380/RMK38
0
RMH700/ RMK700

With regard to fuels with specifications other than those listed above, please contact the Wärtsilä
Services Network, submitting the relevant specification or a fuel sample.

1.1 Distillate fuel

Distillate fuels are all fuels not containing residual oil.

Pure distillates do not require any specific engine equipment.

 Low-sulphur diesel fuel with a sulphur content of < 0.05 % can be used.
Sufficient lubricity must, however, be ensured through the use of additives.
The fuel manufacturer is responsible for guaranteeing this.

1.2 Intermediate fuel


Intermediate fuels are distillate fuels to which small quantities of residual oil have been admixed.
If the cetane number is not specified or cannot be determined, the CCAI value applies (see
nomogram, enclosure 3).
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 3(8)

For D234, D616, D604B and D620 engines, intermediate fuels are only permitted for on-board
assemblies (constant speed auxiliary application). Engine power must be reduced by 10 %.
When running an engine on intermediate fuel, it is important to make sure that the max. injection
viscosity is not exceeded, see section 2.5.3. Otherwise there must be provision for fuel preheating.
D628, D640 and D645 engines run on intermediate fuel to ISO 8217:2005 DMC are to be treated as
for heavy-oil operation with regard to engine power and equipment.
There must be provision for fuel separation, see section 2.6.

1.3 Residual oil

Residual oils (heavy oil) are mixtures and specified to ISO 8217:2005. They are approved for D640
and D645 engines up to RMK700, for D628 engines only up to RMK 380.
Additional Wärtsilä Deutz requirements for the use of residual oils to ISO 8217:2005:

Specification Limit Test method


Asphaltene content: Max. 14% by mass DIN 51595
calculated value based on
CCAI value: ≤ 860
density and viscosity
depends on vanadium
content, see diagram. ICP
Sodium content:
Range A is safe range (Inductively Coupled Plasma)
Range C must by avoided

 Additives on a non-mineral basis are not permitted (used lubricating oil, bituminous shale, coal
oil, vegetable oil, solvents, and waste from the chem. industry).
 State-of-the art separator systems and the manufacturer’s approval are necessary for
densities over 991 [kg/m3].
 Requirements and test methods for fuel before entering the engine.

Characteristic Dimension Limit Value Test method


Total [mg/kg] max. 20 *1
Inorganic additives
Al only [mg/kg] max. 5 *1 ICP or AAS *2
Water % by volume max. 0,2 ISO 3733

*1 Particle size < 5 [μm]


2
* ICP = Inductively Coupled Plasma
AAS = Atomic Absorption Spectroscopy
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 4(8)
Operation with residual oil requires specific engine and plant equipment, the main features of which
are as follows:
 Twin fuel filter with heating (indicator filter, mesh width 34 [μm] ball passage)
 Separately installed fuel pump for D628, D640 and D645
 Closed fuel system
 Automatic fuel back flush-filter (in the plant, mesh width 10 [μm] ball passage)
 Fuel preheating with viscosity-dependent control
 Automatic lubricant back flush-filter (in the plant, mesh width 34 [μm] ball passage) (not
required for D628 burning fuel RMA30 and RMB30)
 Cooled injectors above residual RME180 (≥ 80 [mm2/s] at 100 °C)

2 Notes on fuel
2.1 Ignition quality

For distillate fuels and some intermediate fuels, ignition quality is specified together with the cetane
number and limited to ≥ 40 for Wärtsilä Deutz engines. A cetane number which is too low may cause
starting difficulties, the formation of white smoke and higher HC emissions due to the long ignition
delay. Damage may also occur as a result of thermal and mechanical overloading.

If the cetane number is not specified (in the case of some intermediate fuels and residual oil), ignition
quality is determined by the CCAI value. This can be calculated based on the density ([kg/m3] at
15 °C) and kinematic viscosity ([mm2/s] at 50 °C) using the following nomogram.

The following limits apply:

Engine Permissible CCAI value


D234, D616, D604B, D620, D816 830 - 860
D628, D640, D645 ≤ 860

2.2 Fuel mixtures


When mixing residual fuels of different origin or bunkers, there is the risk of precipitations or
sediments. Fuels from different bunkers should therefore be kept apart.

2.3 Influence of fuel on performance


Non-distilled fuels almost always have a higher density than distillate fuels. This higher density would
- assuming a constant control rod/unchanged pump setting - lead to an (excessively) high power
output. Therefore the injection pump has to be readjust if a fuel is to be used which has a higher
density than on which the factory setting was based.
The work may only be carried out by Wärtsilä Services or an authorised
representative. Independent modification of the injection settings will render
any warranty claims invalid.

2.4 Fuel temperature


Depending on the type of fuel, preheating may be necessary:

 To ensure fuel pumping.


 To optimise fuel separation.
 To ensure proper injection viscosity.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 5(8)
2.4.1 Temperature required for fuel pumping

No particular measures are required for pure distillate fuels and intermediate fuel with regard to fuel
pumping qualities.

Distillates containing residual fuels need to be preheated to ensure pump ability. The fuel should be
heated so that it is at least 10 °C above the pour point, as otherwise there will be difficulties with
pumping.

The limit value for economical pumping (driving power, wear) of residual fuels is approx. 1000
[mm2/s].

2.4.2 Separating temperature

See section 2.6

2.4.3 Fuel temperature at injection pump inlet

Permitted maximum injection viscosity:

Engine Injection viscosity


D234, D616, D604B, D620, D816 max. 5 [mm2/s]
D628 15-17 [mm2/s]
D640, D645 9.5 - 12.0 [mm2/s]

Distillate fuels should enter the injection pump at a minimum temperature of 30 °C. Special
preheating is not normally required. If it is to be expected that (for example if the fuel is exposed to
low outside temperatures) the fuel viscosity in the mixing tank will be higher than the permitted
injection viscosity, the fuel should be preheated.

Intermediate fuels should always be preheated to reach the injection viscosity. With the engines
D628, D640 and D645, preheating is not required if intermediate fuel in accordance with DMB is used,
assuming that the temperature of the injection pump is at least 40 °C.

Residual fuels should always be preheated.

Preheating may be done


 Electrically with electric final pre-heater
(as many heating stages as possible, heat transfer per unit surface max. 1.1 [W/cm2])
 With steam through heat exchanger controlled by steam regulating valve
 With heat carrier oil via heat exchanger

Note for engines D234, D616, D604B, D620, and D816:

The injection pump of these engines permits a maximum outlet temperature of 80 °C. This means
with a Δt in the injection pump (inlet/outlet) of 30 °C a permissible inlet temperature of 50 °C.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 6(8)
2.5 Separation of fuels

Intermediate fuels must be separated. For marine applications separation of distillate fuels is
recommended with regard to water and sludge content.

Only the new generation of self-cleaning fuel separators should be used. These are highly effective
across a wide density spectrum and can effectively separate residual fuels up to a density of
1010 [kg/m3] at 15 °C. The separating effect is automatically monitored and the density-dependent
regulation occurs automatically.

Two separators are always required for fuel treatment (one of which is a reserve separator), whereby
each separator should be designed for 100% throughput. Single-stage and two-stage separation is
possible.

Required separating temperature:

Distillate Intermediate
Residual fuels
fuels fuels
DMA DMB RMA 30 RMD 80 RME 180 RMG 380 RMH 700
DMC RMB 30 RMF 180 RMH 380 RMK 700

20-40 °C 40-60 °C 75-98 °C 80-98 °C 90-98 °C 98 °C 98 °C

On principle, separators should be generously dimensioned in view of deteriorating fuel qualities.

If separators from Wärtsilä Deutz are supplied, optimum suitability is guaranteed. If the separators are
provided by the customer, the separator plant must be set up in consultation with the supplier.

2.6 Injector cooling system

The following engines are equipped with an injector cooling system:

D628 for operation with residual fuel from ISO 8217 RME180 (>80 [mm2/s] at 50 °C)
coolant pump, heat exchanger, tank and control installed separately.
For Wärtsilä Deutz D628 rebuild engines the injector cooling is omitted.

D640 for operation with residual fuel from ISO 8217 RME180 (>80 [mm2/s] at 50 °C)
n = constant: connected to the lube oil circuit of the engine
n = variable: coolant pump, heat exchanger, tank and control installed separately.

D645 for operation with intermediate fuel and residual fuel, connected to the lube oil circuit
of the engine.

In case of separate installation, observe the following:

 In the case of multi-engine plants, each engine should be provided with its own injector cooling
system.
 The cooling agent is lubricating oil
 In view of the high temperature level, a pressure system design is required.
 If engines are shut down without switching to distillate fuel (e.g. pier-to-pier operation) the
injector cooling system must remain switched on during the engine preheating phase.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 7(8)
2.7 Low-load operation with residual fuels

If highly supercharged engines are operated with residual fuels for a longer period of time - without
preventative measures being taken - below 20 % of the rated load, deposits can occur in the
combustion chambers, the exhaust area (as a result of incomplete combustion) and in the inlet area
(as a result of inward acting exhaust emissions). Contamination of the lubricating oil is a further
consequence.

These impairments can be avoided by limiting the amount of time that the engine is operated at low
load.

Limit curve applicable for generator and propeller operation

If the engine is operated below 20 % of its rated


output in the regulated range, it can be seen that
the sum of the daily low-load operating periods
does not exceed the amount shown in the
diagram.

Immediately following low-load operation, the


engine should be operated at 60 – 100 % of the
rated output, whereby the engine should not be
operated at full load for more than 1 hour per day.

A= Engine operation not permitted

B= Engine operation regulated

Bh/d = Operating hours per day

N % = Engine output as % of rated output

2.8 Shutting down and starting the engine


for operation with residual fuel

Every effort should be made to stop and start the engine with residual fuel (pier-to-pier operation). It
must be ensured, however, that the fuel treatment system continues in operation and that residual
fuel is circulated in the low-pressure system. The separately installed injector cooling system must
also continue in operation. The coolant must be heated up to at least 60 °C.

If repair work is planned on the fuel and injection system or if the engine is shut down for longer than
24 hours, the engine should be switched to distillate fuel before it is shut down. Distillate fuel should
be selected early enough to ensure that the fuel system and injection lines remain free of residual oil.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2089 8(8)
If residual oil becomes cold in the system and is no longer able to flow, the following measures must
be carried out with the fuel preheating system switched on:

 Remove the injection lines, heat up e.g. with hot air and clear using the injection valve
washing device.
 Clear the fuel low-pressure system and the injection pump with distillate fuel using the fuel
feeder pump or manual vane pump.

Ordering parts Contact your closest Wärtsilä Services Network. When ordering please
specify the engine serial number and the material numbers.

Letter distribution The Wärtsilä Services Network and users/owners of engines concerned.

Feedback E-mail to: service.sales.nl@wartsila.com

Letter validity Until further notice.


Herewith Technical Bulletin 'TB00/99/2089' - issue 01 has been cancelled.

Enclosures Enclosure 1: Explanation of main fuel properties,


Enclosure 2: Viscosity - Temperature sheet
Enclosure 3: Nomogram for determining CCAI value
Enclosures 4-6: Fuel specification

Disclaimer
This Technical Bulletin is designed to provide accurate and authoritative information with regard to the subject-matter covered as was
available at the time of printing. However, the publication deals with complicated technical matters suited only for specialists in the area and
the design of the subject-products is subject to regular improvements, modifications and changes. Consequently, Wärtsilä Netherlands B.V.
and/or any other Wärtsilä group company cannot accept any responsibility or liability for any eventual errors or omissions in this Technical
Bulletin or for discrepancies arising from the features of any actual item in the respective product being different from those shown in this
Technical Bulletin. Wärtsilä Netherlands B.V. and/or any other Wärtsilä group company shall under no circumstances be liable for any
damages or losses, or injury, suffered by any party making use of this Technical Bulletin or the information contained herein.
Explanation of main fuel properties Enclosure 1

Density
The density is normally specified in [kg/m3] or kg/m3 at 15°C and is important for converting fuel
consumption from units of volume to units of mass. The higher the density, the greater the mass of the
injected fuel. Assuming a constant control rod setting, the higher the density, the greater the engine
output.
Boiling curve
The boiling curve specifies what volume % of the fuel distils over at a certain temperature. The greater
the distillation residue (amount remaining after evaporation) the more combustion deposits can occur in
the engine, particularly with low-load operation.
Viscosity
The figure specified is the kinematic viscosity in [mm2/s] at a specific temperature (1 [mm2/s] = 1 cSt
[centistokes]). For operation of the engine the viscosity must remain within certain limits. If the viscosity
is too high, pre-heating is required.
Flash point
The flash point is of no significance to operation of the engine. It is used to determine the fire hazard
and is important for grading the fuel in one of the hazard classes (important for storage, transportation
and insurance).
Sulphur
High sulphur content and low component temperature can cause increased wear as a result of
corrosion. The sulphur content affects the regularity at which the lubricant has to be changed.
Carbon residue
The carbon residue provides a reference point with regard to the tendency to form deposits in the
combustion chamber.
Water
Too high a water content leads to corrosion and, in connection with corrosive products and sediments,
to sludge. Faults in the fuel and injection systems are the result.
Sediments
Sediments are solids (dust, rust, scale) which cause wear in the injection system and combustion
chamber as well as leaks in the valves.
Ash
Ash is carbon-free combustion residue which can become deposited in the engine and exhaust
turbocharger, resulting in wear.
Low-temperature behaviour
The following values give an indication of the suitability of the fuel for use at low temperatures.
 The solidification point specifies at which temperature the fuel will no longer flow under its own
weight.
 The pour point is approx. 3°C above the solidification point.
 The cloud point specifies at which temperature solid separations (paraffin) become visible.
 The limit value of filterability specifies at which temperature clogging of the filter and pipelines can
occur.
Ignition quality
The cetane number gives information on the ignition performance of the fuel. Too low a cetane
number can, for example, cause starting difficulties, white smoke, increased HC emissions and thermal
and mechanical overloading of the engine. The cetane number is calculated using a test engine.
If the cetane number is not specified the ignition quality is determined by the CCAI value. This is
calculated using the density ([kg/m3] at 15°C) and the kinematic viscosity ([mm2/s] at 50°C).
Heat value
The lower heat value specifies the heat quantity released when 1 [kg] of fuel is burnt.
Viscosity – Temperature sheet Enclosure 2

The diagram shows:


- The viscosity-temperature lines for a number of viscosity grades.
For residual fuels (ISO RM..) the viscosity is specified at 50 °C.
For distillate fuels (ISO DM..) the viscosity is specified at 40 °C.
The line for 380 [mm2/s] at 50 °C fuel for instance is the one running through points H and E.
Lines for fuels with other viscosities run parallel.
- The (horizontal) line at 1000 [mm2/s] above which pumping is difficult.
- The line with sharp bends through point G, which shows the minimum storage temperature for
all viscosity classes. For higher viscosity class fuels a higher storage viscosity is accepted to
limit the heating demand.
- The line with sharp bends through point F, shows the required centrifuging temperature. For
viscosity classes higher than 40 [mm2/s] at 50 °C a higher centrifuging viscosity than 14 [mm2/s]
is accepted to save heating power. Finally the line turns vertical at 98 °C because boiling of the
sealing and operating water in the centrifuge must be avoided. With further increase of viscosity
the throughput through the centrifuge must be reduced for maintaining the required degree of
purification.
Nomogram for determining CCAI value Enclosure 3
Fuel specification
(minimum requirements)
Enclosure 4
Diesel fuel in accordance with
EN 590 : 1999
Fuel specification
(minimum requirements)
Enclosure 5
Distillate and intermediate fuel in accordance with
ISO 8217:2005

Category ISO-F- Test method


Characteristic Unit Limit
DMX DMA DMB DMC a reference

ISO 3675 or
Density at 15 °C kg/m3 max. — 890,0 900,0 920,0
ISO 12185
min. 1,40 1,50 — — ISO 3104
Viscosity at 40 °C mm2/s b
max. 5,50 6,00 11,0 14,0 ISO 3104
min. — 60 60 60 ISO 2719
Flash point °C
min. 43 — — —
Pour point (upper) c
— winter quality °C max. — -6 0 0 ISO 3016
— summer quality max. — 0 6 6 ISO 3016
Cloud point °C max. -16 d — — — ISO 3015
ISO 8754 or
Sulfur % (m/m) max. 1,00 1,50 2,00 e 2,00 e ISO 14596
Cetane index — min. 45 40 35 — ISO 4264
Carbon residue
on 10 % (V/V) distillation
bottoms % (m/m) max. 0,30 0,30 — — ISO 10370
Carbon residue % (m/m) max. — — 0,30 2,50 ISO 10370
Ash % (m/m) max. 0,01 0,01 0,01 0,05 ISO 6245
Appearance f — — Clear and bright f —
Total sediment, existent % (m/m) max. — — 0,10 f 0,10 ISO 10307-1
Water % (V/V) max. — — 0,3 f 0,3 ISO 3733
ISO 14597 or IP 501
Vanadium mg/kg max. — — — 100
or IP 470
ISO 10478 or IP 501
Aluminium plus silicon mg/kg max. — — — 25
or IP 470
Used lubricating oil (ULO) The fuel shall
be free of
ULO g
- Zinc mg/kg max. — — — 15 IP 501 or IP 470
- Phosphorus mg/kg max. — — — 15 IP 501 or IP 500
- Calcium mg/kg max. — — — 30 IP 501 or IP 470
a Note that although predominantly consisting of distillate fuel, the residual oil proportion can be significant.
b 1 mm2/s  1 cSt
c Purchasers should ensure that this pour point is suitable for the equipment on board, especially if the vessel operates in bot h the
northern and southern hemispheres.
d This fuel is suitable for use without heating at ambient temperatures down to  16 °C.
e A sulfur limit of 1,5 % (m/m) will apply in SOx emission control areas designated by the International Maritime Organization, when
its relevant protocol enters into force. There may be local variations, for example the EU requires that sulphur content of certain distillate
grades be limited to 0,2 % (m/m) in certain applications.
f If the sample is clear and with no visible sediment or water, the total sediment existent and water tests shall not be required.
g A fuel shall be considered to be free of used lubricating oils (ULOs) if one or more of the elements zinc, phosphorus and cal cium
are below or at the specified limits. All three elements shall exceed the same limits before a fuel shall be deemed to contain ULOs.
Category ISO-F-
Characteristic Unit Limit RMA RMB RMD RME RMF RMG RMH RMK RMH RMK Test method reference
30 30 80 180 180 380 380 380 700 700

Density at 15 °C kg/m3 max. 960,0 975,0 980,0 991,0 991,0 1010,0 991,0 1010,0 ISO 3675 or ISO 12185

Kinematic viscosity at 50 °C mm 2/s a max. 30,0 80,0 180,0 380,0 700,0 ISO 3104
Flash point °C min. 60 60 60 60 60 ISO 2719

Pour point (upper) b


- winter quality °C max. 0 24 30 30 30 30 ISO 3016
- summer quality max. 6 24 30 30 30 30 ISO 3016
Carbon residue % (m/m) max. 10 14 15 20 18 22 22 ISO 10370
Ash % (m/m) max. 0,10 0,10 0,10 0,15 0,15 0,15 ISO 6245
Water % (V/V) max. 0,5 0,5 0,5 0,5 0,5 ISO 3733
c
Sulfur % (m/m) max. 3,50 4,00 4,50 4,50 4,50 ISO 8754 or ISO 14596

ISO 14597 or IP 501 or


Vanadium mg/kg max. 150 350 200 500 300 600 600
IP 470
Total sediment potential % (m/m) max. 0,10 0,10 0,10 0,10 0,10 ISO 10307-2
ISO 10478 or IP 501 or
Aluminium plus silicon mg/kg max. 80 80 80 80 80
IP 470
ISO 8217:2005

Used lubricating oil (ULO) The fuel shall be free of ULO d


Fuel specification

- Zinc max. 15 IP 501 or IP 470


mg/kg
- Phosphorus max. 15 IP 501 or IP 500
(minimum requirements)

- Calcium max. 30 IP 501 or IP 470

a Annex C gives a brief viscosity/temperature table, for information purposes only. 1 mm2/s  1 cSt
b
Residual marine fuel in accordance with

Purchasers should ensure that this pour point is suitable for the equipment on board, especially if the vessel operates in both the northern and southern hemispheres.
c A sulfur limit of 1,5 % (m/m) will apply in SO x emission control areas designated by the International Maritime Organization, when its relevant protocol comes into force. There may be local
variations.
d A fuel shall be considered to be free of ULO if one or more of the elements zinc, phosphorus and calcium are bel ow or at the specified limits. All three elements shall exceed the same limits
before a fuel shall be deemed to contain ULO.
Enclosure 6
Wärtsilä Deutz
Expendables
TBD645

4.3 Engine lube oil


See Technical Bulletin TB00/99/2090.

For this engine, the values and particulars for the S/BVM 628 engine apply analogously.

1012 0299 4627-0108 Chapter 4 Page 3 of 6


Wärtsilä Deutz
Expendables
TBD645

This page is intentionally left blank.

Chapter 4 Page 4 of 6 0299 4627-0108 1012


TECHNICAL
BULLETIN
Services, Wärtsilä Netherlands B.V.
Engine section Engine type Ref. Date Issue Document No. Page
99 Service information See below WNL-Services 01.05.2 012 03 TB00/99/2090 1(6) + encl.

Lubricating oil
Engine types D234, D510, D528, D540, D604, D604B, D616, D620, D628, D640,
D645, D716, D816
Original bulletin TC 0199-99-2090 6th exchange dated 20.09.2002
Change number n/a

6th exchange Made for the following reasons:


 Change Section 1
 Change Section 2
 Corrections lube oil tables in enclosure

Issue 02 Update of the scope of application.

Issue 03 Update of the approved lubricating oil lists.

Scope of application:

In case engine types are not listed in the various tables, please refer to:

Engine type See engine type


510 645
528 628
540 640
716 816

In case you need further clarification, please contact your Wärtsilä Service Network Company.

Table of contents Enclosure


1 Lube oil grade Lube oil tables D628, D640, D645 and
2 Lube oil viscosity D616, D620
3 Lube oil change intervals
4 Servicing of the engine-mounted lube oil filter
5 Lube oil for seal oil system

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2090 2(6)
1 Lube oil grade
For the engines of series D234, D616, D816, D604, D604B and D620, lube oils according to the
existing specifications have been determined. In the enclosure, some reference oils are indicated,
with which positive operating results have been achieved.
For the use in engines of series D628, D640 and D645, the enclosure comprises reference lube oils.
Here, the assignment depends on the fuel type of the engine.
Lube oils not indicated but having the same capacity level as those mentioned in the enclosure can
be used upon agreement with the oil producer and – compulsory during the warranty period – with the
approval of Wärtsilä Deutz.
The indicated lube oil grades are minimum requirements. Higher quality levels can be used.
The manufacturer is responsible for supplying lube oils of constant quality and with those additives
which were the basis for the release.

1.1 Engine series D234, D616, D816, D604, D604B, D620


The lube oils must at least meet the following lube oil specifications:
Engine Lube oil specifications *2
Engine
ACEA API
D234
E2-96, E3-96 CF, CF-4
D816
E4-99, E5-99 CG-4,CH-4
D604/D604B

Engine speed n > 2100/min Lube oil quality grade I


D616
Engine speed n ≤ 2100/min Lube oil quality grade II
D620
Power group Power range eff. average
pressure Pme
Genset engines in
50 Hz: > 100 kW/cyl. > 18,0 bar
cont. operation
60 Hz: > 120 kW/cyl. > 18,0 bar
> 4 000 op. h/year
Genset engines in
50 Hz: > 110 kW/cyl. > 19,8 bar
peak load operation
60 Hz: > 126 kW/cyl. > 19,0 bar
> 1 000 op. h/year.
Ship drive in rapid Lube oil quality grade I
> 124 kW/cyl. n=1860/min > 18,0 bar
ferries and rapid
> 120 kW/cyl. n=1800/min > 18,0 bar
commercial boats
> 110 kW/cyl. n=1650/min > 18,0 bar
> 3 000 op. h/year
Ship drive for non-
commercial ships
> 130 kW/cyl. n=1860/min > 19,0 bar
(official ships,
> 127 kW/cyl. n=1800/min > 19,0 bar
yachts)
> 1 000 op. h/year
All other engines Lube oil quality grade II

Lube oil quality grade Engine Lube oil specifications *2


I ACEA E4-99
II ACEA E3-96, E5-02 API CF-4, CG-4, CH-4
*2 It is sufficient, if one of the mentioned specifications is met.

Some reference lube oils of lube oil quality grades I and II can be taken from the enclosure.
In lube oil quality grade I, only fully or partly synthetic oils are permitted to be used.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2090 3(6)

1.2 Engine series D628, D640, D645


For engines of series D628, we recommend the use of fuels with a sulphur content of less than
0.2 % by weight to avoid the formation of glazing in the cylinder liners, preferably the use of lube oils
of quality class API CG-4 or API CH-4.
For mixed fuels with sulphur contents > 1.0%, we recommend for the first filling to use an oil with a
TBN of 40 mg/KOH/g, for sulphur contents ≤ 1.0%, a TBN of 30 mg/KOH/g.
To achieve the maximally possible economic operation, for refilling, an oil with lower or higher TBN is
permitted to be used. The producers of mineral oil must be involved in this measure, who give their
recommendations on the basis of regular analyses of the used oils. Moreover, the according limit
values must be observed (see section 3.2).
According to our experience, when being refilled, the engine D645 rather needs an oil with a TBN of
40 mg/KOH/g, the engines D628 and D645, however, rather an oil with a TBN of 30 mg/KOH/g.
When using anti-corrosive oil (emergency genset), contact the parent company.

2 Lube oil viscosity


Selection of the lube oil viscosity shall be based on SAE-classification J 300 9/87 (Society of
Automotive Engineers). Selection of the SAE-class does not give any indication of the oil grade.

2.1 Engine series D234, D616, D816, D604, D604B, D620


The ambient temperature is decisive for selection of the proper SAE-class. Multi-grade oils may be
used for all-year application (summer and winter), e.g. SAE 15W-40.

Viscosity specification:

2.2 Engine series D628, D640, D645


Generally for these engines viscosity class SAE 40 is specified. All-temperature oils SAL 10W-40 or
15W-40 can also be used, provided these oils are indicated in the list of lube oils or are equivalent.

The D628 engines in operation, which were previously operated with a lube oil viscosity of SAE 30
(previous version: oil cooler upstream of charge air cooler), may be operated with SAE 40 or SAE
10W-40 or SAE 15W-40 as from now on.

3 Lube oil change intervals


The oil should be changed only with the engine warmed up to service temperature; the oil is then
highly fluid and drains off much better.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2090 4(6)
3.1 Engine series D234, D616, D816, D604, D604B, D620
The first lube oil change after initial commissioning or re-commissioning following major repair work
shall be effected after 50 running hours at the latest. Thereafter the following lube oil change intervals
shall be adhered to:

Mounted centrifugal lube oil filter


without with
Engine Type of fuel
Distillate fuel MDF mixed oil Distillate fuel MDF mixed oil
ISO 8217 DMB ISO 8217 DMB
D234 500 op. hrs. 250 op. hrs.
TBD 234 250 op. hrs. 125 op. hrs.
D616 250 op. hrs. 125 op. hrs. 500 op. hrs. 250 op. hrs.
D816 250 op. hrs. 500 op. hrs.
D604/B 250 op. hrs. 125 op. hrs. 500 op. hrs. 250 op. hrs.
D620 250 op. hrs. 125 op. hrs. 500 op. hrs. 250 op. hrs.

Oil change once a year at a minimum.


The oil change interval may be extended depending on the engine operating mode and the lube oil
grade.
This must be determined by a series of used-oil analyses. The lube oil must be changed in any case if
one of the following limit values is not reached or exceeded:
Kinematic viscosity at 100°C (DIN 51 562)
Lube oil SAE 30, SAE .. W-30 min. 9,3 mm2/s (cSt)
Lube oil SAE 40, SAE ... W-40 min. 12,5 mm2/s (cSt)
Viscosity increase max. 25% of value when new
Flash point (DIN EN 22719) min. 180°C
Total contamination (DIN 51365 corr. to centrifuge) max. 2.0% by mass
Water content (DIN 51777) max. 0.2% by mass
Total base number (DIN ISO 3771) min. 50% of value when new

3.2 Engine series D628, D640, D645


In the case of these engines, a lube oil change always takes place after a previous used oil analysis.
Upon agreement with the mineral oil producer, the lube oil must be partly replaced or exchanged, if
one of the limit values is exceeded or fallen below. For engines D628 operated with distillate fuel
(entire oil volume in the oil pan), we generally recommend a lube oil change after 5 000 op. hours,
irrespective of the result of the used oil analysis.
If, upon operation with mixed fuel, the TBN-value should fall below the indicated minimum value,
refilling is possible with a lube oil having a TBN-value of 40 mgKOH/g or 50 mgKOH/g (freshening
up), see section 1.2.
Kinematic viscosity at 100°C (DIN 51 562)
Lube oil SAE 40 min. 12,5 mm2/s (cSt)
Viscosity increase max. 25% of value when new
Flash point (DIN EN 22719) min. 180°C
Total contamination (DIN 51365 corr. to centrifuge) max. 1.5% by mass
Water content (DIN 51777) max. 0.2% by mass
Total base number (DIN ISO 3771)
with distillate fuel min. 6 mgKOH/g
with mixed fuel with a sulphur content S ≤1% by wt. min. 12 mgKOH/g
with mixed fuel with a sulphur content S > 1% by wt. min. 18 mgKOH/g
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2090 5(6)
3.3 Used-oil analysis
The oil sample shall be representative of the entire oil filling and shall be taken in good time before
the oil change becomes due (see operation manual). It is best to start a series of analyses during or
shortly after commissioning so as to define a possible variation of the lube oil depending on the
duration of engine operation.
The oil analysis must be made for engines D628 and D640 at least every 500 operating hours, for
engines D645 at least every 1000 operating hours.
The used-oil analysis can be carried out in the laboratories of the oil producers, institutes or at
Wärtsilä Deutz.
The Wärtsilä Deutz test kit allows quick determination of the lube oil grade. This quick test permits a
trend definition of the lube oil variation. The Wärtsilä Deutz test kit with part No. DZ12130382 is
obtainable from the Wärtsilä Service Network.
4 Servicing of the engine-mounted lube oil filters
Lube oil filter servicing is to be carried out as follows (see also relevant operation manual):

D234
Changing oil filter element 50 running hours after commissioning of new or overhauled engine,
thereafter every 500 running hours, after 1 year at the latest
D616
Changing oil filter element 50 running hours after commissioning of new or overhauled engine,
thereafter every 500 running hours,
Cleaning centrifugal lube oil 50 running hours after commissioning of new or overhauled engine,
filter thereafter every 250 running hours, at least after 1 year
D604, D604B, D620
Cleaning strainer
50 running hours after commissioning of new or overhauled engine,
Changing throw-away
thereafter every 500 running hours, at least after 1 year
filter/element
Cleaning centrifugal lube oil 50 running hours after commissioning of new or overhauled engine,
filter thereafter every 250 running hours, at least after 1 year
D816
Cleaning strainer
50 running hours after commissioning of new or overhauled engine,
Changing throw-away
thereafter every 500 running hours
filter/element
Cleaning centrifugal lube oil 50 running hours after commissioning of new or overhauled engine,
filter thereafter every 250running hours
D628
Lube oil filter combination:
 Operating edge-type filter daily
 Cleaning filter chamber every 1,500 running hours
 Paper filter: Changing 50 running hours after commissioning of new or overhauled engine,
paper element thereafter when the permissible differential pressure is exceeded, at the
latest after every
3,000 running hours with distillate fuel operation
1,500 running hours with intermediate fuel operation
Cleaning centrifugal lube oil 50 running hours after commissioning of new or overhauled engine,
filter thereafter every 250 running hours
D640, D645
Cleaning strainer candles 500 running hours after commissioning of new or overhauled engine,
thereafter every 6000 running hours *
* For engine D640 in standby < 300 op. hs./year after all 150 op. hs. at the latest 0,5 years.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2090 6(6)

The quoted service intervals are guide values. The service intervals may have to be reduced
depending on the type of application and mode of operation of the engine.

5 Lube oil for seal oil system


For engines which are provided with separate seal oil system (D628, D640) a lube oil with a low TBN
should be used. Suitable lube oils may be taken from the enclosure. Lube oils conforming to
comparable specifications not listed here are also permissible.

Ordering parts Contact your closest Wärtsilä Service Unit. When ordering parts please specify
the engine serial number and the material numbers.

Letter distribution The Wärtsilä Services Network and users/owners of engines concerned.

Feedback E-mail to: service.sales.nl@wartsila.com

Letter validity Until further notice.


Herewith Technical Bulletin TB00/99/2090 – issue 02 has been cancelled.

Enclosure Enclosure : Lube oil tables D628, D640, D645 and D616, D620

Disclaimer
This Technical Bulletin is designed to provide accurate and authoritative information with regard to the subject-matter covered as was
available at the time of printing. However, the publication deals with complicated technical matters suited only for specialists in the area and
the design of the subject-products is subject to regular improvements, modifications and changes. Consequently, Wärtsilä Netherlands B.V.
and/or any other Wärtsilä group company cannot accept any responsibility or liability for any eventual errors or omissions in this Technical
Bulletin or for discrepancies arising from the features of any actual item in the respective product being different from those shown in this
Technical Bulletin. Wärtsilä Netherlands B.V. and/or any other Wärtsilä group company shall under no circumstances be liable for any
damages or losses, or injury, suffered by any party making use of this Technical Bulletin or the information contained herein.
Enclosure
Lube oil tables
TB00/99/2090
Services, Wärtsilä Netherlands B.V.
Page 1/ 2

Engine lube oil D628, D640, D645


Fuel type Classification of the fuels as per TB00/99/2089
Supplier Distillate fuel and Mixed fuel
Mixed fuel (Heavy Fuel Oil)
(MDO; MDF)
(Viscosity SAE 40)
(Viscosity SAE 40 bzw . ... W-40)
Brand name TBN Brand name TBN
Agip CLADIUM 120 12 Agip CLADIUM 300 30
Agip
- Agip CLADIUM 400 40
BP Energol HPDX 40 12 BP Energol IC-HFX304 30
BP BP Vanellus C3 10.5 BP Energol IC-HFX404 40
- BP Energol IC-HFX504 50
Castrol MHP 154 15.5 Castrol TLX 304 30
Castrol CRD-DB 40 10.6 Castrol TLX 404 40
Castrol
Castrol Seamax Extra 40 12 Castrol TLX 504 50
- Castrol TLX 554 55
- CEPSA Troncoil3040 plus 30
CEPSA - CEPSA Troncoil4040 plus 40
- CEPSA Troncoil5040 plus 50
Delo 1000 MARINE 40 12 Delo 3000 MARINE 40 30
Taro 16 XD 40 16 Delo 3400 MARINE 40 40
Chevron Taro 16 XD 15W-40 16 Taro 30 DP 40 30
- Taro 40 XL 40 40
Taro 50 XL 40 50
ESSOLUBEXT 401
13.3 EXXMAR30TP 40 30
(SAE15W-40)
EXXMAR CM Super 40 15 EXXMAR40TP 40 40
Mobilgard ADL 16 Mobilgard 430 30
Mobilgard HSD 10.5 Mobilgard M 430 30
ExxonMobil
- Mobilgard 440 40
- Mobilgard M 440 40
- Mobilgard 50 M 50
- Mobilgard M 50 50
- Mobilgard SP 55 55
Antar Milantar MT 11 Elf Aurelia 4030 30
Total Rubia TIR 4000 11 Elf Aurelia 4040 40
Total Total Neptuna 11 Fina Aurelia 4030 30
Fina Caprano TD 11 Fina Aurelia 4040 40
Fina Disola M 4015 14 -
Fuchs Titan SDX 11 -
Europe Titan HD Superior 11 -

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com
Enclosure
Lube oil tables
TB00/99/2090
Services, Wärtsilä Netherlands B.V.
Page 2/ 2
Engine lube oil D628, D640, D645
Fuel type Classification of the fuels as per TB00/99/2089
Supplier Distillate fuel and Mixed fuel
Mixed fuel (Heavy Fuel Oil)
(MDO; MDF)
(Viscosity SAE 40)
(Viscosity SAE 40 bzw . ... W-40)
Brand name TBN Brand name TBN
Repsol YPF Neptuno NT
- 30
3000
Repsol YPF
Repsol YPF Neptuno NT
- 40
4000
Shell Sirius FB 40 13 Shell Argina T 40 30
Shell
Shell Gadinia AL 40 15 Shell Argina X 40 40

Lube oil for seal oil system D628, D640, D645


Supplier
(Viscosity SAE 30)
Brand name TBN
Agip Agip ACER 100 -
Agip CLADIUM 50 5
BP BP EnergoI OE- HT 30 6
Castrol Castrol Marine CDX30 5
Chevron VERITAS800MARINE30 5
ExxonMobil EXXMARXA 6
Mobilgard 300 6
Total FINA ALCANO 308 5
Fuchs Europe Renolin MR 30 4
Shell Shell Melina S 30 5

Engine lube oil D616, D620


Lube oil quality Lube oil specifications
grade It is sufficient, if one of the indicated Supplier / Brand name
specifications is met.
Shell Rimula Ultra 5
I ACEA E4-99 Mobil Mobilgard 1 SHC 5
Mobil Delvac 1 SHC
Shell Rimula Super
Shell Sirius X
ACEA E3-96, E5-02
BP Energol HPDX
II
API CF-4, CG-4, CH-4 Mobil Delvac HP
ChevronTexaco Ursa
SuperTD

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com
Wärtsilä Deutz
Expendables
TBD645

4.4 Engine Coolant


See Technical Bulletin TB00/99/2091.

1012 0299 4627-0108 Chapter 4 Page 5 of 6


Wärtsilä Deutz
Expendables
TBD645

This page is intentionally left blank.

Chapter 4 Page 6 of 6 0299 4627-0108 1012


TECHNICAL
BULLETIN
Services, Wärtsilä Netherlands B.V.
Engine section Engine type Ref. Date Issue Document No. Page
99 Service information Various Service 19.10.2010 03 TB00/99/2091 1(6) + encl.

D232, D234, D350,


D358, D440, D441,
D444, D484, D500,
D510, D501, D511,
D518, D528, D540, Engine coolant for
D545, D601, D602, medium and large
D603, D604(B), D616,
D618, D620, D628,
size engines
D640, D645, D716,
D816, D2016, D18/22,
PA6
Original bulletin TC 0199-99-2091 5th exchange dated 07.01.2004
TC 0199-38-2115 dated 12.02.1999
Change number n/a
The 5th exchange is issued amongst other things because of a

• Revision of the data on water quality


• Introduction of the DEUTZ protective agent for cooling circuit in 20 litre cans
• Updating of product recommendations, Enclosure.
Issue 02 is issued because of the combination with TC 0199-38-2115.
Issue 03 is issued because of the change, the extension, of applicability.

Table of Content:
1. General ............................................................................................................................. 2
2. Water quality ..................................................................................................................... 2
3. Protective agents for cooling circuit ................................................................................... 3
3.1 Chemical anti corrosion agents................................................................................... 3
3.2 Antifreeze agents with corrosion inhibitors ................................................................. 4
3.3 Corrosion inhibitors ..................................................................................................... 5
4. Details on cooling circuit.................................................................................................... 5
4.1 Monitoring of cooling circuit ........................................................................................ 5
4.2 Cleaning of cooling circuit ........................................................................................... 6
4.3 Coolant disposal ......................................................................................................... 6
Enclosure 1 .............................................................................................................................. 1
Enclosure 2 .............................................................................................................................. 1

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2091 2(6)

1. General
Coolants of liquid-cooled engines must be treated and monitored since damage may be sustained by
the engine otherwise due to:
• Corrosion
• Cavitation
• Freezing

2. Water quality
The correct water quality is important for the preparation of the coolant. If no specifications are
provided by the manufacturer/supplier, clear and clean water must be used within the following limit
values of analysis:

Limit values of analysis min. max.


pH value at 20°C 6.5 8.5
Chloride ion content mg/dm3 - 100
Sulphate ion content mg/dm3 - 100
Total hardness *1 °dGH 3 12

*1 Share of carbonate hardness in the overall hardness min. 3°dGH.


For more information on the water quality please consult your local waterworks or use the DEUTZ test
kit, Order No. DZ12130382.
Water treatment is indicated if water qualities differ from the above indicated limit values of analysis.
• pH value too low
Add diluted caustic soda or potash lye and mix.
Preparation of small sample mixtures is recommended.
• Total water hardness too high
Mix with softened water *2
• Total hardness and/or carbonate hardness too low
Mix with water of a higher hardness *3

• Chloride and/or sulphate content too high


Mix with softened water *2
*2 Softened water is distilled water, pH-neutral condensate or water treated by ion exchangers.
*3 Water of a higher hardness is available in most cases in form of potable water (town water).
Use the DEUTZ test kit (order No. DZ12130382) for a determination, if the limit values of analysis of
the water to be admixed are unknown.
For safety reasons it is mandatory to carry out another water analysis after water treatment.
Sea water, river water, brackish water or industrial waste water are in no case suitable
for the preparation of the coolant since damage may be sustained by the engine.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2091 3(6)

3. Protective agents for cooling circuit


The coolant is prepared by adding a protective agent to the cooling water as a protection of the
cooling circuit. The following additives are commonly used:
• Chemical anticorrosion agent
• Antifreeze agent with corrosion inhibitors
• Corrosion inhibiting oil

The type of additive can be selected according to the following table:

Chemical Antifreeze agent with Corrosion


anticorrosion agent corrosion inhibitors inhibiting oil
Protection against
Good Good Good
corrosion
Protection against
Satisfactory Satisfactory Good
cavitation
Protection against Up to -45 ºC according to
None None
freezing mixing ratio
Maintenance
Low Low *4 Very high
requirement
Operation reliabilty Good Good Insufficient
Costs Medium Very high Medium

*4 Only the antifreeze effect is checked normally, to be exchanged every 2 years.


Enclosure 1 lists up some representative products which are recommended by us and which as
indicated by the manufacturers/suppliers are suitable for the processing of coolants. Also other
equivalent products of other manufacturer/suppliers may be used as an alternative. Suitability of the
protective agent for the cooling circuit must be warranted/guaranteed by the manufacturer/supplier.
No liability is accepted by us.
The various protective agents for the cooling circuit are described below.

3.1 Chemical anti corrosion agents

Chemical anticorrosion agents are compounds which by way of chemical reaction form a protective
film on the metal surfaces. Their advantage compared to corrosion inhibiting oils lies in the ease of
application and monitoring.

Liquid additives may be admixed directly in the engine; additives in powder form are to be pre-mixed.
The manufacturer’s instructions must be adhered to with regard to the concentration of the chemical
anticorrosion agent and subsequent monitoring.

The manufacturer/supplier shall warrant that his additives do not have a detrimental effect on the
materials used in the engine (e.g. seals/gaskets).

Be careful with aluminium components in the cooling circuit. Not all chemical anticorrosion agents are
suitable in such cases; correct dosing is of particular importance since too low a concentration of the
chemical anticorrosion agent will have a damaging effect on the system. Also considered in the list of
recommended products (see Enclosure 1) is the suitability of the anticorrosion agent for engines with
aluminium components.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2091 4(6)

Make sure that aluminium components are property grounded , no additional electric currents may be
induced by these aluminium components via defective insulations (single pole sensors and monitoring
sensors).
Chemical anticorrosion agents containing silicates may have a negative effect on the service life of
the axial-face seals. Such products should only be used for engines which separately mounted
coolant pumps equipped with seals which are resistant to these chemical anticorrosion agents.
Filter systems are available as an alternative, capable of filtering out solid particles from the cooling
circuit in addition to providing a protection against corrosion. These filters contain a chemical
anticorrosion agent in solid form which is gradually dissolved in the cooling water.
Chemical anticorrosion agents and antifreezes as per Section 3.2 are compatible.
Not all chemical anticorrosion agents and antifreeze agents are compatible. Carcinogenic
nitrosamines will form when mixing amine based chemical anticorrosion agents with
nitrate based antifreeze agents. For compatibility please consult the manufacturer/
supplier. Most of the recommended chemical anticorrosion agents may be mixed with the
antifreeze agent from DEUTZ antifreeze based on ethylene glycol) without incurring any
risk.

3.2 Antifreeze agents with corrosion inhibitors


Antifreeze agents are generally used for DEUTZ engines only if ambient temperatures below zero are
likely to occur. The antifreeze agent may be added to the chemical anticorrosion agent
(manufacturer/supplier to be contacted for compatibility) or may be added to the water as the only
protective agent against freezing and corrosion. Antifreeze agents based on ethylene glycol are used
in general. The anticorrosive substances contained in the antifreeze are agents which prevent
corrosion by forming a protective film on the surface of the components.
Provide for the following concentrations:

Antifreeze agent 10% 15% 20% 25% 30% 35% 40% 45% 50%
Water 90% 85% 80% 75% 70% 65% 60% 55% 50%
Antifreeze
-4 ºC -7 ºC -10 ºC -13 ºC -18 ºC -22 ºC -28 ºC -35 ºC -45 ºC
effective up to

When the antifreeze agent is used as the only anticorrosion agent (without any chemical anticorrosion
agent) it must be left in the coolant both during winter and summer time; minimum concentration 35%.

Use of antifreeze reduces the heat transfer coefficient (thermal capacity) of the coolant.
Check whether the cooling circuit is laid out accordingly.
Admixture of a corrosion inhibiting oil emulsion is not permissible.
Best results are obtained with the DEUTZ protective agent for cooling circuits as an antifreeze
with anticorrosion inhibitors. This ethylene glycol based protective agent for cooling circuits is
matched to the materials used on DEUTZ medium and large size engines and is subject to permanent
control and monitoring. This agent is obtainable from the Wärtsilä Netherlands service organisation
and is supplied in form of
Description Material number
5 litre containers DZ01011490
20 litre containers DZ01016416
210 litre barrel DZ12211500
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2091 5(6)

If the DEUTZ protective agent for the cooling circuit should not be available for important reasons
such as supply restrictions abroad, other products may be used in exceptional cases. Such alternative
products have been grouped together in product groups and are listed up in enclosure 1. Products of
the same product group may be mixed. Products of different product groups may not be mixed. The
entire cooling circuit must be cleaned thoroughly before a product change.

3.3 Corrosion inhibitors


Use of corrosion inhibiting oils is a problem because of the poor stability of the emulsion, the resulting
difficulties in monitoring and the potential damage involved.
Corrosion inhibiting oils are emulsive mineral oils with additives which form a thin protective film on
the components of the cooling circuit preventing corrosion and furring.
The emulsion must be prepared in a container outside the engine cooling water circuit adding the
specified amount of corrosion inhibiting oil to the water stirring the mixture thoroughly. Concentration
as specified by the manufacturer/supplier.
Loss of coolant to be made up for, excessively low concentrations of corrosion inhibiting oil to be
compensated by adding a highly concentrated emulsion.
Corrosion inhibiting oils must not be used for:
• Cooling circuits with connection to a comfort heating system
• Gas engines

4. Details on cooling circuit


4.1 Monitoring of cooling circuit
The cooling circuit must be checked regularly (see current Operating Instructions) which includes
checking for contamination and checking of the coolant level as well as the concentration of the
protective agents of the cooling circuit.
• Chemical anticorrosion agent
Check concentration; suitable tools for testing such as test rods are supplied by the
manufacturers/suppliers.
• Antifreeze agent with corrosion inhibitors
Check antifreeze and anticorrosion effects with antifreeze tester.

• Corrosion inhibiting oil


Check concentration of corrosion inhibiting oil with refractometer, check condition of emulsion.
Renew coolant always in case of:
• Ingress of raw water
• Ingress of lube oil
• Pronounced turbidity due to corrosion residues or other suspended matter
• A spent corrosion inhibiting emulsion
• The antifreeze agent to be renewed every 2 years.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
03 T B00/99/2091 6(6)

4.2 Cleaning of cooling circuit


The cooling circuit must be cleaned if contaminated, corrosion inhibiting oil emulsion is spent or in the
case of lube oil or raw water ingress. The entire coolant must be drained in such as case and the
cooling circuit must be flushed using a suitable detergent. The cooling circuit must also be cleaned
when changing over to another type of protective agent for the cooling circuit.
Suitable detergents are offered on the market, suitability must be guaranteed by the manufacturer/
supplier, however.

4.3 Coolant disposal


The coolant must not be drained into the sewage system. Disposal to be taken care of by a company
specialised in waste disposal in accordance with the national legal requirements and the instructions
of the manufacturer/supplier.
For disposal of the DEUTZ protective agent for the cooling circuit within the Federal
Republic of Germany please refer to Annex 3 (published in German only).

Ordering parts According the standard ordering procedure as described in the engine
specific parts catalogue.

Reporting Reporting according Wärtsilä guidelines is mandatory.


Send your work report to Wärtsilä Netherlands B.V.
The adress is mentioned at frontpage bottom.

Applies to All Wärtsilä – Deutz Marine engines.

Letter distribution The Wärtsilä Service Network and all users/owners of Wärtsilä – Deutz
Marine engines.
(No paper copies distributed).

Feedback E-mail to: service.sales.nl@wartsila.com

Letter validity Herewith Technical Circular 0199-99-2091 4th exchange of 11.05.2001 has
been cancelled.

Enclosure Encl. 1: Recommended products, Protective agents for cooling circuit.


Encl. 2: Technical Circular 0199-38-2115

Disclaimer
This Technical Bulletin is designed to provide accurate and authoritative information with regard to the subject-matter covered as was
available at the time of printing. However, the publication deals with complicated technical matters suited only for specialists in the area and
the design of the subject-products is subject to regular improvements, modifications and changes. Consequently, Wärtsilä Netherlands B.V.
and/or any other Wärtsilä group company cannot accept any responsibility or liability for any eventual errors or omissions in this Technical
Bulletin or for discrepancies arising from the features of any actual item in the respective product being different from those shown in this
Technical Bulletin. Wärtsilä Netherlands B.V. and/or any other Wärtsilä group company shall under no circumstances be liable for any
damages or losses, or injury, suffered by any party making use of this Technical Bulletin or the information contained herein.
Enclosure 1

Recommended Products
Protective agents for cooling circuits

Antifreeze Agents with Corrosion inhibitors

Product group A: for medium and large size engines


Product group B: for medium size engines

Product Manufacturer /
Product name Notes / Available in
group Supplier
Cooling system protective agent:
DEUTZ AG Material number DZ01011490 5 litre container
Material number DZ01016416 20 litre container
Material number DZ12211500 210 litre barrel
ARAL Antifreeze Extra
AVIA Antifreeze APN
BASF Glysantin G48/Protect Plus
BUCHER (Schweiz) Motorex Antifreeze Protect Plus G48
INA Industrija INA Antifriz AL Super
The Burma OIL Castrol Antifreeze NF
A FUCHS EUROPE FUCHS FRICOFIN
TOTAL ELF Glacelf MDX
OMV OMV coolant plus
Shell GlycoShell
VALVOLINE G48 Antifreeze
Veedol Veedol Antifreeze NF
BP BP antif-frost Code No. X 2270 A
Hunold Kühlerschutz ANF
INEOS Napgel C2270/1
Mobil Frostschutz 600
AGIP Antifreeze special
Europe,
ARTECO / Texaco Havoline XLC
South-America
CALTEX Havoline XLC Asia, Australia
ChevronTexaco Chevron Extended Life Coolant
B
Orvema B.V. Orvema Protex LL Netherlands
ELF Glacelf Auto Supra
TOTAL
Total Organifreeze
Havoline Extended Life Coolant USA, w/o Nitrit and
Texaco USA (HELAC) Molybdenum
Extended Life Coolant (TELC) USA, with Nitrit
Chemical anticorrosion agents
Manufacturer / Product name Diesel Diesel Notes
Supplier engines: engines:
D232, D234, D350, D358,
D518, D601, D440, D441,
D602, D603, D444, D484,
D604(B), D500, D501,
D616, D618, D510, D511,
D620, D716, D528, D540,
D816, D545, D628,
D18/22, D640, D645,
D2016 PA6
BEDIA Bedia Liquid BL1 * - X
Bedia BS/BT mit BP1 * - X Filter systems
Bedia BL2 X X
DREW AMEROID DEWT-NC - X Powder
Liquidewt - X
Maxiguard - X
Fuchs FUCHS ANTICORIT
X
S 2000 A
Housemann Limited Cooltreat 651 * - X
NALFLEET 9-108 - X
9-111 * - X
9-131 C - X
See
REICON ODACON Z X X
enclosure 2
Perry Liquid Perry * - X
(W. Lösing) Perry Filter * Filter systems
Texaco Havoline XLI X X
Total Total WT Supra X X
UNITOR ASA Dieselguard NB Pulver - X Not to be mixed
with antifreeze
ROCOR NB Liquid - X agent
Vecom CWT Diesel / QC 2 - X
* Product contains silicates

Corrosion inhibiting oils (not for gas engines)


Manufacturer / Product name Diesel engines: Notes
Supplier All Wärtsilä – Deutz
Marine engines.
DEUTSCHE Castrol CASTROL PRODUCT 481/43 X
Deutsche Shell AG Shell 9156 X
ESSO AG Kutwell 40 X
Mobil Coolant inhibitor X
Enclosure 2

Original Technical circular 0199-38-2115, dated 12.02.1999

Chemical anticorrosion agent for medium and big engines

The chemical anticorrosion agent ODACON ®Z released as alternative to the chemical anticorrosion
agents previously approved for all medium and big engines (diesel and gas versions) in accordance
with Technical Circular TR 0199-99-2091, 3rd Exchange. This product is obtainable from:

REICON® Wärmetechnik und Wasserchemie Leipzig GmbH


Lagerhofstraße 2
D-04103 Leipzig

Telephone : +49 (0)341/6491 20


Fax : +49 (0)341/6491 260
E-mail : info@reicon.de
Internet : www.reicon.de

ODACON ®Z forms a protective film on the metal surfaces and may be used in coo ling circuits without
or with aluminium components. The sealing materials installed in DEUTZ medium and big engines are
not attacked by ODACON ® Z. Simultaneous use of antifreeze agents on ethylene glycol basis (e.g.
DEUTZ cooling system protection) is permissible. Mixing with other chemical anticorrosion agents is
not permissible.

The agent is to be used and proportioned in accordance with the supplier's instructions. The
ODACON ® Z active ingredient concentration should be determined by way of extra action analysis
with the help of a colour comparison card or photometer. This should be done for the first time about 1
month after initial proportioning. Any replacement of components requires secondary proportioning.

It is mandatory to observe the supplier's instructions for disposal of ODACON® Z. It is possible to


obtain a safety data sheet.
Wärtsilä Deutz
Maintenance
TBD645

5 Maintenance 4
5.1 Maintenance plan
5.1.1 General remarks
5.1.2 Maintenance categories
5.1.3 Explanation of symbols “ToDo”
5.1.4 Specific Maintenance Plan
5.1.4.1 Maintenance Plan I
Operation with distillate and mixed fuel
(without Grade 4-D), ship and unit
5.1.4.2 Hour matrix I
5.1.4.3 Maintenance Plan II
Operation with residual oil and mixed fuel Grade 4-
D, ship
5.1.4.4 Hour matrix II
5.1.4.5 Maintenance Plan III
Operation with residual oil and mixed fuel Grade 4-
D, unit
5.1.4.6 Hour matrix III
5.1.4.7 Maintenance and servicing as per instructions from
component manufacturers
5.1.5 Action as necessary

5.2 Tools
5.2.1 Standard tools
5.2.2 Special tools and devices
5.2.3 Other equipment
5.2.3.1 Cleaning agents
5.2.3.2 Water treatment agents

1012 0299 4628-0108 Chapter 5 Page 1 of 2


Wärtsilä Deutz
Maintenance
TBD645

This page is intentionally left blank.

Chapter 5 Page 2 of 2 0299 4628-0108 1012


TBD 645 Maintenance

5 Maintenance 5
5.1 Maintenance plan
5.1.1 General remarks
The maintenance plan lists the work routines required for maintaining your engine’s operational reliability and
safety, together with the appropriate maintenance intervals in each case. This maintenance plan applies for
the engine itself only, and of course for its built-on components. Maintenance on other parts of your system
must be carried out at the times specified and in accordance with the work instructions issued by the
manufacturer concerned. You will find the relevant information in the manufacturers’ documents supplied in
each case. The job cards stated will describe the procedural sequences for the maintenance work involved.
The work described must be performed by properly trained staff. The intervals stated are average figures, and
based on long years of empirical feedback from actual operation. They are conditional on proper compliance
with the relevant expendables instructions and on punctual performance of the maintenance work concerned.

The intervals concerned may vary due to particular operating conditions. For example, frequent starts,
long operating times at zero load, an excessive number of load changes, and frequent operation at
overload will lead to increased wear and tear, and to concomitantly shorter maintenance intervals.
You must perform cleaning routines more frequently if you are encountering increased soiling.

5.1.2 Maintenance categories


Category: Performed by:

E10 Initial maintenance,


after commissioning and E50, E60, E70 authorised qualified personnel
E20 daily check patrol operator
E22 additional check patrol operator
E23 Maintenance work as per plan operator
E30 Inspection authorised qualified personnel
E35 Maintenance work as per plan authorised qualified personnel
E40 1st extended inspection authorised qualified personnel
E50 2nd extended inspection authorised qualified personnel
E60 Intermediate overhaul authorised qualified personnel
E65 Maintenance work as per plan authorised qualified personnel
E70 Major overhaul authorised qualified personnel

• After Maintenance Categories E20 to E50 have been repeatedly performed, then an intermediate overhaul
(E60) must be carried out after the time interval specified in each case has been reached. Depending on
the condition of the engine concerned, a major overhaul (E70) will be required after reaching approximately
double the number of operating hours (oh).
• Keep an eye on the number of operating hours your system has been running, so as to check when a new
maintenance category has to be performed. Well in advance, agree a scheduled maintenance date with the
service people responsible for you. When agreeing a date, please also inform us of any irregularities which
may have occurred in your system (see any operation monitoring log).
• To make things easier for you, we offer you an option for concluding a maintenance agreement. Please talk
to our service department about it. You can request authorized skilled staff from DEUTZ Service Division,
for example.

© 1200 0299 4628-0108 Chapter 5 - Page 3


Maintenance TBD 645

5 5.1.3 Explanation of symbols “ToDo”

“Visual inspection” “Drain”


visual check; e.g. lube oil, water
adjustment work, reworking or replacing
may become necessary. “Clean”
e.g. by hand / automatically
“Measure - Adjust”
e.g. torques, dimensions, pressures, etc.; “Grease - Lubricate”
reworking or replacing may become e.g. rod assemblies
necessary.
“Overhaul”
“Replace” Checking function groups, reworking
replace, change parts and replacing wear parts

5.1.4 Specific Maintenance Plan


This engine has been built solely for the purpose corresponding to the scope of delivery – as defined by the
equipment manufacturer (use as prescribed). Depending on the particular purpose involved, the engine is
identified by a performance symbol, as per DIN ISO 3046. See Chapter 2 for performance symbol.
Maintenance Plan I
Operation with distillate and mixed fuel (without Grade 4-D), ship and unit

Inspection Maintenance work 1st extended 2nd extended Intermediate Maintenance work Major
as per plan inspection Inspection overhaul as per plan overhaul

every 1,000 oh every 3,000 oh every 6,000 oh every 9,000 oh every 18,000 oh every 24,000 oh every 36,000 oh

Maintenance Plan II
Operation with residual oil and mixed fuel Grade 4-D, ship

Inspection Maintenance work 1st extended 2nd extended Intermediate Maintenance work Major
as per plan inspection inspection overhaul as per plan overhaul

every 1,000 oh every 3,000 oh every 6,000 oh every 9,000 oh every 18,000 oh every 24,000 oh every 36,000 oh

Maintenance Plan III


Operation with residual oil and mixed fuel Grade 4-D, unit

Inspection Maintenance work 1st extended 2nd extended Intermediate Maintenance work Major
as per plan inspection inspection overhaul as per plan overhaul

every 1,000 oh every 2,500 oh every 5.000 oh every 7,500 oh every 15,000 oh every 24,000 oh every 36.000 oh

Chapter 5 - Page 4 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.1 Maintenance Plan I 5


Operation with distillate and mixed fuel (without Grade 4-D), ship and unit
When the number of operating hours specified in the following maintenance plan has been reached, the
routines stated in the description must be carried out.

E10 E20 E22 E23 E30 E35 E40 E50 E60 E65 E70 Description ToDo JC
every 50…250 oh
every 24 h (daily)

every 18,000 oh

every 24,000 oh

every 36,000 oh
every 1,000 oh

every 3,000 oh

every 6,000 oh

every 9,000 oh
once after …

every 250 oh

x Expendables supplies B 0-1-1


x Operating values B 0-1-2
x Drain air cylinder B 10-7-1
x Turbocharger compressor B 6-12-1
x x x x x x x x Anti-corrosion/antifreeze agent proportion in coolant B 9-1-1
x x x x x x x x Engine diagnostics B 0-2-5
x x x x x x x x Valve rotating device B 1-3-1
100 oh x x x x x x x Valve clearance 1) B 1-1-1
250 oh x x x x x x x Lube oil analysis B 8-1-1
x x x x x x x Air filter B 6-3-1
x x x x x x x Lube oil in turbocharger B 6-6-2
x x x x x x x Monitor B 11-1-22 ff
x x x x x x x Gear train (drive end) B 4-4-4
x x x x x x Engine mounting B 3-7-1
x x x x x x Lube oil, speed governor/actuator B 5-3-1
x x x x x x Valve seat lubrication B 8-14-1
x x x x x x Mechanical face seal, coolant pump B 9-7-2
x x x x Injection nozzle B 7-7-2
x x x x Regulating shaft B 5-4-1
x x x x Backwash filter (engine end) B 8-10-3
x x x x Exhaust valves W 1-5-3
x x x Baffle screw W 7-4-13
x x Axial clearance of crankshaft W 2-1-4
x x Gear train (free end) B 4-4-2
x x Gear train (drive end) B 4-4-4
x x Lower valve actuator W 4-2-1
x x Camshaft bearing W 4-1-1
x x Inlet valves W 1-5-2
x x Piston top W 2-9-6
x x Piston pin clearance W 2-12-3
x x Piston rings, grooves W 2-10-3
x x Cylinder liner W 3-3-1
x x Conn.-rod bearing W 2-9-3
x x Injection pump element and seal W 7-4-2
x x Vibration absorber, camshaft (unit) ** W 4-9-1

1) Check valve clearance additionally 1x after 100 oh after valve replacement


* only 6 and 8 cyl. / ** only 9 cyl.

© 1200 0299 4628-0108 Chapter 5 - Page 5


Maintenance TBD 645

E10 E20 E22 E23 E30 E35 E40 E50 E60 E65 E70 Description ToDo JC
every 50…250 oh
every 24 h (daily)

every 18,000 oh

every 24,000 oh

every 36,000 oh
every 1,000 oh

every 3,000 oh

every 6,000 oh

every 9,000 oh
once after …

every 250 oh

x Vibration absorber, camshaft (ship) ** W 4-9-1


x Rotary vibration absorber * W 12-1-4
x Governor, bearing W 5-3-5
x Main bearing W 2-7-2
Replacement times for turbocharger components: see manufacturer’s
documentation

* only 6 and 8 cyl. / ** only 9 cyl.

Chapter 5 - Page 6 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.2 Hour matrix I 5


Hours Maintenance category Date Signature
250 E23
500 E23
750 E23
1,000 E30
1,250 E23
1,500 E23
1,750 E23
2,000 E30
2,250 E23
2,500 E23
2,750 E23
3,000 E35
3,250 E23
3,500 E23
3,750 E23
4,000 E30
4,250 E23
4,500 E23
4,750 E23
5,000 E30
5,250 E23
5,500 E23
5,750 E23
6,000 E40
6,250 E23
6,500 E23
6,750 E23
7,000 E30
7,250 E23
7,500 E23
7,750 E23
8,000 E30
8,250 E23
8,500 E23
8,750 E23
9,000 E50
9,250 E23
9,500 E23
9,750 E23
10,000 E30
10,250 E23
10,500 E23
10,750 E23
11,000 E30
11,250 E23
11,500 E23
11,750 E23
12,000 E40

© 1200 0299 4628-0108 Chapter 5 - Page 7


Maintenance TBD 645

5
Hours Maintenance category Date Signature
12,250 E23
12,500 E23
12,750 E23
13,000 E30
13,250 E23
13,500 E23
13,750 E23
14,000 E30
14,250 E23
14,500 E23
14,750 E23
15,000 E35
15,250 E23
15,500 E23
15,750 E23
16,000 E30
16,250 E23
16,500 E23
16,750 E23
17,000 E30
17,250 E23
17,500 E23
17,750 E23
18,000 E60
18,250 E23
18,500 E23
18,750 E23
19,000 E30
19,250 E23
19,500 E23
19,750 E23
20,000 E30
20,250 E23
20,500 E23
20,750 E23
21,000 E35
21,250 E23
21,500 E23
21,750 E23
22,000 E30
22,250 E23
22,500 E23
22,750 E23
23,000 E30
23,250 E23
23,500 E23
23,750 E23
24,000 E65

Chapter 5 - Page 8 0299 4628-0108 © 1200


TBD 645 Maintenance

5
Hours Maintenance category Date Signature
24,250 E23
24,500 E23
24,750 E23
25,000 E30
25,250 E23
25,500 E23
25,750 E23
26,000 E30
26,250 E23
26,500 E23
26,750 E23
27,000 E50
27,250 E23
27,500 E23
27,750 E23
28,000 E30
28,250 E23
28,500 E23
28,750 E23
29,000 E30
29,250 E23
29,500 E23
29,750 E23
30,000 E40
30,250 E23
30,500 E23
30,750 E23
31,000 E30
31,250 E23
31,500 E23
31,750 E23
32,000 E30
32,250 E23
32,500 E23
32,750 E23
33,000 E35
33,250 E23
33,500 E23
33,750 E23
34,000 E30
34,250 E23
34,500 E23
34,750 E23
35,000 E30
35,250 E23
35,500 E23
35,750 E23
36,000 E70

Number of maintenance categories up to major overhaul


E23 E30 E35 E40 E50 E60 E65 E70
Total: 108 24 4 3 2 1 1 1

© 1200 0299 4628-0108 Chapter 5 - Page 9


Maintenance TBD 645

5 This page intentionally left blank.

Chapter 5 - Page 10 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.3 Maintenance Plan II 5


Operation with residual oil and mixed fuel Grade 4-D, ship
When the number of operating hours specified in the following maintenance plan has been reached, the
routines stated in the description must be carried out.

E10 E20 E22 E23 E30 E35 E40 E50 E60 E65 E70 Description ToDo JC
every 50…250 oh
every 24 h (daily)

every 18,000 oh

every 24,000 oh

every 36,000 oh
every 1,000 oh

every 3,000 oh

every 6,000 oh

every 9,000 oh
once after …

every 250 oh

x Expendables supplies B 0-1-1


x Operating values B 0-1-2
x Drain air cylinder B 10-7-1
x Turbocharger compressor B 6-12-1
2)
x Turbocahrger turbine B 6-13-1
3)
x Control rod, manual free movement check -
x x x x x x x x Anti-corrosion/antifreeze agent proportion in coolant B 9-1-1
x x x x x x x x Engine diagnostics B 0-2-5
x x x x x x x x Valve rotating device B 1-3-1
100 oh x x x x x x x Valve clearance1) B 1-1-1
250 oh x x x x x x x Lube oil analysis B 8-1-1
x x x x x x x Air filter B 6-3-1
x x x x x x x Lube oil in turbocharger B 6-6-2
x x x x x x x Monitor B 11-1-22 ff
x x x x x x x Gear train (drive end)) B 4-4-4
x x x x x x Engine mounting B 3-7-1
x x x x x x Lube oil, speed governor/actuator B 5-3-1
x x x x x x Valve seat lubrication B 8-14-1
x x x x x x Mechanical face seal, coolant pump B 9-7-2
x x x x Injection nozzle B 7-7-2
x x x x Fuel lines of control rod lubrication B 7-2-3
x x x x Control unit and fuel pressure of control rod lubrication B 7-2-4
x x x x Leakage fuel lines B 7-3-4
x x x x Regulating shaft B 5-4-1
x x x x Backwash filter (engine end) B 8-10-3
x x x x Exhaust valves W 1-5-3
x x x Baffle screw W 7-4-13
x x Axial clearance of crankshaft W 2-1-4
x x Gear train (free end) B 4-4-2
x x Gear train (drive end) B 4-4-4
x x Lower valve actuator W 4-2-1
x x Camshaft bearing W 4-1-1
x x Inlet valves W 1-5-2
x x Piston top W 2-9-6
x x Piston pin clearance W 2-12-3
x x Piston rings, grooves W 2-10-3
x x Cylinder liner W 3-3-1
x x Conn.-rod bearing W 2-9-3
x x Injection pump element and seal W 7-4-2
1) Check valve clearance additionally 1x after 100 oh after valve replacement
2) Cleaning may become necessary earlier, depending on the quality of the fuel involved
3) every time the turbocharger turbine is cleaned

© 1200 0299 4628-0108 Chapter 5 - Page 11


Maintenance TBD 645

E10 E20 E22 E23 E30 E35 E40 E50 E60 E65 E70 Description ToDo JC
every 50…250 oh
every 24 h (daily)

every 18,000 oh

every 24,000 oh

every 36,000 oh
every 1,000 oh

every 3,000 oh

every 6,000 oh

every 9,000 oh
once after …

every 250 oh

x Vibration absorber, camshaft (ship) ** W 4-9-1


x Rotary vibration absorber * W 12-1-4
x Governor, bearing W 5-3-5
x Main bearing W 2-7-2
Replacement times for turbocharger components: see manufacturer’s
documentation

* only 6 and 8 cyl. / ** only 9 cyl.

Chapter 5 - Page 12 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.4 Hour matrix II 5


Hours Maintenance category Date Signature
250 E23
500 E23
750 E23
1,000 E30
1,250 E23
1,500 E23
1,750 E23
2,000 E30
2,250 E23
2,500 E23
2,750 E23
3,000 E35
3,250 E23
3,500 E23
3,750 E23
4,000 E30
4,250 E23
4,500 E23
4,750 E23
5,000 E30
5,250 E23
5,500 E23
5,750 E23
6,000 E40
6,250 E23
6,500 E23
6,750 E23
7,000 E30
7,250 E23
7,500 E23
7,750 E23
8,000 E30
8,250 E23
8,500 E23
8,750 E23
9,000 E50
9,250 E23
9,500 E23
9,750 E23
10,000 E30
10,250 E23
10,500 E23
10,750 E23
11,000 E30
11,250 E23
11,500 E23
11,750 E23
12,000 E40

© 1200 0299 4628-0108 Chapter 5 - Page 13


Maintenance TBD 645

5
Hours Maintenance category Date Signature
12,250 E23
12,500 E23
12,750 E23
13,000 E30
13,250 E23
13,500 E23
13,750 E23
14,000 E30
14,250 E23
14,500 E23
14,750 E23
15,000 E35
15,250 E23
15,500 E23
15,750 E23
16,000 E30
16,250 E23
16,500 E23
16,750 E23
17,000 E30
17,250 E23
17,500 E23
17,750 E23
18,000 E60
18,250 E23
18,500 E23
18,750 E23
19,000 E30
19,250 E23
19,500 E23
19,750 E23
20,000 E30
20,250 E23
20,500 E23
20,750 E23
21,000 E35
21,250 E23
21,500 E23
21,750 E23
22,000 E30
22,250 E23
22,500 E23
22,750 E23
23,000 E30
23,250 E23
23,500 E23
23,750 E23
24,000 E65

Chapter 5 - Page 14 0299 4628-0108 © 1200


TBD 645 Maintenance

5
Hours Maintenance category Date Signature
24,250 E23
24,500 E23
24,750 E23
25,000 E30
25,250 E23
25,500 E23
25,750 E23
26,000 E30
26,250 E23
26,500 E23
26,750 E23
27,000 E50
27,250 E23
27,500 E23
27,750 E23
28,000 E30
28,250 E23
28,500 E23
28,750 E23
29,000 E30
29,250 E23
29,500 E23
29,750 E23
30,000 E40
30,250 E23
30,500 E23
30,750 E23
31,000 E30
31,250 E23
31,500 E23
31,750 E23
32,000 E30
32,250 E23
32,500 E23
32,750 E23
33,000 E35
33,250 E23
33,500 E23
33,750 E23
34,000 E30
34,250 E23
34,500 E23
34,750 E23
35,000 E30
35,250 E23
35,500 E23
35,750 E23
36,000 E70

Number of maintenance categories up to major overhaul


E23 E30 E35 E40 E50 E60 E65 E70
Total: 108 24 4 3 2 1 1 1

© 1200 0299 4628-0108 Chapter 5 - Page 15


Maintenance TBD 645

5 This page intentionally left blank.

Chapter 5 - Page 16 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.5 Maintenance Plan III 5


Operation with residual oil and mixed fuel Grade 4-D, unit
When the number of operating hours specified in the following maintenance plan has been reached, the
routines stated in the description must be carried out.

E10 E20 E22 E23 E30 E35 E40 E50 E60 E65 E70 Description ToDo JC
every 50…250 oh
every 24 h (daily)

every 15,000 oh

every 24,000 oh

every 36,000 oh
every 1,000 oh

every 2,500 oh

every 5,000 oh

every 7,500 oh
once after …

every 250 oh

x Expendables supplies B 0-1-1


x Operating values B 0-1-2
x Drain air cylinder B 10-7-1
x Turbocharger compressor B 6-12-1
2)
x Turbocharger turbine B 6-13-1
3)
x Control rod, manual free movement check -
x x x x x x x x Anti-corrosion/antifreeze agent proportion in coolant B 9-1-1
x x x x x x x x Engine diagnostics B 0-2-5
x x x x x x x x Valve rotating device B 1-3-1
100 oh x x x x x x Valve clearance1) B 1-1-1
250 oh x x x x x x Lube oil analysis B 8-1-1
x x x x x x Air filter B 6-3-1
x x x x x x Lube oil in turbocharger B 6-6-2
x x x x x x Monitor B 11-1-22 ff
x x x x x x Gear train (drive end) B 4-4-4
x x x x Engine mounting B 3-7-1
x x x x Lube oil, speed governor/actuator B 5-3-1
x x x x Valve seat lubrication B 8-14-1
x x x x Mechanical face seal, coolant pump B 9-7-2
x x Injection nozzle B 7-7-2
x x Fuel lines of control rod lubrication B 7-2-3
x x Control unit and fuel pressure of control rod lubrication B 7-2-4
x x Leakage file lines B 7-3-4
x x Regulating shaft B 5-4-1
x x Backwash filter (engine end) B 8-10-3
x x Exhaust valves W 1-5-3
x x Baffle screw W 7-4-13
x Axial clearance of crankshaft W 2-1-4
x Gear train (free end) B 4-4-2
x Gear train (drive end) B 4-4-4
x Lower valve actuator W 4-2-1
x Camshaft bearing W 4-1-1
x Inlet valves W 1-5-2
x Piston top W 2-9-6
x Piston pin clearance W 2-12-3
x Piston rings, grooves W 2-10-3
x Cylinder liner W 3-3-1
x Conn.-rod bearing W 2-9-3

1) Check valve clearance additionally 1x after 100 oh after valve replacement


2) Cleaning may become necessary earlier, depending on the quality of the fuel involved
3) every time the turbocharger turbine is cleaned

© 1200 0299 4628-0108 Chapter 5 - Page 17


Maintenance TBD 645

E10 E20 E22 E23 E30 E35 E40 E50 E60 E65 E70 Description ToDo JC
every 50…250 oh
every 24 h (daily)

every 15,000 oh

every 24,000 oh

every 36,000 oh
every 1,000 oh

every 2,500 oh

every 5,000 oh

every 7,500 oh
once after …

every 250 oh

x Injection pump element and seal W 7-4-2


x Vibration absorber, camshaft (unit) ** W 4-9-1
x Rotary vibration absorber * W 12-1-4
x Governor, bearing W 5-3-5
x Main bearing W 2-7-2
Replacement times for turbocharger components: see manufacturer’s
documentation

* only 6 and 8 cyl. / ** only 9 cyl.

Chapter 5 - Page 18 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.6 Hour matrix III 5


Hours Maintenance category Date Signature
250 E23
500 E23
750 E23
1,000 E30
1,250 E23
1,500 E23
1,750 E23
2,000 E30
2,250 E23
2,500 E35
2,750 E23
3,000 E30
3,250 E23
3,500 E23
3,750 E23
4,000 E30
4,250 E23
4,500 E23
4,750 E23
5,000 E40
5,250 E23
5,500 E23
5,750 E23
6,000 E30
6,250 E23
6,500 E23
6,750 E23
7,000 E30
7,250 E23
7,500 E50
7,750 E23
8,000 E30
8,250 E23
8,500 E23
8,750 E23
9,000 E30
9,250 E23
9,500 E23
9,750 E23
10,000 E40
10,250 E23
10,500 E23
10,750 E23
11,000 E30
11,250 E23
11,500 E23
11,750 E23
12,000 E30

© 1200 0299 4628-0108 Chapter 5 - Page 19


Maintenance TBD 645

5
Hours Maintenance category Date Signature
12,250 E23
12,500 E35
12,750 E23
13,000 E30
13,250 E23
13,500 E23
13,750 E23
14,000 E30
14,250 E23
14,500 E23
14,750 E23
15,000 E60
15,250 E23
15,500 E23
15,750 E23
16,000 E30
16,250 E23
16,500 E23
16,750 E23
17,000 E30
17,250 E23
17,500 E35
17,750 E23
18,000 E30
18,250 E23
18,500 E23
18,750 E23
19,000 E30
19,250 E23
19,500 E23
19,750 E23
20,000 E40
20,250 E23
20,500 E23
20,750 E23
21,000 E30
21,250 E23
21,500 E23
21,750 E23
22,000 E30
22,250 E23
22,500 E50
22,750 E23
23,000 E30
23,250 E23
23,500 E23
23,750 E23
24,000 E65

Chapter 5 - Page 20 0299 4628-0108 © 1200


TBD 645 Maintenance

5
Hours Maintenance category Date Signature
24,250 E23
24,500 E23
24,750 E23
25,000 E40
25,250 E23
25,500 E23
25,750 E23
26,000 E30
26,250 E23
26,500 E23
26,750 E23
27,000 E30
27,250 E23
27,500 E35
27,750 E23
28,000 E30
28,250 E23
28,500 E23
28,750 E23
29,000 E30
29,250 E23
29,500 E23
29,750 E23
30,000 E60
30,250 E23
30,500 E23
30,750 E23
31,000 E30
31,250 E23
31,500 E23
31,750 E23
32,000 E30
32,250 E23
32,500 E35
32,750 E23
33,000 E30
33,250 E23
33,500 E23
33,750 E23
34,000 E30
34,250 E23
34,500 E23
34,750 E23
35,000 E40
35,250 E23
35,500 E23
35,750 E23
36,000 E70

Number of maintenance categories up to major overhaul


E23 E30 E35 E40 E50 E60 E65 E70
Total: 101 27 5 5 2 2 1 1

© 1200 0299 4628-0108 Chapter 5 - Page 21


Maintenance TBD 645

5 This page intentionally left blank.

Chapter 5 - Page 22 0299 4628-0108 © 1200


TBD 645 Maintenance

5.1.4.7 Maintenance and servicing as per instructions from component manufacturers 5


Check and clean drive compartment monitor

after ... operating hours or interval * Description

500 1,500 6,000


(monthly *) (quarterly *) (yearly *)
Underpressure in the
measuring chamber B 11-5-1
Sinter bronze filter in the
measuring add-on B 11-5-1
Fresh air bores in the
measuring add-on B 11-5-1
Infra-red filter glasses in
the measuring add-on B 11-5-1
Sinter bronze filter in the
pressure controller B 11-5-1

* if the operating hours specified are not achieved in the corresponding interval.

5.1.5 Action as necessary

Reasons

Action

After maintenance work on bearings, pistons, cylinder liners:


- Follow running-in instructions W 0-1-3

After opening the covers, check the seal and replace if necessary:
- Inspection hole cover and control shaft cover B 3-1-4

Cylinder liners: examine valve wear status, without removing the cylinder head
or the valves beforehand:
- Endoscope the combustion chamber W 0-2-7

After any extensive work on the drive mechanism or after fitting/modifying a generator,
for instance:
- Check crank web breathing W 2-1-5

Repair is required, e.g. if the tappet roller is defective or the injection pump drive
has jammed:
- Remove and install injection pump drive W 7-4-7

After levers have been loosened, they must be re-adjusted at the set screw
(lead-sealed in the factory):
- Adjust the injection pump control rod W 7-2-2

© 1200 0299 4628-0108 Chapter 5 - Page 23


Maintenance TBD 645

5 This page intentionally left blank.

Chapter 5 - Page 24 0299 4628-0108 © 1200


TBD 645 Maintenance

5.2 Tools 5
The sections below contain particulars of the tools and equipment which you will need for the maintenance
jobs involved.

5.2.1 Standard tools


Toolbox (Ill. 501)
Standard basic kit
Ordering Number 1215 0000

80061 0

Ill. 501 Toolbox

Toolbox (Ill. 502)


Standard additional kit
Ordering Number 1215 0001

80062 0

Ill. 502 Toolbox


© 1200 0299 4628-0108 Chapter 5 - Page 25
Maintenance TBD 645

5 Tool chest, wood (Ill. 503)


Contains toolsets in three boxes
Ordering Number 1243 0501
These three sets of tools are also available separately:
Toolbox
Special basic kit, Part 1
Ordering number 1243 0502
Toolbox
Special basic kit, Part 2
Ordering Number 1243 0503
Toolbox
Set of hydro screw pretensioning systems
Ordering Number 1218 5038

80063 0

Ill. 503 Tool chest, wood


Chapter 5 - Page 26 0299 4628-0108 © 1200
TBD 645 Maintenance

Contents of toolbox 5
Standard basic kit
Ordering Number 1215 0000
No. pcs. Designation
1 1 Toolbox C 1602/01 approx. 445 x 185 x 55 mm
2 1 Spanner 8 x 10 DIN 3110
3 1 Spanner 12 x 14 DIN 3110
4 1 Spanner 14 x 15 DIN 3110
5 2 Spanner 13 x 17 DIN 3110
6 2 Spanner 19 x 22 DIN 3110
7 2 Spanner 24 x 27 DIN 3110
8 1 Spanner 30 x 32 DlN 3110
9 1 Spanner 13 x 17 DIN 838
10 1 Spanner 19 x 22 DIN 838
11 1 Spanner 24 x 27 DIN 838
12 1 Feeler gauge 0.05 - 1 mm x 100 mm
13 1 Insert 10 x 12.5 DIN 3124
14 1 Insert 13 x 12.5 DIN 3124
15 1 Insert 14 x 12.5 DIN 3124
16 1 Insert 17 x 12.5 DIN 3124
17 1 Insert 19 x 12.5 DIN 3124
18 1 Insert 22 x 12.5 DIN 3124
19 1 T-handle A 12.5 DIN 3122
20 1 Extension B 12.5 x 250 DIN 3123
21 1 Cardan joint C 12.5 DIN 3123
22 1 Screwdriver A 0.8 x 5.5 x 125 DIN 5265
23 1 Screwdriver A 1 x 7 x 150 DIN 5265

© 1200 0299 4628-0108 Chapter 5 - Page 27


Maintenance TBD 645

5 Contents of toolbox
Standard additional kit
Ordering Number 1215 0001
No. pcs. Designation
1 1 Toolbox C 1603/02 approx. 505x215x105 mm
2 1 Spanner No. 2 SW 46 DIN 894
3 1 Spanner No. 2 SW 55 DIN 894
4 1 Spanner 36 x 41 DIN 3110
5 1 Insert 24 x 20 DIN 3124
6 1 Insert 27 x 20 DIN 3124
7 1 Insert 30 x 20 DIN 3124
8 1 Insert 32 x 20 DIN 3124
9 1 Insert No. 60 SW 36 4kt 25
10 1 Insert No. 60 SW 41 4kt 25
11 1 Slide head No. 886 A 4kt 25
12 1 Extension B 25x200 DIN 3123
13 1 Extension B 25x400 DIN 3123
14 1 Cardan joint C 20 DIN 3123
15 1 Attachment A 20 x 12.5 DIN 3123
16 1 Attachment A 20 x 25 DIN 3123
17 1 Attachment A 25 x 20 DIN 3123
18 1 Torque wrench 0 - 21 daNm
19 1 Extension lever 0 - 42 daNm
20 1 Extension lever 0 - 63 daNm
21 1 Pipe grip
22 1 Ratchet head 4kt 12.5 / 0 - 40 daNm
23 1 Ratchet head 4kt 20 / 0 - 100 daNm
24 1 Screwdriver 3 DIN 911
25 1 Screwdriver 4 DIN 911
26 1 Screwdriver 5 DIN 911
27 1 Screwdriver 6 DIN 911
28 1 Screwdriver 8 DIN 911
29 1 Screwdriver SW 3/16"
30 1 Pliers A 10 DIN 5254
31 1 Pliers A 19 DIN 5254
32 1 Pliers B 10 DIN 5254
33 1 Pliers C 19 DIN 5256
34 1 Pliers C 40 DIN 5256
35 1 Screwdriver D 1.2 x 9 DIN 5265
36 1 Screwdriver D 1.6 x 11 DIN 5265
37 1 Cleaning brush
38 1 Insert 33x10
39 1 Insert 34x12
40 1 Insert 35x14
41 1 Mandrel for loosening the inserts
42 1 Insert 15 x 12,5 DIN 3124
43 1 Set of feeler gauges 0.05 to 1 mm

Chapter 5 - Page 28 0299 4628-0108 © 1200


TBD 645 Maintenance

Contents of the tool chest 5


Contains sets of tools in three boxes
Ordering Number 1243 0501
Box 1 contents: set of tools
Special basic kit Part 1
(separate Ordering Number 1243 0502)
No. pcs. Designation
1 1 Toolbox (112 kg), 950 x 600 x 440 mm
2 1 Insert, SW 46 x 25 DIN 3124, for counterweight screws
3 1 Insert, SW 50 x 25, extra-deep, for cylinder head screws
4 1 Spanner, SW 50 DIN 894, for screw union at the starting air line
5 1 Extension lever, 3.5-fold, for torque wrench
6 1 Plug-on extension, ARD 28 / ARD 30x238, for 1" slide head
7 1 Slide head, 1"
8 1 Hydraulics pump, 3000 bar, on baseplate, with pressure gauge 0-2500 bar
9 1 High-pressure pipe
10 1 Extension pipe, R 1/8": R 1/4"
11 1 Spanner, SW 24 cpl., for loosening the rear injection pump mounting
12 1 Device for lowering the bearing covers
13 1 Device for lifting off the injection pump
14 1 Relief valve lift-out device for injection pump
15 1 Clamp for removing the piston
16 1 Piston ring pliers
17 1 Ring for installing the pistons
18 1 High-pressure grease gun
19 1 Device for installing and removing inlet and exhaust valves, exhaust valve housings
20 1 Tool for grinding the inlet and exhaust valves
21 8 Raising screw for tappetl
22 1 Insert, SW 41, 3/4" 4 sq.
23 1 Socket spanner insert, SW 8, 1/2" 4 sq.
24 1 Plug-in handle for indicator valve
25 1 Bolt drawer for connecting rod bolts
26 1 Face spanner for plug at vibration absorber
27 1 Tapping tube for sampling at vibration absorber
28 1 Tommy bar, A 8 DIN 900

Box 1 offers space for the following sets of tools, which must be ordered separately:
1 Set of tools Standard basic kit
1 Set of tools Standard additional kit

© 1200 0299 4628-0108 Chapter 5 - Page 29


Maintenance TBD 645

5 Box 2 contents: set of tools


Special basic kit Part 2
(separate Ordering Number 1243 0503)
No. pcs. Designation
1 1 Toolbox
2 1 Socket spanner, SW 50, for cylinder head screws
3 1 Pliers, J 5 DIN 5256, for piston bolt circlips
4 1 Device for removing the injection valves
5 1 Ring spanner, SW 24, for loosening the rear injection pump mounting
6 1 Pipe grip
7 1 Traverse for dismantling and assembling the cylinder head
8 1 Device for installing and removing and grinding the cylinder liner
9 1 Spatula
10 2 Device, cpl., for removing the control shaft
11 1 Slide rail, cpl., for installing and removing the connecting-rod bearing covers
12 1 Device
13 1 Spanner, Al 36 DIN 3113, for fuel pressure line
14 1 Tenon for removing the main bearing shells
15 8 Hexagonal nuts M 33 x 2
16 1 Device for adjusting the fuel pump cam

Contents of box 3: set of tools


Hydro screw pretensioning device
(separate Ordering number 1218 5038)
No. pcs. Designation
1 1 Toolbox
2 1 Hydraulics pump
3 5 High-pressure hose
4 1 Manifold
5 2 Hydraulic oil (1 dm3 each))
6 4 Screw pretensioning device for cylinder head
7 2 Screw pretensioning device for main bearing
8 2 Screw pretensioning device for connecting rod-bearing
9 2 Tommy bar, A 8 DIN 900
10 1 Spanner, SW 65 DIN 894

Chapter 5 - Page 30 0299 4628-0108 © 1200


TBD 645 Maintenance

5.2.2 Special tools and devices 5


Manual test instrument for injection valve
Ordering Number 1243 0481
Consisting of:
Manual test rig
Connection pipe

80066 0

Ill. 504 Manual test instrument

Test case for coolant and lube oil


Ordering Number 1213 0382

80067 0

Ill. 505 Test case

Peak pressure gauge for measuring the ignition


pressure
Ordering Number 0409 3598 60 80

1000
10

800 1200
40

600 1400

400 1600
120
20

200 KIENE 1800


DIESEL INDICATOR
0 2000
0
0
14

80068 0

Ill. 506 Peak pressure gauge


© 1200 0299 4628-0108 Chapter 5 - Page 31
Maintenance TBD 645

5 Fuel injector cleaning tool


Ordering Number 1215 6073

80069 0

Ill. 507 Fuel injector cleaning tool

Suspension device
Ordering Number:

1 2 - 6- and 8-cylinder engine: 1221 0829


- 9-cylinder engine: 1221 0828
Application:
- Lifting the engine off its foundation
- Transport.
● Bolt suspension anchor 1 to the free cylinder head
screws between the cylinders.
● Pass two wire-cable slings (2.5 m double length,
33 mm ø, 130 daN/mm2) under traverse 2, and
suspend at the crane hook.
● Mount the traverse
80070 0 6-cylinder engine over cylinders 2, 3 and 4
8-cylinder engine over cylinders 3, 4 and 5
Ill. 508 Suspension device 9-cylinder engine over cylinders 3, 4, 5 and 6.

Chapter 5 - Page 32 0299 4628-0108 © 1200


TBD 645 Maintenance

5.2.3 Other equipment 5


5.2.3.1 Cleaning agents 5.2.3.2 Water treatment agents
1. for engine parts Supplier company 1. Hardness determination for cooling water
P3 Kaltreiniger (liquid) Messrs. Henkel & Cie Aquamerck Messrs. E. Merck
40002 Düsseldorf Art. No. 11129 64293 Darmstadt
Vecom B 24 B (liquid) Messrs. Vecom Ordering Number from DEUTZ SERVICE
21107 Hamburg 1215 8292

Carbon remover or Drew Ameroid GmbH


Ameroid ACC-9 (liquid) 20457 Hamburg 2. Cooling water hardening
Vecom CN 3 (powder) Messrs. Vecom
2. for engine cooling system 21107 Hamburg

P3 T 288 (powder) Messrs. Henkel & Cie


P3 Standard (powder) 40002 Düsseldorf 3. Cooling water softening
Vecom BA-S (powder) Messrs. Vecom Trisodium phosphate Messrs. A. Benckiser
Vecom BA-30 (liquid) 21107 Hamburg (powder) GmbH
SAF-Acid (powder) Drew Ameroid GmbH 67059 Ludwigshafen
HDE-777 (liquid) 20457 Hamburg

3. for intercooler and raw water circuit


P3 T 1166 (liquid) Messrs. Henkel & Cie
P3-croni (neutralization) 40002 Düsseldorf
SAF-Acid (powder) Drew Ameroid GmbH
Ameroid ACC-9 (liquid) 20457 Hamburg

4. for tank systems


Vecom B 24 B (liquid) Messrs. Vecom
Vecom B 14 (liquid) 21107 Hamburg
Tank cleaner Nr. 4 (fl.) Drew Ameroid GmbH
20457 Hamburg

5. for lube oil filter


Ameroid ACC-9 (liquid) Drew Ameroid GmbH
20457 Hamburg
P3 RST, P3 SAXIN Messrs. Henkel & Cie
(powder) 40002 Düsseldorf
Filterclean Messrs. Vecom
21107 Hamburg

6. for air filter


1. Soda solution, 1%
2. Paraffin oil
3. Mixture of: 6.5 % trichloroethylene
9.5 % Teepol (Shell)
4 % cyclohexanon
80 % fresh water

© 1200 0299 4628-0108 Chapter 5 - Page 33


Maintenance TBD 645

5 This page intentionally left blank.

Chapter 5 - Page 34 0299 4628-0108 © 1200


DEUTZ MWM Operational
TBD 645 malfunctions

6 Operational malfunctions 6
6.1 Malfunction Table

1197 0299 4629-0108 Chapter 6 - Page 1


Operational DEUTZ MWM
malfunctions TBD 645

6 6 Operational malfunctions

6.1 Malfunction Table

Malfunction
Engine does not turn when started
Engine does not ignite, or stops after several ignitions
Engine is not reaching the specified output/speed
Engine not running smoothly
Engine is knocking
Engine black-out
Exhaust gas colouration abnormal
Oil vapour from crankcase venting
Water in the lube oil
Oil pressure too low or too high
Leak at coolant pump
Charging air temperature too high
Pressure drop at charging air cooler too high

Possible causes and remedies


● Starting air pressure deficiency
● ● Starting and/or control valves
● ● Fuel cock closed, fuel starvation
● ● ● Monitor tripped
● ● Stop lever in stop position / Stop lever limit switch defective
● ● No control air or no control current
● ● ● Air in fuel system
● ● Engine too cold
● ● Charging pressure too low
● ● ● ● Divergent exhaust gas temperature or ignition pressure
● ● Fuel filter soiled
● ● Fuel delivery pump defective
● ● ● Governor defective or control rodding is sticking
● ● Injection pump defective
● Lube oil temperature too high
● ● Defect at valve actuator
● ● ● ● ● Defect at drive mechanism
● Cylinder liner in crankcase leaking
● Leak at lube oil cooler
● Delivery inception incorrect
● ● Check injection valve
● Overhaul lube oil pump
● Overhaul safety valve
● Check oil pressure control valve
● ● Check coolant pump
● Check control response
● ● Clean intercooler
● Check backwash filter

Chapter 6 - Page 2 0299 4629-0108 1197


DEUTZ MWM Operational
TBD 645 malfunctions

The list includes malfunctions which may occur in engine operation, plus their possible causes.
The causes of the malfunctions are listed in the order in which they will be easiest and quickest to
localize.
The Job Cards listed contain advice on how to correct the malfunction concerned. Please remember
in this context that jobs from the Workshop Manual require more highly qualified staff, with appropriate
training, knowledge and skills. If you are in any doubt, please contact on of the addresses listed on
the last page - Chapter 11, Service.
In general, please consult the Job Cards specified below, where divergences in pressure and
temperature are dealt with in more precise detail. In the event of malfunctions, first perform the
measurement procdures described there:
Job Card B 0-1-2 “Checking operating values”.
Job Card B 0-2-5 “Engine diagnostics”.

Job Card in File


B 0-1-1 Operating Instructions
Chap. 2 Operating Instructions
B 0-1-1 Operating Instructions
B 0-2-5 / B 11-1-22 / B 11-2-1 / B 11-2-3 / B 11-3-1 Operating Instructions
Stop lever in operating position –
B 0-1-1 Operating Instructions
vent –
– –
B 6-3-1 / B 6-12-1 Operating Instructions
B 0-2-5 Operating Instructions
– see manufacturer’s description
– see manufacturer’s description
B 5-4-1 Operating Instructions
W 7-4-2 / W 7-4-4 Workshop Manual
W 8-8-2 Workshop Manual
B 1-3-1 / W 1-5-2 Operating Instructions / Workshop Manual
B 4-4-2 / B 4-4-4 / W 2-7-2 Operating Instructions / Workshop Manual
W 3-3-1 Workshop Manual
W 8-8-2 Workshop Manual
W 7-6-1 Workshop Manual
B 7-7-2 Operating Instructions
W 8-4-3 Workshop Manual
W 8-4-4 Workshop Manual
W 8-11-1 Workshop Manual
W 9-7-2 Workshop Manual
B 5-2-1 Operating Instructions
W 6-4-3 Workshop Manual
B 8-10-3 Operating Instructions

1197 0299 4629-0108 Chapter 6 - Page 3


Operational DEUTZ MWM
malfunctions TBD 645

6 This page intentionally left blank.

Chapter 6 - Page 4 0299 4629-0108 1197


DEUTZ MWM Conserving
TBD 645

7 Conservation 7
7.1 General remarks

7.2 Cleaning

7.3 Interior conservation


7.3.1 Lube oil system
7.3.2 Coolant system
7.3.3 Fuel system
7.3.4 Conservation run
7.3.5 Subsequent routines
7.4 Exterior conservation

7.5 Deconservation

7.6 Technical Circular TR 0199 2068

1197 0299 4630-0108 Chapter 7 - Page 1


Conserving DEUTZ MWM
TBD 645

7 7 Conservation

7.1 General remarks


If your engine is going to be out of operation for a lengthy period, it has to be conserved so as to prevent any
corrosion damage. This also applies if the engine is not going to be put into operation until more than 3 months
after delivery.

7.2 Cleaning
Before the engine is conserved, all the parts for conservation must be given a thorough cleaning. Any incipient
corrosion must be removed completely.

7.3 Interior conservation


7.3.1 Lube oil system
● Run your engine until it has reached its operating temperature.
● Drain off all the lube oil.
● Clean the lube oil single or double filters and replace the cartridges, replace the replaceable filters.
● Fill your engine with conserving agent (level between upper and lower dipstick markings).
7.3.2 Coolant system
If there is already a coolant inside your engine consisting of water and anti-corrosion oil as detailed in Chapter
7.6, no further action is needed for the coolant system; otherwise:
● Drain off the coolant.
● Prepare a conserving agent from fresh water and anti-corrosion oil, see Chapter 7.6.
● Fill with conserving agent.
7.3.3 Fuel system
● Drain off all the fuel from the fuel tank.
● Prepare a conserving agent from distillate fuel and anti-corrosion oil, see Chapter 7.6.
● Fill with conserving agent.

7.3.4 Conservation run


● Run your engine in idling mode for approx. 15 minutes.

Chapter 7 - Page 2 0299 4630-0108 1197


DEUTZ MWM Conserving
TBD 645

7.3.5 Subsequent routines 7


● Detach the charging air line.
● Unscrew the exhaust gas thermometers.

During the subsequent spray routine, turn the crankshaft for at least 2 revolutions by hand, so that all
valves open and conserving agent penetrates into the cylinder heads and combustion chambers.
Use only completely dry compressed air!

● Use a pressure-jet atomizer to spray conserving agent into the inlet channels and bores of the exhaust-gas
thermometers.
● Fit the charging air line back in place.

Don’t turn the crankshaft any more, to ensure that the conserving agent is not stripped off by the piston
rings.

● Remove the cylinder head hoods.


● Spray the top valve mechanism with conserving agent.
● Fit the cylinder head hoods back in place.
● Fill the raw water compartments with anti-corrosion oil without any water added, see also Chapter 4.4.
● Drain off the anti-corrosion oil.
● Drain off or pump out the conserving agent from the oil pan.
● Drain the coolant system, leave the drain cocks open.

The conserving agent can be collected for conserving additional engines.

7.4 Exterior conservation


● Conserve bright and corrosion-susceptible parts with protective grease.
● Rub talcum powder into rubber parts and V-belts.
● Unflange the intake and exhaust gas lines from the sockets of the exhaust gas turbocharger, and close off
the openings with covers to prevent any moisture entering.
● Repair any damage to paintwork.

7.5 Deconservation
● Wash off the anti-corrosion grease with distillate fuel.
● Drain off or pump out (if pump fitted) residues of conserving agent from the oil pan.
● Use a suitable cleaning agent to clean coolant compartments conserved with anti-corrosion oil before
pouring in a chemical anti-corrosion agent.

7.6 Corrosion protection

6HH7HFKQLFDO%XOOHWLQ7%&RURVLRQSUHRWHFWLRQIRUPHGLXPDQGODUJHHQJLQHV.

1197 0299 4630-0108 Chapter 7 - Page 3


Conserving DEUTZ MWM
TBD 645

7 This page intentionally left blank.

Chapter 7 - Page 4 0299 4630-0108 1197


TECHNICAL
BULLETIN
Services, Wärtsilä Netherlands B.V.
Engine section Engine type Ref. Date Issue Document No. Page
99 Service information See below WNL-Services 01.06.2 012 01a TB00/99/2116 1(6)

Corrosion protection for medium and large


engines
Engine types D232, D234, D350, D358, D440, D441, D444, D484, D500, D501, D510,
D511, D528, D540, D545, D601, D602, D603, D604(B), D616, D618, D620,
D628, D640, D645, D716, D816, D18/22, D2016

Issue 01 Re-issue of original bulletin TC 0199-99-2116/2 12/2008

Table of Contents
1. General information 1
2. Corrosion protection for engines which have been in operation 1
2.1 Interior corrosion protection 1
2.2 Exterior corrosion protection 3
2.3 Storage and packaging 3
3. Subsequent corrosion protection of engines 3
3.1 Interior corrosion protection 3
3.2 Exterior corrosion protection 4
3.3 Storage and packaging 4
4. Removal of corrosion protection 4
4.1 Removal of interior corrosion protection 4
4.2 Removal of exterior corrosion protection 5
5. Corrosion protection agents and cleaning agents 5

1. General information
New engines and replacement parts are protected against corrosion before
being shipped from the plant. The duration of protection against corrosion
depends on the type of corrosion protection, the packaging and the storage
conditions. Corrosion protection may be guaranteed for 12 months or 24
months depending on what the customer requires.

2. Corrosion protection for engines which have been in operation


2.1 Interior corrosion protection
Interior corrosion protection is always provided by wetting of the walls with the
implemented corrosion protection agent.
Fuel system This includes the injection valves, fuel filter, fuel pump, overflow valve, fuel
lines and tank.

Wärtsilä Netherlands B.V. Office: Hanzelaan 95 Telephone: +31 38 425 32 53


P.O. Box 10608 8017 JE Zwolle Telefax: +31 38 422 35 64
8000 GB Zwolle The Netherlands service.sales.nl@wartsila.com
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
01a T B00/99/2116 2(6)
 Engines operated with a mixed fuel must be switched over to distilled fuel
at least 3 hours before shutting down.
 Fill the fuel tank with a mixture of:
- 85% distilled fuel
- 15% corrosion protection oil SAE 30W-30, or Rimula R3

 Perform a corrosion protection run with the engine at idle speed (together
with corrosion protection run for the lube oil system), duration approx. 10
minutes.
Lube oil system This includes oil sump, lube oil pump, lube oil cooler, oil pressure control
valve, oil filter, main oil channels, crankshaft, con-rod and camshaft bearings,
tappets and tappet chambers, cylinder liners, valve springs and toggle levers.

 If the engine runs with Rimula R3, no separate protection run is required.
 Drain lube oil from warm engine.
In additional devices with their own oil filling (these include turbochargers,
governors, injection pumps etc.) drain lube oil and fill with new lube oil
according to manufacturer specifications.

 If the engine is equipped with crankcase covers, remove them, and


install VCI chips per cylinder unit (in case of v-engines, one per unit.)
Cooling water system If a coolant with corrosion protection properties is poured into the engine, no
further action is necessary after draining the coolant.
For water requirements, please refer to TB/99/2091.
If this is not the case, the coolant must be drained and a corrosion protection
run performed with a mixture of corrosion protection agent with corrosion
protection properties and fresh water so that a coating forms on the interior
surfaces of the cooling system.
The duration of the corrosion protection run and the concentration of the
corrosion protection agent are specified by the manufacturer of the corrosion
protection agent.
Then drain the coolant.
Combustion chamber The injection valves on all locations must be removed at the end of the
corrosion protection run. The respective piston must be set to Bottom Dead
Centre (BDC).
The accessible part of the cylinder liner should be coated with corrosion
protection or engine oil Rimula R3 oil, applied with a spray lance through the
opening.
Oil drips on the piston are not permissible and must be sucked off if
necessary.
Receiver pipe and Spray corrosion protection oil 30 W-30 into the receiver pipe and the main
starter air line starter line.
Oil drips in lines are not permissible and must be sucked off if
necessary.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
01a T B00/99/2116 3(6)

2.2 Exterior corrosion protection


The engine must be cleaned thoroughly with a cleaning agent before exterior
corrosion protection.
Any signs of corrosion and damage to the paintwork must be removed. See
section for corrosion protection agents and cleaning agents.
Bare exterior surfaces All bare surfaces must be coated or sprayed with a corrosion protection agent.
and parts Brush the crankshaft flange with corrosion protection agent and wrap tightly or
cover with foil or packing cloth.
Control rods and joints Coat control rods and joints with protective grease.
Rubber parts Rub rubber parts with talcum powder.
Rubber parts must not come into contact with oil, grease and paint.

Engine openings All engine openings must be fitted with air-tight, water-tight covers to delay the
liquefication process of the corrosion protection agents.
Air should be locked out to avoid ventilation of the engine (chimney effect).
2.3 Storage and packaging
After being protected against corrosion, the engine must be stored in a dry,
ventilated hall or suitably covered. The cover must be placed loosely over the
engine so that the air can circulate around it to prevent condensation from
forming. Use a desiccant if necessary.

3. Subsequent corrosion protection of engines


If the maximum duration of corrosion protection has been reached and the
engine is to remain in storage, it must be subjected to subsequent corrosion
protection. The subsequent corrosion protection protects the engine for
another 12 months. Subsequent corrosion protection must be provided
accordingly for stored replacement parts.
Mark the position of the flywheel or crankshaft flange. Deposits may form on
the cylinder liner in the area of the piston rings. For this reason, the pistons
must be set to a different position each time corrosion protection is carried out.
The engine packaging and the covers over the engine openings must be
removed.
3.1 Interior corrosion protection
Fuel system This includes the injection valves, fuel filter, fuel pump, overflow valve, fuel
lines and tank.

 Fill the fuel tank with a mixture of:


- 85% diesel fuel
- 15% corrosion protection oil SAE 30W-30
 Pump fuel with a separate pump or fuel hand pump until the fuel system is
full.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
01a T B00/99/2116 4(6)

Lube oil system This includes oil sump, lube oil pump, lube oil cooler, oil pressure control
valve, oil filter, main oil channels, crankshaft, con-rod, camshaft bearings,
tappets and tappet chambers, cylinder liners, valve springs and toggle levers.

 If the engine is equipped with crankcase covers and VCI chips before
proceeding.
 Pump corrosion protection oil into the lube oil circuit with separate pump
or pre-lubrication hand pump. Turn the engine manually or with electric
turning gear so that all bearings and bearing liners are coated. The engine
can also be turned with the starter without starting.
 Remove the cylinder head cover and spray valves, valve springs and
toggle levers with corrosion protection oil SAE 30W-30.
 Install new VCI chips, if applicable.
In additional devices with their own oil filling (these include turbochargers,
governors, injection pumps etc.) drain lube oil and fill with new lube oil
according to manufacturer specifications.
Cooling water system Fill up the coolant system with a mixture of corrosion protection agent with
corrosion protection properties (see section) and fresh water and circulate with
an external pump so that a new coating forms on the interior surfaces of the
cooling system.
The duration of the corrosion protection run and the concentration of the
corrosion protection agent are specified by the manufacturer of the corrosion
protection agent.
Then drain the coolant.
Combustion chamber See chapter 2.1 - Combustion chamber
Suction intake and See chapter 2.1 - Suction intake and starter air system, receiver pipe
starter air system,
receiver pipe
3.2 Exterior corrosion protection
See chapter 2.2

3.3 Storage and packaging


See chapter 2.3

4. Removal of corrosion protection


The corrosion protection must be removed from the engine before starting.
The packaging must be removed as well as all covers from the sealed
openings. Any signs of corrosion and damage to paintwork must be removed.
See section for cleaning agents.
4.1 Removal of interior corrosion protection
Fuel system  If there is a mixture of diesel fuel/corrosion protection oil in the fuel tank,
drain it.
 Fill the fuel tank and fuel system with the proper fuel.
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
01a T B00/99/2116 5(6)

Lube oil system  If there is corrosion protection oil in the oil tray, drain it, or pump it out.
 Fill the engine with the lube oil intended for operation. Flushing is not
necessary.
 In additional devices with their own oil filling (these can include
turbochargers, governors, injection pumps etc.) drain lube oil and fill with
new lube oil according to manufacturer specifications.
Cooling water system  If the implemented corrosion protection agent is compatible with the
coolant to be used, this can be filled directly into the coolant system as
specified.
 If it is uncertain whether the implemented corrosion protection agent is
compatible with the coolant, the cooling system should be flushed with
fresh water for about 15 minutes before filling.

4.2 Removal of exterior corrosion protection

 Wash all surfaces and components coated with corrosion protection agent
with distilled fuel or a suitable cleaning agent.
 Wash out grooves of V-belt pulleys if necessary.

5. Corrosion protection agents and cleaning agents


Below a list of some reference products for corrosion protection or cleaning
with which the best results have been achieved. Equivalent products can be
used whereby the supplier must guarantee the suitability of the product for the
application.

Usage Product Product reference


Cleaning of engine parts Diesel acc. to
Distilled fuel
and fuel systems DIN EN 590
Corrosion protection oil
SAE 30W-30, BP Hamburg
BP-MEK 30
Corrosion protection for
lube oil systems, additional Rimula R3 Shell
devices with own oil filling
Viscosity according
and fuel systems.
engine type
requirements. See
TB00/99/2090
Corrosion protection agent
See TB00/99/2091
for coolant systems.
Corrosion protection agent Deutsche Castrol
(wax-like) for exterior Gelserol Super 76829 Landau
corrosion protection. Germany
Protective grease for control Fuch Europa
Renolit MP2
rods and joints. 68169 Mannheim
Silbermann GmbH & Co
Talcum for rubber parts Talcum fine, white 86456 Gablingen
Germany
Haug-Chemie GmbH
Cleaning agent to remove
Eskapon S 255 74889 Sinsheim
corrosion protection agent.
Germany
Services, Wärtsilä Netherlands B.V. Technical bulletin
Issue Do cument No. Page
01a T B00/99/2116 6(6)
Usage Product Product reference
Cleaning agent, thinner to Fuch Europa
remove corrosion protection Renopal B 150 68169 Mannheim
agent (wax like). Germany

Related Technical bulletin TB00/99/2090 Lube oil requirements


documentation Technical bulletin TB00/99/2091 Engine coolant for medium and large
size engines

Documentation Add this information to your engine manual.


Ordering parts Contact your Wärtsilä Service Unit. When ordering parts please specify the
engine serial number and the material numbers.

Letter distribution The Wärtsilä Services Network and users/owners of engines concerned.
Feedback E-mail to: service.sales.nl@wartsila.com
Letter validity Until further notice.

Disclaimer
This Technical Bulletin is designed to provide accurate and authoritative information with regard to the subject-matter covered as was
available at the time of printing. However, the publication deals with complicated technical matters suited only for specialists in the area and
the design of the subject-products is subject to regular improvements, modifications and changes. Consequently, Wärtsilä Netherlands B.V.
and/or any other Wärtsilä group company cannot accept any responsibility or liability for any eventual errors or omissions in this Technical
Bulletin or for discrepancies arising from the features of any actual item in the respective product being different from those shown in this
Technical Bulletin. Wärtsilä Netherlands B.V. and/or any other Wärtsilä group company shall under no circumstances be liable for any
damages or losses, or injury, suffered by any party making use of this Technical Bulletin or the information contained herein.
DEUTZ MWM Technical particulars
TBD 645

8 Technical particulars 8
8.1 Engine data

8.2 Adjsutment data

8.3 Operating data

8.4 Weights

8.5 Tightening instructions

8.6 Torsional backlash

1197 0299 4631-0108 Chapter 8 - Page 1


Technical particulars DEUTZ MWM
TBD 645

8 8 Technical particulars

8.1 Engine data


Operating mode Four-stroke
Direct injection
Exhaust gas turbocharging
Intercooling
Cylinder configuration Row
Number of cylinders 6 8 9
Bore mm 330
Stroke mm 450
Piston capacity per cylinder dm3 38.5
Compression ε 13.5
Rated control times / test control times*:
Inlet opens °CS bef. TDC 66/40
Inlet closes °CS after BDC 36/10
Outlet opens °CS before BDC 73/41
Outlet closes °CS after TDC 48/32
Firing orders
Anticlockwise 1-5-3-6-2-4 1-3-2-5-8-6-7-4 1-2-4-6-8-9-7-5-3
Clockwise 1-4-2-6-3-5 1-4-7-6-8-5-2-3 1-3-5-7-9-8-6-4-2
Max. perm. engine tilt
continuous, longit./transverse degrees 12 / 25
short-time, longit./transverse degrees 15 / 35
* with 3 mm valve clearance

8.2 Adjustment data


(guideline values)**
Lube oil pressure
afer backwash filter bar 5.0
Lube oil temperature
Engine inlet °C 57 ± 5
Cooling water temperature
Engine outlet °C 75 bis 85
Opening pressure
Injection nozzles bar 330
Valve clearance
Inlet mm 0.4
Outlet mm 0.8
** The binding values are those of the commissioning report.

Chapter 8 - Page 2 0299 4631-0108 1197


DEUTZ MWM Technical particulars
TBD 645

8.3 Operating data 8


The values applying for your particular engine that are not listed below can be found in the acceptance test report
included as an appednix to these operating instructions. Depending on the operational and environmental
conditions involved, the operating data will vary from system to system.

Number of cylinders 6 8 9
Lube oil content (approx.)
Engine with built-on
cooler and filter dm3 140 180 200
3
Lube oil quantity in system dm /kW 1.3
Lube oil pump, delivery rate m3/h 54 71 80
Lube oil temperature °C 57 ± 5
3
Coolant content, engine dm 340 440 490
Coolant pump (HT-circuit)
delivery rate m3/h 70 90 100
delivery pressure bar 2.5
Coolant temperature, outlet
intercooler (HT-circuit) °C max. 87
Permissible temperature differential, HT-circuit
Engine, inlet - outlet °C 7 - 10
Engine, outlet - intercooler outlet °C approx. 6
Permissible pressure differential, HT-circuit
Engine, inlet - intercooler oulet bar 0.9
Coolant temperature, inlet
intercooler(LT-circuit) °C 40
Coolant pre-heat temeprature
in marine engine operation with:
gas oil °C 50
mixed fuels °C min. 65
Continuous operation with :
gas oil °C 20
mixed fuels °C 50
Permissible underpressure
in filter sound absorber
or air intake fitting mbar 20
Permissible counterpressure
Exhaust gas line mbar 25

1197 0299 4631-0108 Chapter 8 - Page 3


Technical particulars DEUTZ MWM
TBD 645

8 8.4 Weights
(approx.)
No. of cylinders 6 8 9
Exhaust gas turbochargerVTR 304 kg 820 - -
Exhaust gas turbocharger VTR 354 kg - 1,700 1,700
Exhaust valve cage kg 29 29 29
Injection pump kg 32 32 32
Counterweight kg 64 64 64
Main bearing cover kg 106 106 106
Piston kg 72 72 72
Piston pin kg 30 30 30
Crankcase kg 8,700 12,300 13,700
Crankshaft kg 3,460 5,230
Crankshaft vibration absorber kg -
Charging air cooler kg
Engine (dry) kg 25,500 32,500 39,000
Camshaft kg 560 720 810
Camshaft gear kg 32 32 32
Oil sump kg 1,240 1,960
Connecting rod kg 120 120 120
Governor/Actuator kg 30 30 30
Lube oil filter kg 105 105 105
Lube oil cooler kg 430 460 500
Lube oil pump kg 56 100 104
Idler gear with hub kg 100 100 100
Cylinder liner kg 208 208 208
Cylinder head kg 297 297 297

Chapter 8 - Page 4 0299 4631-0108 1197


DEUTZ MWM Technical particulars
TBD 645

8.5 Tightening instructions 8


Code Screw connection** Dimension Strength Tightening type, sequence Remark
No.* Material H V1 V2 F L V F
01/1 Cylinder head - M33x2x618 10.9 W 1-4-4
Crankcase
01/2 Control shaft bearing cover - M16x130 12.9 + 200 350 - - - -
Crankcase
01/3 Main bearing cover - M42x2x555 12.9 W 2-7-2
Crankcase M42x2x620 12.9
01/4 Main bearing cover - M30x2x380 10.9 W 2-7-2
Transverse distortion
01/5 Idler gear hub- M24x230 10.9 + 300 - 1 - - 0.5
Crankcase
01/6 Idler gears- M14x140 10.9 + 150 - 1 - - -
Idler gear hub
02/1 Oil pan- M16x90 10.9 + 300 - - - - -
Crankcase M16x50 8.8 + 210 - - - - -
05/1 Intermed. flange- M33x2x190 12.9 + 300 600 1 - - 1 -
Crankshaft gear (KS)
05/2 Counterweight- M30x2x285 12.9 -
Crankshaft 8+9 cyl.
05/4 Oil thrower - M10x30 12.9 + 70 - - - - -
Intermediate flange
06/1 Conn. rod cover - M27x2x292 12.9 W 2-9-3
Conn. rod
07/1 Anti-fatigue bolt in M16x1.5x205 10.9 SERVICE
Piston top M14x1.5x205 10.9
07/2 Piston bottom - M16x1.5x205 10.9 SERVICE
Piston top M14x1.5x205 10.9
08/1 Bush for injection valve - M64x2 Ck 35 K+G + 800 - - - - -
Cylinder head
08/2 Injection valve - M12x170 8.8 + 25 50 - - - -
Cylinder head
08/3 Exhaust valve - M24x285 10.9 W 1-5-3
Cylinder head
08/4 Valve lifter block- M20x210 8.8 + 410 - - - - -
Cylinder head M20x300 8.8 + 410 - - - - -
08/5 Valve lifter block - M12x60 10.9 + 120 - - - - -
Clamping screw
08/6 Closure piece or start valve - M12x130 10.9 + 50 110 - - - -
Cylinder head
08/7 Injection line - M16 8.8 + 50 150 - - - -
Cylinder head
08/8 Injection line - M30x1,5 9 S Mn Pb 28 K + 180 - - - - -
Injection pump
08/9 Flange for injection line - M12x25 10.9 + 120 - - - - -
Cylinder head
10/1 Camshaft axial bearing - M8x40 10.9 + 35 - - - - -
Camshaft bearing cover M8x50 10.9 + 35 - - - - -
10/2 Camshaft flanged bearing KS - M12x35 12.9 + 145 - - - - -
Crankcase
H = tighten by hand with standard spanner (+ = execute)
V1 = pretighten with torque wrench to ... Nm
V2 = tighten further with torque wrench to ... Nm
F = tighten by ... hex turns (60° turn angle each)
L = loosen screw connection again (+ = execute)
V = pretighten again with torque wrench to ... Nm
F = tighten by ... hex turns (60° turn angle each)

*Code No. = Module / ser. No.


**see Note 1
1197 0299 4631-0108 Chapter 8 - Page 5
Technical particulars DEUTZ MWM
TBD 645

8
Code Screw connection** Dimension Strength Tightening type, sequence Remark
No.* Material H V1 V2 F L V F
10/3 Camshaft gear - M16x70 10.9 + 200 - 1 - - - -
Hub on camshaft
10/4 Camshaft - M48x3x238 10.9 -
Vibration damper add-on M30x2x238 10.9
10/5 Vibration damper mount. M12x75 10.9 + 120 - - - - -
Camshaft
14/1 Coupling flange - M30x2x80 8.8 + 300 600 1 - - - -
Crankshaft (KGS)
14/3 Gear - vibration M20x100 10.9 + 580 - - - - -
damper- coupling flange
14/4 Gear- M12x95 12.9 + 140 - - - - - 8 and 9 cyl.
Oil pump
14/5 Gear- M16x110 10.9 + 300 - - - - - 8 and 9 cyl.
Oil pump
14/6 Gear- M30x2 10.9 + 300 - - - - - 6 cyl.
Oil pump
17/1 Injection pump drive - M12x85 10.9 + 60 120 - - - -
Crankcase
17/2 Injection pump drive - M16x140 10.9 + 150 300 - - - -
Crankcase
17/3 Connection piece- M12x40 10.9 + 100 - - - - -
Injection pump M10x50 12.9 + 80 - - - - -
19/1 Injection nozzle- + 300+50 - - - - -
Injection valve (nozzle nut)
27/1 Gears- M20x1,5 42CrMoS4K+V + 250 - - - - -
Intermed. shaft for governor M30x1,5 42CrMoS4K+V + 300 - - - - -
27/2 Gear- M20x1,5 42CrMoS4K+V + 250 - - - - -
Governor shaft
37/1 Gear- M30x2 X5CrNi189K + 300 - - - - -
Centrifugal pump
37/2 Impeller - M20x1,5 X5CrNi189K + 265 - - - - -
Centrifugal pump
41/1 Exhaust gas bend - M16x40 10.9 + 300 - - - - -
Cylinder head
41/2 Exhaust gas pipe - M12x35 10.9 + 120 - - - - -
Exhaust gas turbocharger
43/1 ETC bracket - M16x110 8.8 + 210 - - - - -
Crankcase
43/2 Exh. gas turbocharger - M20x60 10.9 + 580 - - - - -
ETC bracket M24x180 10.9 + 1000 - - - - -

58/1 Intercooler - M10x60 8.8 + 50 - - - - -


Intake pipe M10x80 10.9 + 70 - - - - -
58/2 Housing for air guide M10x35 8.8 + 50 - - - - -
Intercooler M10x60 10.9 + 70 - - - - -
84/1 Bracket for catwlk and M16x110 8.8 + 210 - - - - -
oil cooler holder - crankcase
H = tighten by hand with standard spanner (+ = execute)
V1 = pretighten with torque wrench to ... Nm
V2 = tighten further with torque wrench to ... Nm
F = tighten by ... hex turns (60° turn angle each)
L = loosen screw connection again (+ = execute)
V = pretighten again with torque wrench to ... Nm
F = tighten by ... hex turns (60° turn angle each)

*Code No. = Module / ser. No.


**see Note 1
Chapter 8 - Page 6 0299 4631-0108 1197
DEUTZ MWM Technical particulars
TBD 645

8
Code Screw connection** Dimension Strength Tightening type, sequence Remark
No.* Material H V1 V2 F L V F
84/2.1 Holder, bracket for catwalk and M16x190 8.8 + 210 - - - - -
oil cooler holder - bracket M16x325 5.8 + 130 - - - - -
84/2.2 Holder, bracket for catwalk and M16x390 8.8 + 210 - - - - -
oil cooler holder - bracket
87/1.1 Intake pipe - M16x130 10.9 + 300 - - - - -
Cylinder head M16x80 10.9 + 300 - - - - -
87/1.2 Intake pipe - M16x40 8.8 + 210 - - - - -
Cylinder head

H = tighten by hand with standard spanner (+ = execute)


V1 = pretighten with torque wrench to ... Nm
V2 = tighten further with torque wrench to ... Nm
F = tighten by ... hex turns (60° turn angle each)
L = Loosen screw connection again (+ = execute)
V = pretighten again with torque wrench to ... Nm
F = tighten by ... hex turns (60° turn angle each)

*Code No. = Module / ser. No.


**see Note 1
1197 0299 4631-0108 Chapter 8 - Page 7
Technical particulars DEUTZ MWM
TBD 645

8 Notes
1. Connections with more than one screw:
tighten alternately, in diagonal or opoosite or
diagonally opposite sequence.
Lubricant:
Oil or tallow-red lead; exceptions are specified.

Chapter 8 - Page 8 0299 4631-0108 1197


DEUTZ MWM Technical particulars
TBD 645

8.6 Torsional backlash 8

1 2 3 4 5 6 4 3 2 1

Sd = 0.4…0.5 Sd = 0.2…0.27
Sd = 0.35…0.45 Sd = 0.37…0.45
Sd = 0.28…0.35 Sd = 0.2…0.27

Sd = 0.07…0.16
Sd
X Y

80071 1 en

Fig. 801 Torsional backlash sd

Flywheel side Operator side


1 Crankshaft 1 Lube oil pressure pump
2 Idler gear, large 2 Coolant pump
3 Idler gear, small 3 Crankshaft
4 Camshaft 4 Lube oil intake pump
5 Governor idler gear
6 Governor gear (horizontal position)

1197 0299 4631-0108 Chapter 8 - Page 9


Technical particulars DEUTZ MWM
TBD 645

8 This page intentionally left blank.

Chapter 8 - Page 10 0299 4631-0108 1197


DEUTZ MWM Job Cards
TBD 645

9 Job Cards 9
9.1 Overviews
9.1.1 Arranged alphabetically
9.1.2 Arranged by Job Card Numbers
9.1.3 Description of symbols
9.2 Job Cards arranged by Job Card Numbers

1197 0299 4632-0108 Chapter 9 - Page 1


Job Cards DEUTZ MWM
TBD 645

9 9 Job Cards

9.1 Overviews
9.1.1 Arranged alphabetically
Job Job Card
Anti-corrosion or anti-freeze agent in the coolant, checking B 9-1-1
Checking the control unit and fuel pressure of the control rod lubrication system B 7-2-4
Cleaning the fuel leakage lines B 7-3-4
Cleaning the fuel lines for the control rod lubrication function B 7-2-3
Control response, checking B 5-2-1
Coolant system, draining B 9-0-1
Drive compartment monitor, checking and cleaning B 11-5-1
Engine diagnostics B 0-2-5
Engine mount, checking B 3-7-1
Engine-end backwash filter, checking and cleaning B 8-10-3
Exhaust gas temperature monitor, checking B 11-2-3
Expendables supply, checking B 0-1-1
Gear train (Drive End), checking B 4-4-4
Gear train (Free End), checking B 4-4-2
Injection pump drive, raising the roller tappet B 7-2-1
Injection valve, checking and repairing B 7-7-2
Injection valve, removing and installing B 7-7-1
Inlet and exhaust valve clearances, checking and adjusting B 1-1-1
Inspection hole, gear box and camshaft cover seals, replacing B 3-1-4
Intake air filter, cleaning B 6-3-1
Lube oil change B 8-1-2
Lube oil change in exhaust gas turbocharger B 6-6-2
Lube oil change in governor/actuator B 5-3-1
Lube oil sampling B 8-1-1
Operational values, checking B 0-1-2
Pressure transmitter, checking B 11-1-22
Regulating shaft, lubricating B 5-4-1
Safety instructions for governor B 5-0-1
Speed monitor, checking B 11-3-1
Starting air cylinder, filling and draining B 10-7-1
Temperature monitor, checking B 11-2-1
Torsional vibration absorber, taking a silicone oil sample B 12-1-1
Turbocharger compressor, cleaning B 6-12-1
Turbocharger turbine, cleaning B 6-13-1
Valve rotating device, checking, removing and installing B 1-3-1
Valve seat lubrication, checking B 8-14-1

Chapter 9 - Page 2 0299 4632-0108 1197


DEUTZ MWM Job Cards
TBD 645

9.1.2 Arranged by Job Card Numbers


Job Card Job
B 0-1-1 Expendables supply, checking
B 0-1-2 Operational values, checking
B 0-2-5 Engine diagnostics
B 1-1-1 Inlet and exhaust valve clearances, checking and adjusting
B 1-3-1 Valve rotating device, checking, removing and installing
B 3-1-4 Inspection hole, gear box and camshaft cover seals, replacing
B 3-7-1 Engine mount, checking
B 4-4-2 Gear train (Free End), checking
B 4-4-4 Gear train (Drive End), checking
B 5-0-1 Safety instructions for governor
B 5-2-1 Control response, checking
B 5-3-1 Lube oil change in governor/actuator
B 5-4-1 Regulating shaft, lubricating
B 6-3-1 Intake air filter, cleaning
B 6-6-2 Lube oil change in exhaust gas turbocharger
B 6-12-1 Turbocharger compressor, cleaning
B 6-13-1 Turbocharger turbine, cleaning
B 7-2-1 Injection pump drive, raising the roller tappet
B 7-2-3 Cleaning the fuel lines for the control rod lubrication function
B 7-2-4 Checking the control unit and fuel pressure of the control rod lubrication system
B 7-3-4 Cleaning the fuel leakage lines
B 7-7-1 Injection valve, removing and installing
B 7-7-2 Injection valve, checking and repairing
B 8-1-1 Lube oil sampling
B 8-1-2 Lube oil change
B 8-10-3 Engine-end backwash filter, checking and cleaning
B 8-14-1 Valve seat lubrication, checking
B 9-0-1 Coolant system, draining
B 9-1-1 Anti-corrosion or anti-freeze agent in the coolant, checking
B 10-7-1 Starting air cylinder, filling and draining
B 11-1-22 Pressure transmitter, checking
B 11-2-1 Temperature monitor, checking
B 11-2-3 Exhaust gas temperature monitor, checking
B 11-3-1 Speed monitor, checking
B 11-5-1 Drive compartment monitor, checking and cleaning
B 12-1-1 Torsional vibration absorber, taking a silicone oil sample

1197 0299 4632-0108 Chapter 9 - Page 3


Job Cards DEUTZ MWM
TBD 645

9 9.1.3 Description of symbols


There are various symbols used on the Job Cards, in order to designate information not directly related to the
actual work sequence involved.

Tools:
- The tools normally required are listed against this symbol.

Equipment:
- Things like pressure gauges, lube oil, hydraulic oil.

Spare parts:
- Seals, locking parts, etc.

Job Cards/Cross-references:
- Douments, reports or Job Cards to which reference is made in this Job Card.

9.2 Job Cards arranged by Job Card Numbers

Chapter 9 - Page 4 0299 4632-0108 1197


General
DEUTZ MWM Job Card
TBD 645 B 0-1-1

Expendables supply, checking


Tools:
- Normal tools

Equipment:
- U-tube pressure gauge
or as a makeshift
- a transparent hose
- T-piece for between pipe, pressure
monitor and U-tube pressure gauge
(make it yourself)
- Turbine oil

Cross-references:
- Job Card B 9-1-1
- Expendables specifications
- Operating instructions from Messrs.
ABB
Checking the fuel level
● Check the fuel level in the day tank and top up if
necessary (transfer pump). Depending on the size
of the tank, and the engine loading, top up the day
tank several times a day. In the event of lengthy
breaks in operation (standby or emergency
operation), the fuel must be recirculated every 2
months (in the storage tank as well), in order to
avoid condensation water settling.

Checking the coolant level


● Check the coolant level in the expansion tank and
in the fan cooler; top up with pure water if necessary.
Use only pure water of the quality specified in the
expendables specifications. If you top up with
relatively large quantities of coolant, check the
composition of the coolant mixture (Job Card
B 9-1-1).
Do not fill the expansion tank or the cooler
completely in cold condition, since the coolant
will expand as it warms up. If you top up
coolant in the engine while it is still warm from
operation, run the circulation pump or the
engine in order to avoid a sudden drop in
temperature inside the engine.

Checking the lube oil level in the


operating tank
● The engine has dry-sump lubrication. This is why
a separate tank is provided for the lube oil. Check
the lube oil level in this tank. When the lower limit
value is reached, top up with lube oil as far as the
upper limit value.

1197 0299 4633-0108 Page 1 of 2


General
Job Card DEUTZ MWM
B 0-1-1 TBD 645

Checking the lube oil level in the


governor/actuator
● Check the lube oil level in sight glass 1 of the
governor/actuator. If the lower marking has been
reached, pour SAE 40 engine oil (see the operating
instructions for quality details) into the filling aperture
of screw union 2, as far as the upper marking in the
sight glass. 2
Top up with oil very slowly, since equalization
in the sight glass proceeds only slowly (the
passages between the governor housing and 1
the sight glass have small cross-sectional
areas). Use drain plug 3 to drain off any
excess lube oil. 3

80051 0

Fig. 1 Governor/Actuator, lube oil level indicator

Checking the turbine oil level in the


turbocharger
● The turbocharger has one oil sump on both the
turbine and the compressor sides. Check the turbine
oil level in both sight glasses (4 turbine side, plus
corresponding for the compressor side under the
flap). If turbine oil level is near the lower marking,
top up to the upper marking with mineral-oil-based
turbine oil featuring a viscosity of 35 to 55 mm2/s
(cSt) at 50 °C, with antifoaming additives and
ageing inhibitors (see Operating instructions from
Messrs. ABB).
4

80121 0

Fig. 2 Turbocharger, oil level indicator, turbine


side

Page 2 of 2 0299 4633-0108 1197


General
DEUTZ MWM Job Card
TBD 645 B 0-1-2

Operational values, checking


The data you read off must be compared with those in Cross-references:
the test report. You will find it helps to enter the - Job Cards B 0-2-5, B 7-7-2, W 8-8-2
readings in a new report, so that you can trace any - Acceptance test report
gradual alterations, making it easier to find the causes
involved.

Lube oil
Values to check:
7
● Pressure after the filter, pressure gauge 1
4
● Temperature at engine inlet, display 2

2 6
Problems, possible causes:
Lube oil pressure before the filter too low 1
- Lube oil too warm 5
(cooling insufficient)
- Lube oil too thin-bodied 3
(wrong viscosity, fuel in the lube oil)
- Oil control valve sticking (clean it, check it)
- Pressure gauge defective
- Lubrication system damaged
(leak in pressure line, lube oil pump defective, 80107 0
worn bearing). Fig. 1 Instrument panel
Lube oil pressure before the filter too high
- Lube oil (still) too cold
- Lube oil too viscous
(wrong viscosity, lube oil soiled)
- Lube oil filter soiled (clean it)
- Oil control valve sticking (clean it, check it)
- Pressure gauge defective
Lube oil pressure after the filter too low
- Lube oil pressure differential (pressure before
filter minus pressure after filter) too great
(clean lube oil filter)
- And/or the same causes as for
„Lube oil pressure before the filter too low“
Lube oil temperature too high
- Engine overloaded
- Lube oil pressure too low
- Cooling water circulation insufficient, because
cooling system soiled or damaged
- lube oil cooler soiled
(Job Card W 8-8-2)
1197 0299 4634-0108 Page 1 of 4This page intentionally left blank.
General
Job Card DEUTZ MWM
B 0-1-2 TBD 645

Coolant
Values to check:
● Coolant pressure, pressure gauge 3
● Coolant temperature at engine outlet,
display 4

Problems, possible causes:


Pressure too low
- Leak in cooling system
- Feed to pump impeded
(valves closed)
- Coolant pump damaged
- Pressure gauge defective
Pressure too high
- Flow resistance in cooling system too high,
because
- Valves closed
- Cooling system soiled,
silted up or blocked
Temperature too low
- Engine still too cold
- Raw water irruption, because
heat exchanger damaged
- thermostat damaged
- thermometer defective
Temperature too high
- Engine overloaded
- Coolant level too low (top up)
- Raw water pressure too low
- Raw water temperature too high
Temperature differential between engine inlet and
outlet becomes smaller:
- Heat exchanger or cooler soiled

Charging air
Values to check:
● Charging pressure, pressure gauge 5
The charging air pressure is load-dependent
● Charging air temperature, display 6

Problems, possible causes:


Pressure too low Temperature too low
- Intake air filter soiled - Charging-pressure-controlled three-way valve
- Turbocharger compressor soiled defective
Pressure too high - Charging air pressure too low
- Engine overloaded Temperature too high
- Turbocharger turbine soiled - Intercooler soiled
- Inlet/exhaust valves leaking - Charging-pressure-controlled three-way valve
(valve clearance not correct) defective
- Charging air pressure too high
Page 2 of 4 0299 4634-0108 1197
General
DEUTZ MWM Job Card
TBD 645 B 0-1-2

Exhaust gas
Values to check:
8
● Exhaust gas temperatures after cylinder, display
and thermometer 8
● Exhaust gas colouration in the exhaust
Read off exhaust gas temperatures and write them
down.
Compare the differential between the lowest and
highest temperature values with the values previously
measured.

Problems, possible causes:


Temperature differential has risen by 25 K or more
- Check appropriate injection valves 80111 0

(Job Card B 7-7-2).


Fig. 2 Exhaust gas thermometer
Significant increase in exhaust gas cloudiness
- Check injection valves
For further trouble-shooting
- Perform engine diagnostic routine
(Job Card B 0-2-5)

1197 0299 4634-0108 Page 3 of 4This page intentionally left blank.


General
Job Card DEUTZ MWM
B 0-1-2 TBD 645

This page intentionally left blank.

Page 4 of 4 0299 4634-0108 1197


General
DEUTZ MWM Job Card
TBD 645 B 0-2-5

Engine diagnostics
Deviations in the individual measured values are an Tools:
indication of defects, which if allowed to continue may - Peak pressure meter 0409 3598
lead to serious damage (piston seizing, turbine Piston size 1/2, Spring Number 100
damage, etc.). For proper assessment, you must - Spanner for indexing cock
ascertain exhaust gas temperatures, charging air - Heat-resistant gloves
temperature and pressure, injection pump filling and
ignition pressure. A comparison of these values with
those entered in the acceptance test report (see the
Cross-references:
supplement) will provide you with indications of any - Acceptance test report
changes affecting operational reliability. You will find
it helpful to enter the measured values you find in a
report of your own, so that you can make your own
comparisons in the future.

Preparations for engine diagnostics


Load the engine with rated output (see acceptance
test report). If the engine is blocked at a lower (reduced)
speed, this will be mentioned in the acceptance test
report. In this case, take your measurements at this
output.
Speed-independent loading (e.g. generator
operation):
If the engine does not reach the specified speed at full-
load filling, reduce the loading until full-load speed has
been reached. Filling blocking must not be allowed to
occur.
Speed-dependent loading (e.g. fixed-pitch propeller):
If filling blocking occurs, reduce the speed.
1
80112 0

Fig. 1 Filling indicator for injection pump

Measuring the exhaust gas


temperatures, injection pump filling, 3
charging air temperature and charging
air pressure
● Read off the injection pump filling at the filling
indicator 1, and note it down in a report.
● Read off the charging air pressure (Pressure Gauge
2
2) and charging air temperature (Thermometer 3),
and note them down in your report.
● Read off the exhaust gas temperature (Thermo-
meter 4), and note it down in your report.

80113 0

Fig. 2 Pressure and tempefcrature indicators,


charging air
1197 0299 4635-0108 Page 1 of 4
General
Job Card DEUTZ MWM
B 0-2-5 TBD 645

80114 0

Fig. 3 Exhaust gas thermometer

Measuring the ignition pressure


The peak pressure meter (indicator) will warm
up during measurement. Wear heat-resistant 60 80

gloves! 1000

10
800 1200
40

0
600 1400

● Open indexing cock and allow it to blow off. 400 1600

120
20

200 KIENE 1800


DIESEL INDICATOR

● Close indexing cock and screw on the indicator. 0


0 2000
14
0

● Open indexing cock completely, and write down


the pressure gauge reading.
● Close indexing cock.
● To bleed off the pressure, loosen wing bolt (Fig. 4), 1
indicator must now go to zero.
● Tighten wing bolt again.
● Move indicator to next cylinder.
80068 0

Fig. 4 Peak pressure meter, ignition pressure

80273 0

Fig. 5 Indexing cock


Page 2 of 4 0299 4635-0108 1197
General
DEUTZ MWM Job Card
TBD 645 B 0-2-5

Evaluation
Load deviations result in uniform deviations in
measured values at all cylinders. If uniform deviations
still persist in spite of meticulous checks of the output
(consumers), clean and check the turbocharger and
the air filter. Possible sources of the error are listed
below under the measured-value deviation involved.
In brackets, we have specified the measured value
which will normally deviate in this case as well.

Charging air pressure too high Ignition pressure too high


- Pressure gauge defective perm. deviation: max. 4 bar from mean value
- Exhaust valves leaking (exhaust gas - Delivery beginning set too early
temperature) (exhaust gas temperature has dropped)
- Delivery beginning set too late - Injection nozzle defective (exhaust gas
(exhaust gas temperature has risen, ignition temperature)
pressure has dropped) - Injection pump filling too high
- Injection nozzles defective (exhaust gas (exhaust gas temperature)
temperature, ignition pressure) Ignition pressure too low
- Turbocharger turbine soiled (exhaust gas
perm. deviation : max. 4 bar from mean value
temperature)
(max. perm.: 10 bar below acceptance test
Charging air pressure too low
report value)
- Charging air pressure gauge defective, line - carry out a check measurement with cooled,
leaking cleaned indicator
(even minor leaks will cause a severe - Injection nozzle defective (exhaust gas
pressure drop at the pressure gauge) temperature)
- Intake filter soiled - Delivery beginning set too late
- Turbocharger compressor soiled or defective (exhaust gas temperature has risen)
- Beginning of delivery has been set too early - Injection pump defective (exhaust gas
(Exhaust gas temperature has dropped, temperature)
ignition pressure has risen) - Indexing cock clogged or not completely
- Injection nozzle defective (exhaust gas open
temperature, ignition pressure) - Inlet or exhaust valves leaking
- Injection pump defective (exhaust gas - Charging pressure too low
temperature, ignition pressure)
Exhaust gas temperature too high
- Thermometer defective or incorrect
immersion depth
- Injection nozzle defective (ignition pressure)
- Delivery beginning set too late (ignition
pressure has dropped)
Exhaust gas temperature too low
- Thermometer defective or immersion depth
incorrect
- Injection nozzle defective (ignition pressure)
- Injection pump defective (ignition pressure)
- Delivery beginning set too early (ignition
pressure has risen)
1197 0299 4635-0108 Page 3 of 4
General
Job Card DEUTZ MWM
B 0-2-5 TBD 645

This page intentionally left blank.

Page 4 of 4 0299 4635-0108 1197


Cylinder head
DEUTZ MWM Job Card
TBD 645 B 1-1-1

Inlet and exhaust valve clearances, checking and adjusting


Tools:
- Set 1215 0000
- Feeler gauge

Specifications
The valve clearance must be checked and adjusted
while the engine is cold.
After every dismantling routine for the valve lifters, the
valve clearance must always be re-adjusted.
Valve clearance setpoint value X (cold engine):
Inlet 0.4 mm
Outlet 0.8 mm (long valve lifter)

X
Valve clearance setpoint value X (warm engine):
Inlet 0.3 mm
Outlet 0.7 mm (long valve lifter)
Valve clearance setpoint value X (hot engine):
Inlet 0.2 mm
Outlet 0.6 mm (long valve lifter)
80012 0

Fig. 1 Valve clearance X

Checking and adjusting the valve


clearance 4 3
● Open indexing cocks.
● Set piston of the cylinder concerned to ignition 1
TDC (exhaust and inlet valves closed, both stop
rods destressed).
2
● Push feeler gauge in the thickness of the specified
valve clearance between thrust piece 1 and valve
stem end 2.
1
● To adjust, loosen counternut 3 of set screw 4 and
turn the set screw until clearance-free contact has
been established. 2
● Lock with hexagonal nut 3, then recheck the valve
clearance with the feeler gauge.
● Close indexing cocks. 80145 0

Fig. 2 Cylinder head


1197 0299 4636-0108 Page 1 of 1
Cylinder head
Job Card DEUTZ MWM
B 1-1-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4636-0108 1197


Cylinder head
DEUTZ MWM Job Card
TBD 645 B 1-3-1

Valve rotating device, checking, removing and installing


In order to achieve even temperature distribution at Tools:
the circumference of the valve seating, the valves - Set 1215 0000
have to rotate while the engine is operating. - Valve removal device

Checking the rotary movement of the


valve rotating device. 3 6
● Push off the inspection hole cover of the cylinder
head hood. 1 5
● Mark the valve rotating devices with a clearly
visible coloured dot. 7
● Engine speed for the check procedure: 600 min-1.
If the time necessary for one rotation is more 2
than 80s, you must replace the valve rotating
device.

Replacing the exhaust valve rotating


device
● Open the indexing cocks
80011 0
● Turn the piston of the cylinder concerned until inlet
and exhaust valves are closed (valve clearance at Fig. 1 Cylinder head, sectional view
both valve lifters).
● Remove valve lifter 3.
● Unscrew nuts 4 and use the removal device to pull 4
exhaust valves 5 out of the cylinder head.
● Screw valve removal device onto the valve housing.
● Use the removal device to press down the valve
spring and remove valve cone pieces 6.
Make sure you do not mix up the valve cone
pieces when you remove more than one
rotating device.
● Check valve stems and valve cone pieces for
damage.
4
● Replace the valve rotating device, and re-assemble
in the opposite sequence.
● Check the valve clearance. 80170 0

Fig. 2 Cylinder head, plan view


1197 0299 4637-0108 Page 1 from 2
Cylinder head
Job Card DEUTZ MWM
B 1-3-1 TBD 645

Replacing the inlet valve rotating device


● Remove the exhaust valves as described in Section
2 on the previous page.
● Check piston position in TDC.
● Screw the valve removal device onto the cylinder
head.
● Use the removal device to press down the valve
spring and remove valve cone pieces 7.
● You can place the valve disc carefully onto the
piston head.
Make sure you do not mix up the valve cone
pieces when you remove more than one
rotating device.
● Replace the valve rotating device, and re-assemble
in the opposite sequence.
● Check the valve clearance.

Page 2 from 2 0299 4637-0108 1197


Crankcase
DEUTZ MWM Job Card
TBD 645 B 3-1-4

Inspection hole, gear box and camshaft cover seals, replacing


Tools:
- Knife
- Ruler

Spare parts:
- Round cord ø 8 mm

Replacing the inspection hole and


control shaft cover seals
The covers for the assembly openings at the drive 2 1
mechanism and the control shaft are sealed with a
round cord. If this cord is damaged, you have to
replace it.
● Unscrew the fixing screws of the cover concerned.
● Take off the cover carefully.
● Remove the old sealing cord, and clean the sealing 3
surfaces.
● Cut off a new round cord.
Length required:
for control shaft cover 1:
3
LCover : 896 mm = LRound cord 2309-10 mm 80124 0
LCover : 782 mm = LRound cord 2081-10 mm
Fig. 1 Camshaft side, inspection hole cover
for control shaft cover 2:
LRound cord 680 mm
for inspection hole cover 3:
LRound cord1572 -10 mm
● Insert round cord in the slot of the cover (see
Fig. 2).
L
● Take care not to twist the round cord (no gap in the
joint). 30°
L
● At control shaft cover 2, cut round cord to length if
necessary, so it is flush with the edge of the cover
● Fit the cover carefully.
● Install fixing screws of the cover concerned.
L
L

30°
L
80125 0

Fig. 2 Insertion hints for round cord

1197 0299 4638-0108 Page 1 of 12


Crankcase
Job Card DEUTZ MWM
B 3-1-4 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4638-0108 1197


Crankcase
DEUTZ MWM Job Card
TBD 645 B 3-7-1

Checking the engine mount


Since the foundation may change due to heat and Tools:
deformation phenomena, the fixing screws must be - Standard tools
checked for possible loosening. This is particularly
essential after the first operating hours.

Checking the engine mount


● Check shims in the case of rigid mounts or packings
in the case of elastic mounts, by tapping them
(including those which are not easily accessible,
e.g. due to superimposed pipes).
A metallic sound heard when tapping the
shims indicates that the connection is tight.
● Tighten loose screws as per Tightening Instructions
by the erection company involved.
● Check the alignment.
Ensure a maximized degree of cleanness; in
particular keep oil and water away from the
foundation.

1197 0299 4639-0108 Page 1 of 2


Crankcase
Job Card DEUTZ MWM
B 3-7-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4639-0108 1197


Engine control
DEUTZ MWM Job Card
TBD 645 B 4-4-2

Gear train (non-drive end), checking


Lube oil and coolant pumps are, if built onto the Tools:
engine, flanged onto the operator control side at the - Set 1215 0000
end wall cover. A spur gear fitted to the crankshaft - Hand lamp
drives the pumps. It only becomes necessary to
check the gear train if a pump is built onto the
engine.
Cross-references:
- Job Cards W 4-4-1

Visual inspection
Gears:
1 - Pure water pump
2 - Crankshaft
3 - Lube oil pressure pump
4 - Lube oil suction pump
● Remove flange 8 from the end wall cover 6 and
check the gears through these holes. Turn the
engine while you are doing this by at least 1 ro-
tation, so that you can check the entire circum-
ference of all gears concerned.
1 2
Replace all gears in the gear train according
to the Workshop Manual (Job Card
W 4-4-1) if any traces of scoring, pitting or 4 3
wear of the tooth flank are visible.
80197 1

Fig. 1 Non-drive end

Assembly
● Re-assemble in the reverse sequence. Check 8 8
the seals while you are doing this and, if neces-
sary, replace them.

6
80137 1

Fig. 2 Cover for gear check


1197 0299 4640-0108 Page 1 of 2
Engine control
Job Card DEUTZ MWM
B 4-4-2 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4640-0108 1197


Engine control
DEUTZ MWM Job Card
TBD 645 B 4-4-4

Gear train (drive-end), checking


Tools:
- Set 1215 0000

Cross-references:
- Job Cards B 3-1-4, W 4-4-3
- Chapter 8, Technical Particulars

First visual inspection


You can make a first visual inspection without removing
the actuator through the flange at the side of the
actuator drive.
1
● Check the gears of the gear train for damage. To
do this, turn the engine by 2 revolutions, so that you
can examine the entire circumference of the gears.

Visual inspection after removing the


actuator housing
If the result of the first visual inspection is not clear, 1
proceed as follows: 2
● Screw off counter nut of fixing screws 1, unscrew
fixing screws 1 and remove control rodding.
● Remove lube oil line for the actuator drive. 80135 0

● Take off electrical cables from the actuator. Fig. 1 Actuator and rodding attachment
● Unscrew fixing screws 2 and remove the actuator
together with the base plate.
Put the governor down carefully in its installed 6
configuration, to make sure that the oil filling
does not leak out.
3
● Remove camshaft cover 3. 5
● Unscrew fixing nuts 4 and remove the actuator 6
drive.
● Check the gears of the gear train for damage. To
do this, turn the engine by 2 revolutions, so that you
can examine the entire circumference of the gears.
2
4

80136 0

Fig. 2 Camshaft cover and actuator drive


1197 0299 4641-0108 Page 1 of 2
Engine control
Job Card DEUTZ MWM
B 4-4-4 TBD 645

Replace all gears in the gear train according to


the Workshop Manual (Job Card W 4-4-3) if
any traces of scoring, pitting or wear of the
tooth flank are visible. Raw tooth flanks and an
excessive flank clearance will increase running
noise.

Assembly
The actuator housing is re-assembled in the reverse
sequence. While you are doing this, observe the
tightening torques (Chapter 8, Technical Particulars).
- Use new molded seal for the drive housing.
Check the seal for the camshaft cover and, if
necessary, replace it as detailed in Job Card
B 3-1-4.
Mounting of the camshaft cover:
- Screw in screws 5, tighten nuts 6 one after the
other, starting at the actuator drive, then tighten
screws 5.

Page 2 of 2 0299 4641-0108 1197


Governor
DEUTZ MWM Job Card
TBD 645 B 5-0-1

Safety instructions for governor


When working at or on the governor/actuator, the
navigating stand, the control rodding and the
injection pumps, you must comply with the
following safety instructions:

Before starting work


● Shut down the engine, i.e. set the throttle to “Stop”,
or press the stop pushbutton.
● Close the shut-off valves 2 at the compressed air 4
tanks 1.
● Vent supply air line 3 to starting valve 4.

1 2 3

25575 0

Fig. 1 Valves and compressed air tank

After finishing work


● Open shut-off valves 2 at the compressed air
tanks 1.
● The first time a repaired engine is started up, and
during the trial run, station a fitter at lever 5 for
manual switch-off.

S
T
O
P

5
80251 0

Fig. 2 Manual switch-off


1197 0299 4642-0108 Page 1 of 1
Governor
Job Card DEUTZ MWM
B 5-0-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4642-0108 1197


Governor
DEUTZ MWM Job Card
TBD 645 B 5-2-1

Control response, checking


If the control response is unsatisfactory, there are Cross-references:
various points you must check. - Job Cards B 4-4-4, B 5-0-1, B 5-3-1,
B 7-7-2, W 7-4-2
- Operating instructions for governor/
actuator
Definition
Irregularities in control response are distinguished as The checks described here will generally prove
follows: successful, provided the staff involved possess
Zigzaging the requisite experience and specialized
knowledge. In case of doubt, please consult
small, fast control oscillations, about 10 oscilla- the service facility responsible for you.
tions per second and more;
Sawing The safety instructions must be complied
! with as detailed in Job Card B 5-0-1.
large, slow control oscillations, about 1 to 2
oscillations per second and less.

General checks Check procedure in detail


Zigzaging ● Check oil level at hydraulic governors. Check
condition of oil. Contamination or excessive
If you are experiencing zigzaging, particularly when
viscosity of the oil are often a reason for
the engine is idling, first check:
malfunctions; change the oil (Job Card B 5-3-1).
- whether all cylinders are working properly
(indexing) and ● Check control rodding, especially the joints between
- that there are no misfires occurring, governor and injection pump. The control rod has
- the injection valves (Job Card B 7-7-2) or to move freely in its mounting, but without
- whether the spring of the emergency shut- perceptible play. Check bearing block for the lever
down in the injection pump is too weak, or to the spring rod at the equipment support, and the
- the pressure valves in the injection pumps fixing screws of components like levers, fork levers
(Workshop Manual Job Card W 7-4-2) and couplings for secure fit.
are defective.
● Check whether the speed change observed is
In the case of these small, fast speed changes, the attributable to engine overload.
fault involved is often in the engine governor as
● Check governor for excessive play or wear and
well. The cause may be
tear as detailed in Job Card B 4-4-4.
- excessive tooth clearance or
- gears jamming in the governor
or For trouble-shooting, please also consult the
- excessive clearance in the control rodding. operating instructions from the manufacturer
of the governor/actuator.

Sawing 3. Repair
If your engine is sawing, check: Repair work must be performed in strict accordance
- control rodding to see if it’s sticking, with the detailed operating instructions of the governor
- fine-control valve of pneumatic speed manufacturer, by authorized trained staff. If the
adjuster for soiling, zigzaging and sawing cannot be eliminated, the cause
- governor oil for excessive viscosity. may lie in the driven units, like clutch, transmission,
If these large-slow, speed changes cannot be shaft line, propeller, etc.
eliminated by altering the setting, or if the governor
fails completely, then either repair or replace.

1197 0299 4643-0108 Page 1 of 2


Governor
Job Card DEUTZ MWM
B 5-2-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4643-0108 1197


Governor
DEUTZ MWM Job Card
TBD 645 B 5-3-1

Lube oil change in the governor /actuator


The governor/actuator has a separate lube oil filling, Tools:
not connected to the engine’s lube oil circuit. The high- - Set 1215 0000
precision internals of the governor/actuator require - Size 6 hexagon socket wrench
absolutely clean lube oil in order to work properly. To - Oilcan, 2 dm3
set the requisite injection pump filling at engine start- - Collecting vessel
up, a lube oil pressure is required in the governor/
actuator’s control section. It takes some time to build
up this lube oil pressure with the lube oil pump
Equipment:
installed in the governor/actuator. To shorten the - Lube oil SAE 30 or SAE 40
starting procedure, a cylinder is built on for supplying
the pressurized oil circuit of the governor/actuator
during the start-up routine. The cylinder is operated by
starting air.

Lube oil change in governor/actuator


Change the lube oil when the engine is at
operating temperature.
● Drain off lube oil at drain screw 1.
● Remove pipe connections 3 from booster 2 (start
cylinder), unscrew screws 4 and remove cylinder.
● Unscrew screws 5, and take off cover 6. This cover 7
is stressed from inside with a compression spring.
● Pour lube oil out of the cylinder (taking care not to
damage piston and compression spring). 8
● Fill cylinder with new lube oil, fit cover 6.
● Fit the start cylinder to the engine, and conenct the 1
pipes.
● Screw in drain screw 1. 80082 0

● Pour lube oil into the filling fitting 7 util it reached the Fig. 1 Lube oil level indicator, governor/actuator
top marking in the sight glass 8.
Always top up lube oil slowly, at intervals,
since equalization between lube oil sump and
sight glass takes place only slowly, through 3
narrow channels.

5 4

6
2

4
3
80083 1

Fig. 2 Start cylinder


1197 0299 4644-0108 Page 1 of 2
Governor
Job Card DEUTZ MWM
B 5-3-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4644-0108 1197


Governor
DEUTZ MWM Job Card
TBD 645 B 5-4-1

Regulating shaft, lubricating


To make sure the injection pump is properly regulated Tools:
without zigzagging or sawing, the regualting shaft has - Brush
to be lubricated at intervals.
Equipment:
- Molycote lubricant (“Gleit-Molycote”)

● You must lubricate:


the fork lever (cf. Fig. 1).
● You must oil:
the axial mounting of the regulating shaft
if necessary the radial mounting of the regulating
shaft (cf. Fig. 2, rear).

80247 1

Fig. 1 Regulating shaft

1197 0299 4645-0108 Page 1 of 2


Governor
Job Card DEUTZ MWM
B 5-4-1 TBD 645

80276 0

Fig. 2 Axial mounting for the regulating shaft

Page 2 of 2 0299 4645-0108 1197


Exhaust gas system
DEUTZ MWM Job Card
TBD 645 B 6-3-1

Intake air filter, cleaning


An oil-wetted-air cleaner is fitted to the intake housing Tools:
of the turbocharger. This oil-wetted-air cleaner filters - Cleaning container, e.g. open drum
the intake air, and dampens the noises produced by - Soft brush
the compressor. If soiling is severe, you must clean
the air cleaner more frequently.
Equipment:
Please note: If the intake air is sucked in through an - Cleaning agent
intake line outside, an air filter will be installed in the
latter. Different filters are used, depending on the
system and environmental conditions involved. In this
Cross-references:
- ABB operating instructions
case, a description of the filter will be attached to
Chapter 10 of these operating instructions.

Cleaning the air filter segments


(see also ABB operating instructions)
Carry out the cleaning procedure when the filter
segments are visibly covered with dust fluff outside,
and at the latest if the charging pressure drops below 2
the setpoint value.
● Unscrew fixing screws 2 and remove air filter
segments 1.
● Prepare a cleaning bath:
Cleaning agents 1
- Soda solution, max. 1%
(10 g of soda for 1 dm3 of water)
- or: benzine
- or: kerosene.
● Rinse the filter segments by moving them to and 80095 0

fro in the bath. Assist the cleaning function with a Fig. 1 Side view of the oil-wetted air cleaner
soft brush, and if the soiling is severe, take out the
knitted filter fabric.
Do not boil out the filter; the maximum bath
temperature is 80 °C.
● Blow through the filter segments from inside with 1
compressed air (max. 8 bar).

80096 0

Fig. 2 Filter segments


1197 0299 4646-0108 Page 1 of 2
Exhaust gas system
Job Card DEUTZ MWM
B 6-3-1 TBD 645

● Soak the filter segments in clean lube oil. Allow all


superfluous lube oil to drip drain off (Fig. 3).

80097 0

Fig. 3 Filter segment cleaning

● Replace any damaged knitted filter fabric (Fig. 4).


● Fit the filter segments.
● Tighten fixing screws 2.

80098 0

Fig. 4 Filter knitted fabric

Page 2 of 2 0299 4646-0108 1197


Exhaust gas system
DEUTZ MWM Job Card
TBD 645 B 6-6-2

Lube oil in the exhaust gas turbocharger, changing


The rotor in the turbocharger is mounted in special ball Tools:
bearings on the turbine side and on the compressor - Set 1215 0000
side. The rotor’s rotational speed necessitates perfect - Container for used oil
lubrication of these bearings, which are lubricated - Filling funnel
from their own oil sump by means of built-in hollow-
shaft pumps. Regular oil changes on the turbine and
compressor sides will prolong the lifetimes of the rotor
Equipment:
bearings and enhance the system’s operational - Turbine oil
reliability.
Cross-references:
- Expendables specifications (Chapt. 4)
- ABB Operating instructions

Changing the lube oil in the exhaust


gas turbocharger
(see also ABB Operating instructions)
Change the oil when the engine is still warm
from operation. Turbine side 1 and compressor
side 2 each have their own oil sump. Change
the oil on both sides.
● Clean the surroundings of the drain plugs 3 and
filling plugs 4.
● Unscrew drain plugs 3 and drain off the lube oil.
Screw the drain plugs back in again.
● Unscrew filling plugs 4 and pour in turbine oil as far
as the upper marking; 1.5 litres for the bearing on
the compressor side, 1.1 litres for the bearing on
the turbine side. Screw the filling plugs back in
again.
● Check drain plugs 3 for leaks. 1
2
Abnormal foam is formed relatively often, due
to contaminations in the oil. Mostly you will 80099 0
find it sufficient to change the oil two or three
times. Oil foaming is harmless as long as no Fig. 1 Total view of exhaust gas turbocharger
losses occur.

3
3

80100 0 80101 0

Fig. 2 Compressor side Fig. 3 Turbine side


1197 0299 4647-0108 Page 1 of 2
Exhaust gas system
Job Card DEUTZ MWM
B 6-6-2 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4647-0108 1197


Exhaust gas system
DEUTZ MWM Job Card
TBD 645 B 6-12-1

Turbocharger compressor, cleaning


To clean the compressor during operation, use only Tools:
fresh water (not salt) without any cleaning or solvent - Set 1215 0000
additives.

Cleaning the compressor


● Subject the engine to full loading (high charger
speed).
● Unscrew screw plug 1 and fill tank 2 with clean
fresh water (not salt).
● Screw in threaded plug 1 and tighten it.
● Open cock 3 (turn cock handle upwards):
Charging air will press on the cleaning water.
● Open cock 4 (turn cock handle upwards):
Water will now be injected into the compressor.
Brief pumping of the compressor occurring during
injection is harmless.
2
● Repeat the cleaning procedure after 10 minutes.
● After completing cleaning, run the motor for at 80091 0
least another 5 minutes under the same load.
Fig. 1 Water tank for compressor cleaning

3 4

1
2

80092 0

Fig. 2 Individual components of the compressor


cleaning system
1197 0299 4648-0108 Page 1 of 2
Exhaust gas system
Job Card DEUTZ MWM
B 6-12-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4648-0108 1197


Exhaust gas system
DEUTZ MWM Job Card
TBD 645 B 6-13-1

Turbocharger turbine, cleaning


The turbine may be cleaned in operation only with Tools:
fresh (not salt) water, without any cleaning additives - Indexing valve spanner handle
or solvents.
Cross-references:
- ABB Operating instructions,
Chapter on cleaning the turbine
- Acceptance test report

Cleaning the turbine


For the first cleaning procedure, set the
cleaning water pressure (approx. 2 to 3 bar)
so that 0.3 to 0.5 l/min of dirty water exit at the
drain. During the cleaning procedure, keep
the turbine’s exhaust gas temperature under
observation. Deviations in the exhaust gas
temperature will affect the dirty water quantity.
● Run the engine warm.
● Reduce the engine output and rpm according to
the information sign at the washing accommodation.
The exhaust gas temperature (Measuring Point 1)
should be 350 ° to 430 °C.
1
● Open sleeve gate valve 2 and check whether the
line is free (exhaust gas exits). If this is not the
case, take out the line and clean it.
Do not insert any objects into the opening at
the turbine while the engine is running. This 80093 0
may result in serious damage to the turbine.
Fig. 1 Turbine cleaning add-ons
● First completely open sleeve gate valve 3, then
corner valve 4 (indexing valve spanner handle).
● After approx. 5 minutes, close first corner valves 4,
then sleeve gate valve 3 again. If dirty water is still
exiting at the end of the washing procedure, repeat
the washing procedure.
● Close sleeve gate valve 2 when there is no more
3 4
water exiting at the drain.
● After completing the washing procedure, run the
engine for approx. 5 minutes at the same load as
above, so that the turbocharger parts can dry.
If in spite of these cleaning procedures the
normal charging pressure and normal exhaust
gas temperatures (see acceptance test report)
are not reached, the turbocharger must be
dismantled for thorough cleaning (see ABB 2
operating instructions).
80094 0

Fig. 2 View of the turbine cleaning system


1197 0299 4649-0108 Page 1 of 2
Exhaust gas system
Job Card DEUTZ MWM
B 6-13-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4649-0108 1197


Fuel system
DEUTZ MWM Job Card
TBD 645 B 7-2-1

Injection pump drive, raising the roller tappet


To enable the camshaft to be removed, all roller Tools
tappets 3 of the injection pump drives must be secured - Set 1215 0000
above the TDC with the raising devices.
If an injection pump fails, the procedure is similar, so
that the engine can continue to be operated for a brief
period with the cylinder involved switched off.

Carry out this work only when the


! engine has been shut down.

● Take off the camshaft cover


● Position fuel cam at the appropriate injection pump
drive in the TDC.
● Loosen screw 1 amd push tab washer 2 as far as
it will go to the right.
● Insert bolt 4 of eccentric screw 5 into the tappet 5 2 1
cup 6.
● Turn eccentric screw 5 by 180° (note the marking!).
● Push tab washer 2 to the left as far as it will go, and
secure in place.
After finishing the work, loosen the tappet
from its raised position by reversing the above
procedure.

80241 0

Fig. 1 Raising device

3
80242 0

Fig. 2 Injection pump drive

1197 0299 4650-0108 Page 1 of 2


Fuel system
Job Card DEUTZ MWM
B 7-2-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4650-0108 1197


Fuel system
DEUTZ MWM Job Card
TBD 645 B 7-7-1

Injection valve, removing and installing


Tools:
- Removal device

Removing the injection valve


● Unscrew union 4 of the bridge. 3 2 1
● Remove fuel pressure line 1.
● Use solenoid to pull thrust piece 2 out of the
cylinder head borehole.
● Unscrew nuts 11 of the valve mounting.
● Use the removal device to pull injection valve 3 out
of the cylinder head.

4
80013 1

Fig. 1 Fuel injection system

1197 0299 4651-0108 Page 1 of 2


Fuel system
Job Card DEUTZ MWM
B 7-7-1 TBD 645

Installing the injection valve


Install new sealing ring 8 and o-rings 9.
● Insert the injection valve in the cylinder head; while
doing so make sure that the flattened oval flange
side 10 and the borehole 12 are facing the injection
pump.
● Pull injection valve with nuts 11 onto the seal seat,
and unscrew nuts 11 again.
● Insert thrust piece 2 into the borehole of the cylinder
head.
● Tighten fuel pressure line 1 at the injection pump.
Tightening torque: 180 Nm.
● Loosely attach bridge with screw 4; while this is
being done, the injection valve is centred by means
of the thrust piece 2.
● Tighten nuts 11 of the injection valve.
Tightening torque: 25 Nm to pretigh
and 50 Nm to finish tightening.
● Tighten union 4 of the bridge.
Tightening torque: 120 Nm.

80002 1

Fig. 2 Cooled injection valve

Page 2 of 2 0299 4651-0108 1197


Fuel system
DEUTZ MWM Job Card
TBD 645 B 7-7-2

Injection valves, checking and repairing


You must check the injection valves whenever a Tools:
significant increase in exhaust gas turbidity is observed, - Nozzle tester
or the exhaust gas temperatures after the cylinders - Brass brush
drift apart. Each cylinder must be examined separately, - Nozzle cleaning tool
and independently of the others; the exhaust gas
temperature after the cylinder may exceed the value
from the commissioning report by a maximum of 25
Aids:
°C. - Diesel fuel or kerosene

Remember that at higher or lower intake temperatures


the overall level of the exhaust gas temperatures may
Cross-references:
be correspondingly higher or lower as well. - Job Cards B 7-7-1.

Checking the injection valve


● Connect the injection valve to the nozzle tester.
Use diesel fuel or test oil as the test liquid. Use the 13
7
tester to measure the injection pressure.
7
13
Take care not to get any fuel on your
! skin - risk of skin damage !

Cleaning the nozzle


● Destress the injection nozzle by turning back the
set screw 13.
● Remove nozzle by unscrewing nozzle nut 5 from
nozzle holder 3, and clean in diesel fuel or kerosene.
● Use nozzle cleaning needles to remove coke
deposits in the nozzle holes. 11
● Use the brass brush to clean the nozzle cap.
Touch the nozzle needle only at the pressure
point; risk of corrosion from sweat on hands.
10
Do not mix up the nozzle needles and nozzle
bodies of different nozzles, since both these
parts will have been lapped in together. 9

12 6

8 5

80002 1

Fig. 1 Cooled injection valve

1197 0299 4652-0108 Page 1 of 2


Fuel system
Job Card DEUTZ MWM
B 7-7-2 TBD 645

Installing the nozzle


● Secure nozzle 6 in the holder (tightening torque for
nozzle nut 5: 300+50 Nm).

Setting the injection pressure


● Loosen counternut 7 of the set screw, and use the
set screw to set the specified opening pressure
(330 bar).
● Tighten the counternut, and check the pressure
again. If the correct pressure cannot be set, then
replace the nozzle concerned,
see Job Card B 7-7-1.

Page 2 of 2 0299 4652-0108 1197


Fuel system
DEUTZ MWM Job Card
TBD 645 B 7-2-3

Cleaning the fuel lines for the control rod lubrication function
To prevent the control rods, the control sleeves and Tools:
the remaining internal components of the injection - Normal tools
pump from coking with mixed fuel, they are wetted at
regular intervals with distillate fuel. Supply is via lines
which have to be cleaned at regular intervals.
Accessories:
- Distillate fuel
- Compressed air

Cleaning the fuel lines and hollow


screws
● Unscrew screw connection 4 and hollow screw 2.
Remove fuel line 1.
● Catch any fuel which is drained off.
● Clean fuel line 1 and hollow screw 2 in distillate fuel
and pass through with compressed air.
● Check permeability of fuel line 1 and hollow screw
2.
● Mount the fuel line in the reverse order, fit new
sealing rings 3.
● Proceed analogously on all other cylinders.

1197 0299 5857-0108 Page 1 of 2


Fuel system
Job Card DEUTZ MWM
B 7-2-3 TBD 645

2 3 1

82160 0

Fig. 1 Fuel line for lubricating the control rods

Page 2 of 2 0299 5857-0108 1197


Fuel system
DEUTZ MWM Job Card
TBD 645 B 7-2-4

Checking the control unit and fuel pressure of the


control rod lubrication system
Tools:
- 1 set of tools 1215 0000
- Manometer

Checking the relay of the control rod


lubrication system
● Unscrew the 4 screws on the cover, Fig. 1, and
swing the cover to the left.
● Check the settings on the relay, Fig. 2. The four
control knobs 2-5 must be set as shown in Fig. 2.
If this is not the case, adjust the control knobs.
● Close the cover, Fig. 1.
● Loosen a union nut 9 and check the times,
for pause = 60 minutes medium flowing
for pulse = 02 minutes medium not flowing
with the engine running.
● Tighten union nut 9.
82164 0

Fig. 1 Control unit

1197 0299 5859-0108 Page 1 of 2


Fuel system
Job Card DEUTZ MWM
B 7-2-4 TBD 645

Checking the fuel pressure of the


control rod lubrication system
● Fit a manometer with a range of 0 - 0.6 bar, class
at least 2.5, at the inlet of the distillate fuel distributor
8.
1
● Start the engine and, with the engine running and
in the pulse phase (medium flowing), measure the
pressure in the distillate fuel distributor line.
● The pressure must equal 0.15 + 0.1 bar.
● Higher or lower pressure is not permitted.
● In the event of deviations, the cross-section of the
0.6 – 6 sec
flow line must be changed.

{
6 – 60 sec
● Remove the manometer again. 0.6 – 6 min 2
6 – 60 min

7
0.6 – 6 sec
6 – 60 sec
0.6 – 6 min 3
1 red LED 6 – 60 min

2 control knob, grey (pause)

{
3 control knob, red (pulse) 4
5
4
5
4 control knob, grey (pause) 3 3
6 6
6
5 control knob, red (pulse) 2 2
6 time setting 1 1
Pulse Pause
7 time range setting

5 4

Fig. 2 Relay

82165 0

Fig. 3 Fuel lines

Page 2 of 2 0299 5859-0108 1197


Fuel system
DEUTZ MWM Job Card
TBD 645 B 7-3-4

Cleaning the fuel leakage lines


Tools:
- 1 set of tools 1215 0000

Accessories:
- Distillate fuel
- Cold-cleaning compound
- Compressed air

Spare parts:
- 2 washers
- 2 O-rings

Cleaning the fuel-leakage lines between


the injection pump and the collector
line
● Switch off the engine and close the fuel cock.
● Unscrew connections 1 and 2 and remove fuel
lines 3.
● Catch any fuel which is drained off.
● Unscrew hollow screws 4 and unions 5.
● Clean parts 3, 4 and 5 in a cleaning bath with
distillate fuel or cold-cleaning compound
● If there are hard deposits in parts 3, 4 and 5, clean
them in an ultrasonic cleaning bath, following the
instructions of the manufacturer.
● After cleaning, pass compressed air through the
components.
● Fit the unions 5 with new O-rings and washers.
● Fit fuel lines 3.
● Check for leaks with the engine running, tighten
any screw connections as required.

1197 0299 5858-0108 Page 1 of 2


Fuel system
Job Card DEUTZ MWM
B 7-3-4 TBD 645

82166 0

Fig. 1 Fuel lines

Page 2 of 2 0299 5858-0108 1197


Lube oil system
DEUTZ MWM Job Card
TBD 645 B 8-1-1

Lube oil sampling


Smooth operation and good wearing characteristics Tools:
depend very largely on the state of the lube oil. So - Set 1215 0000
checking the lube oil is one of the most important - Container for used oil
maintenance jobs.
An analysis by the lube oil manufacturer is requried, Equipment:
since a precise examination cna be performed only in - Lube oil SAE 40
the laboratory. If no other option is available, DEUTZ
MWM will perform the analysis at cost price.
Cross-references:
- Operating instructions from filter
manufacturer
- Job Cards B 8-1-2

Taking a lube oil sample


Take lube oil at the sampling cock of the engine-side
lube oil filter (indictor filter). About 1 dm3 of lube iol is
needed for testing.
The particulars required are:
1. lube oil brand and type,
2. reading of the operating hour counter,
3. lube oil consumption since the last sample
was taken,
4. location of sampling.

Action
If the result of the analysis is negative, then depending
on the actual result, the lube oil must either be:
- topped up with fresh oil,
- cleaned, or
- completely changed,
see Job Card B 8-1-2.

80275 0

Fig. 1 Sampling cock


1197 0299 4653-0108 Page 1 of 2
Lube oil system
Job Card DEUTZ MWM
B 8-1-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4653-0108 1197


Lube oil system
DEUTZ MWM Job Card
TBD 645 B 8-1-2

Lube oil change


If a lube oil analysis shows that the lube ol not longer Tools:
conforms to the specified value, or if after damage to - Set 1215 0000
the engine thre are too many foreign particles in the - Container for used oil
lube oil, and the required values can no longer be
achieved by topping up, you have to change the lube
oil.
Equipment:
- Lube oil SAE 40

Cross-references:
- Job Cards B 8-10-3

● Drain off lube oil from lube oil cooler.


● Drain off lube oil or pump out from separate lube oil
reservoir.
● Clean all lube oil filters (see also Job Card B 8-10-3).
● Fill the lube oil reservoir with lube oil up to the top
marking.
● Pump the lube oil forwards until a lube oil pressure
of not less than 0.2 bar has been built up.

1197 0299 4654-0108 Page 1 of 2


Lube oil system
Job Card DEUTZ MWM
B 8-1-2 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4654-0108 1197


Lube oil system
DEUTZ MWM Job Card
TBD 645 B 8-10-3

Engine-end backwash filter, checking and cleaning


Increasing blockage of the filter fabric will be signalled Cross-references:
by the red field in the pressure drop indicator becoming - Boll&Kirch operating instructions
larger. This is why the engine-side backwash filter
must be checked, irrespective of the specified intervals,
whenever the pressure drop at the filter becomes
disproportionally large.

Check every day whether the hydraulic motor is every 6,000 operating hours:
turning:
● Check and clean the backwash filter (cf. Boll&Kirch
● Visual inspection at the shaft (cf. Fig. 1); an rpm of operating instructions in the Appendix).
13 to 35 min-1 is determined at an operating
pressure of between 3 and 8 bar (cf. Boll&Kirch
operating instructions in the Appendix).

80272 0

Fig. 1 Backwash filter, filter drive shaft


1197 0299 4655-0108 Page 1 of 2
Lube oil system
Job Card DEUTZ MWM
B 8-10-3 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4655-0108 1197


Lube oil system
DEUTZ MWM Job Card
TBD 645 B 8-14-1

Valve seat lubrication, checking


Tools:
- Set 1215 0000

Visual inspection
Make your check at the drip controller 1.
If the valve seat lubrication function is operating, drips
will form at the controller’s valve, falling in a slow
sequence.
If this is not the case, find out the cause, and restore 1
the system to a fully operational condition.

80249 0

Fig. 1 Drip controller

Checking the flow rate


● You measure the flow rate of the valve seat 2
lubrication sysztem in drips at the controller 1.
Setpoint value:
40 drips/4 min. at engine rpm of 600 min-1.
● If the flow rate has to be reduced, correct the
flow rate using the latching screw 2 at the oil
pump.
Turn clockwise: reduction.

80250 0

Fig. 2 Latching screw at the oil pump


1197 0299 4656-0108 Page 1 of 2
Lube oil system
Job Card DEUTZ MWM
B 8-14-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4656-0108 1197


Coolant system
DEUTZ MWM Job Card
TBD 645 B 9-0-1

Coolant system, draining


For certain jobs, e.g. on the cylinder head, crankcase, Tools:
exhaust gas turbocharger, cooler, coolant pump and - Set 1215 0000
pipes, the coolant has to be partially or completely
drained off.
If your engine is going to be shut down for a lengthy Equipement:
period and there is a risk of frost, the coolant must be - Compressed air
completely removed from the engine, and out of all the
add-on components.
Cross-references:
If your engine is going to be shut down for a lengthy - Job Cards B 9-1-1
period, perform a conservation procedure as described
in Section 4.5.

● Shut off all coolant lines (supply to and return from


the engine).
● Open all drain cocks and drain plugs 1 and 2, and
drain off the coolant. 3
● If anti-freeze or anti-corrosion agents have been
added to the coolant, collect the coolant, and re-
use it.
● Drain water out of compressed air tank,
see Job Card B 10-7-1.
● At all coolant pipes where a pocket of coolant might
collect, open the drain plugs, otherwise detach the
pipes and blow out the coolant. 1 2
● Blow out the pressure gauge lines with compressed
air.
● Then screw in all the screws again, and secure the 80089 1
pipes in place.
Fig. 1 Heat exchanger drain plug

80294 0

Fig. 2 Coolant line drain plug


1197 0299 4657-0108 Page 1 of 2
Coolant system
Job Card DEUTZ MWM
B 9-0-1 TBD 645

80295 0

Fig. 3 Coolant line drain plug

80089 1

Fig. 4 Coolant pump drain cock

Page 2 of 2 0299 4657-0108 1197


Coolant system
DEUTZ MWM Job Card
TBD 645 B 9-1-1

Anti-corrosion or anti-freeze agent in the coolant, checking


In order to protect the coolant compartments against Tools:
corrosion, an anti-corrosion agent is added to the - Measuring instrument from the additive
coolant. This protection, however, is only assured if manufacturer
the proportion of anti-corrosion agent does not fall
below a defined minimum content. If more anti-
corrosion agent than necessary is present in the
Cross-references:
coolant, the cooling effect will be reduced. If more anti- - Expendables specifications
corrosion agent than necessary is present in the
coolant, the cooling effect will be reduced.
If an antifreeze is admixed to the coolant, this must
also possess anti-corrosion properties. In this case,
you do not have to add an anti-corrosion agent as well.
The proportion of antifreeze in the coolant must be
carefully calculated, for the reasons mentioend above.

Checking the proportion of anti-


corrosion agent or anti-freeze
● Take a coolant sample from the cooler, the
expansion tank or the water drain cock.
● Check additive content with the measuring
instrument.
● Setpoint value as laid down in the expendables
specifications.

Correcting the proportion of anti-


corrosion agent or anti-freeze
Proportion of additive too low:
Quantity of the additionally required additive =
total fill volume x (setpoint value - measured value) / 100

To top up, drain off approximately 100 litres of


coolant, mix it thoroughly with the quantity of
additive you want to admix, and then pour the
mixture back in.
Too high a proportion of additive:
Drain off the appropriate amount of coolant, and
top up with pure water (quality as per expendables
specifications).
Coolant quantity to be drained off =
(1 - setpoint value / measured value) x total fill quantity

1197 0299 4658-0108 Page 1 of 2


Coolant system
Job Card DEUTZ MWM
B 9-1-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4658-0108 1197


Compressed air system
DEUTZ MWM Job Card
TBD 645 B 10-7-1

Starting air cylinder, filling and draining


Tools:
- Normal tools

● Slowly open the drain valve 5 unitl water exits.


When no more water is exiting, close the drain
valve again. 5
Do not open the drain cock too far, since if the
flow velocity is too high the water will be
displaced, and only air will exit. When the air
cylinders are installed in a vertical
configuration, a riser 6 is provided. The air
pressure in the air cylinder forces the water
through this riser into the atmosphere.
If no water exits during several maintenance
periods, have the air cylinder checked.
6
● Top up the air cylinder to 30 bar prior to every
shutdown of the engine.

80122 0

Fig. 1 Starting air cylinder

1197 0299 4659-0108 Page 1 of 2


Compressed air system
Job Card DEUTZ MWM
B 10-7-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4659-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-1-22

Pressure transmitters, checking


The job of the monitoring equipment is to signal any Tools:
malfunctions at the engine acoustically and/or visually. - Set 1215 0000
If there is any acute danger for the engine, the - Ammeter
monitoring equipment will halt it. if available:
Make regular checks to ensure that the equipment is - DEUTZ MWM tester for
functioning properly. pressure monitors / pressure transmitters
1214 5414

Check the following points in unmonitored engine


operation:
Pressures:
- Lube oil pressure at n > 400 min-1
- Lube oil pressure at n < 400 min-1
- Lube oil differential pressure
- Coolant pressure, HT circuit
- Coolant pressure, LT circuit
- Fuel admission pressure
- Starting air pressure
- Control air pressure
- Charging air pressure
- Fuel admission pressure (differential) before
and after pump
- Prelubrication pressure for start disable

Checking the pressure transmitters


(0 - 6 bar)
The pressure transmitters are built on to the engine,
and connected to the medium being monitored by X
means of a feed line.
A three-way cock is installed between the line and the
Y
pressure transmitter, and you must conenct the
pressure tester to this.
5

80156 1

Fig. 1 Pressure transmitter


1197 0299 4660-0108 Page 1 of 4
Monitoring system
Job Card DEUTZ MWM
B 11-1-22 TBD 645

Carry out pressure testing while the engine is


running.
● Unscrew closure cap 1.
● Connect pressure tester 2 by means of a hose Y
to three-way cock “y”.
● Connect compressed air (max. 6 bar) with quick-
release coupling to tester. Set test pressure of 5
- 6 bar at reducing knob 4.
● Switch over three-way cock 5 to the tester. 4 3
● Reduce operating pressure at tester using the
reducing knob 4, while checking the below-listed
operating points of the monitoring units. The
switching pressures to be checked are each
stated at the devices concerned. 2
The signals listed in Table 1 will now be triggered (with 80248 0

reference to monitoring for automatic mode): Fig. 2 Pressure tester

Monitoring Test pressure Alarm and safety system


bar

Lube oil pressure at n > 400 min -1 < 3.8 Warning


Lube oil pressure at n < 400 min-1 < 1.0 Warning
Lube oil differential pressure 0.8 Warning
Coolant pressure, HT circuit < 0.8 Warning
Coolant pressure, LT circuit < 0.6 Warning
Fuel admission pressure < 3.0 Warning
Control air pressure < 5.5 Warning
Charging air pressure > 0.8 Bypass
Fuel admission pressure (differential)
before and behind pump 0.5 Reserve pumps “ON”

Lube oil pressure at n > 400 min-1 < 3.5 Shutdown


Lube oil pressure at n < 400 min-1 < 0.8 Shutdown
Coolant pressure, HT circuit < 0.6 Automatic output reduction
Prelubrication pressure for start disable 0.5 Open
Table 1
For electrical testing of the pressure transmitters, you
need an ammeter and a 24 V - voltage source.
Connect as shown in Fig. 3; assignments as specified
in Table 2.
● Correct any inaccurate settings.
+
● Replace any units which do not function
24 V 4 ... 20 mA
properly. –
– +
When you are replacing a pressure transmitter,
always hold it up with a size-27 spanner. You
must never allow the hexagon X at the
I
transmitter (Fig. 1) to be turned. This will result
in destruction of the measuring cell. P
80162 0

Fig. 3 Schematics for alarm and engine stop

Page 2 of 4 0299 4660-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-1-22

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
mA

0 1 2 3 4 5 6 7 8 9 10 Control
bar air

0 1 2 3 4 5 6
bar Coolant

0 1 2 3 4 Charging
bar air

0 5 10 15 20 25 30 35 40 Starting
bar air

80308 0

Table 2

1197 0299 4660-0108 Page 3 of 4


Monitoring system
Job Card DEUTZ MWM
B 11-1-22 TBD 645

This page intentionally left blank.

Page 4 of 4 0299 4660-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-2-1

Temperature monitor, checking


The job of the monitoring equipment is to signal any Tools:
malfunctions at the engine acoustically and/or visually. - Set 1215 0000
If there is any acute danger for the engine, the - Ammeter
monitoring equipment will halt it. - Heatable container with thermometer
Make regular checks to ensure that the equipment is
functioning properly. Cross-references:
- Job Cards B 11-2-3

Check the following points in unmonitored engine


operation:
Temperatures:
- Lube oil temperature
- Coolant temperature, HT circuit
- Charging air temperature
- Exhaust gas temperature (JC B 11-2-3)
- Main bearing temperature

Checking the temperature monitoring


function
The temperature monitors (switching devices) for this
function are installed in terminal box 6 (Fig. 1), the
temperature pick-ups in the lines for the media
concerned.
Since an actual simulation of the operationally
dangerous temepratures would be too great a risk for 7
the engine, perform the check routine as follows:
● Run engine till it reaches its operating
temperature.
6
● Open terminal box.
● At all switching devices, mark the switching
temperature set in the factory on the device
scale. 80265 0

Fig. 1 Terminal box

1197 0299 4661-0108 Page 1 of 4


Monitoring system
Job Card DEUTZ MWM
B 11-2-1 TBD 645

● In succession, read off the current operating


temperature of the medium being checked (lube
oil, coolant, etc. at theindicator devices.
● Trigger the signal contact by adjusting the signal
contact selector switch 7 at the device scale, up
to the current operating temperature. Then set
the switch back to the marked temperature.
● If this does not work: remove pick-ups and
switching devices, and check them in a water
bath (cf. “Checking the temperature pick-ups”
further on in this section).
● If you find you have to replace something, set
the new devices to the appropriate operating
points before installing them.

Monitor function Switching temperature Alarm and safety system


°C

Lube oil temperature > 70 Warning


Lube oil temperature 75 Automatic output reduction
Coolant temperature, HT circuit > 85 Warning
Coolant temperature, HT circuit 90 Automatic output reduction
Charging air temperature > 65 Warning

Table 1

Checking the temperature pick-ups:


● Remove temperature pick-up from its protective
jacket.
● Interrrupt the signal circuit, and connect an ammeter
as shown in Fig. 2.
● Warm up the temperature pick-up in a water bath. 3 1
+
Setpoint value: Between 4 and 20 mA, depending PT 100
on the temperature involved; assignments as
shown in Table 2. 4 2
+ –

80163 0

Fig. 2 Ammeter connection

Page 2 of 4 0299 4661-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-2-1

4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
mA

0 20 40 60 80 100 120
°C

80260 0

Table 2 Valid for lube oil, coolant, charging air temperatures

Checking the main bearing temperature pick-up


● Remove temperature pick-up at main bearing.
● Compare temperature pick-up in heated oil or
water bath with a thermometer (digital display on
instrument panel).
● If you find any divergence, replace the
temperature pick-up.

1197 0299 4661-0108 Page 3 of 4


Monitoring system
Job Card DEUTZ MWM
B 11-2-1 TBD 645

This page intentionally left blank.

Page 4 of 4 0299 4661-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-2-3

Exhaust gas temperature monitor, checking


The job of the monitoring units is to signal malfunctions Tools:
at the engine acoustically and/or visually. If there is - Set 1215 0000
acute danger for the engine, the monitoring system
will shut it down.
Cross-references:
Make regular checks, to ensure proper functioning. - Job Cards B 11-2-1

In unmonitored engine operation, check the following:


Temperatures:
- Lube oil temperature (Job Card B 11-2-1)
- Coolant temperature in HT circuit
(Job Card B 11-2-1)
- Charging air temperature (JC B 11-2-1)
- Exhaust gas temperature
- Main bearing temperature
(Job Card B 11-2-1)

● For the exhaust gas mean value monitor, reduce


spread (setpoint value + 30 °C) down to contact
tripping.
Checking the exhaust gas temperature
● Interrogate the temperatures at 2 adjoining
cylinders(digital display in instrument panel)).
● Interchange cabling of the two temperature pick-
ups, adn interrogate the temperature again.
If you find temperature differences
compared to the first measurements,
replace the defective pick-up.
● Reconnect the cabling in the original
configuration.

1197 0299 4662-0108 Page 1 of 2


Monitoring system
Job Card DEUTZ MWM
B 11-2-3 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4662-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-3-1

Speed monitor, checking


The job of the monitoring equipment is to signal Tools:
engine malfunctions, acoustically and/or visually. If - Set 1215 0000
there is acute danger for the engine, the monitoring - Voltmeter
system will halt it.
Make regular checks to ensure perfect functioning.

Overspeed test while engine is runnning Speed indicator system


You use the “85 % overspeed” test button on the A joint engine/turbine speed indicator with a switchover
withdrawable speed module at the KN 1140 to lower feature is provided at the instrument box. By switching
the operating point to 85% of the preset overspeed over, you can first check the indicator unit. You make
operating point. In this test, the system is prevented your evaluation using proximity-type speed pick-ups
from switching off due to overspeed. This will cause and the VV41 measuring transducer.
the green “overspeed loop o.k.” LED to go out, and an
The voltage output at measuring transducer VV41 is
open circuit will be signalled. When you let go of the
0 to 10 V = corresponding to the ongoing speed, and
test button, the open circuit will be cancelled, and the
can be checked with a voltmeter at Terminal 4/5 of the
normal operating state is restored.
VV41: then compare with Table 1.

0 1 2 3 4 5 6 7 8 9 10
V

0 75 150 225 300 375 450 525 600 675 750


min-1

80261 0

Table 1
1197 0299 4666-0108 Page 1 of 2
Monitoring system
Job Card DEUTZ MWM
B 11-3-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4666-0108 1197


Monitoring system
DEUTZ MWM Job Card
TBD 645 B 11-5-1

Drive compartment monitor, checking and cleaning


The job of the monitoring units is to signal malfunctions Cross-references:
at the engine acoustically and/or visually. If there is - Operating instructions from the Schaller
acute danger for the engine, the monitoring system company
will shut it down.
Make regular checks, to ensure proper functioning.

Checking and cleaning the drive


compartment
● after 500 operating hours (or once a month *):
- Check the underpressure in the
measuring compartment

● after 1,500 operating hours (or every 3 months *):


- Replace the sintered bronze filters in the
measuring add-on.
Filters cannot be cleaned.
- Clean the two fresh air bores in the
measuring add-on.
- Clean the infra-red filter glasses in the
measuring add-on.

● after 6,000 operating hours (or once a year *):


- Replace the sintered bronze filters in the
pressure controller.
Filters cannot be cleaned.

* if the number of operating hours specified is not


reached in the period concerned.

Carry out the work in accordance with the instructions


from the Schaller company.

80258 0

Fig. 1 Drive compartment monitor


1197 0299 4665-0108 Page 1 of 2
Monitoring system
Job Card DEUTZ MWM
B 11-5-1 TBD 645

This page intentionally left blank.

Page 2 of 2 0299 4665-0108 1197


Other components
DEUTZ MWM Job Card
TBD 645 B 12-1-1

Torsional vibration absorber, taking a silicone oil sample


Tools:
- Set 1215 0000
- Sampling tube
- Face spanner
- Triangular scraper

Taking a silicone oil sample


● Run the engine warm, and shut it down. Let the
torsional vibration absorber cool down to approx.
40° C. The raised temperature of the torsional
vibration absorber will help the silicone oil to flow
out more quickly.
● Remove cover 1, and turn the crankshaft so that a
screw plug 2 is located underneatht he opening.
● Remove closure caps 3 at sampling tube. Unscrew
screw plug 2 and screw the sampling tube into the
threaded bore as far as it will go. Unscrew sampling
tube approx. 1 turn.
● Remove the burr caused by the lock. Replace
sealing ring at screw plug 2.
1
● Write down the absorber type and serial number 80132 0
stated on the torsional vibration absorber’s rating
Fig. 1 Cover for torsional vibration absorber
plate (next to the sampling plug).
● When silicone oil is exiting from the sampling tube,
fit closure cap 3 to sampling tube.
You can make the silicone oil flow out more 2
quickly by removing the second screw plug 2.
● Unscrew sampling tube, fit second closure cap 3,
and screw in the screw plug 2. 4
Tightening instructions for screw plug 2:
screw in the screw plug with your thumb anbd
forefinger as far as it will go, then tighten by
another 45° (one eighth of a revolution).
● Secure screw plugs 2 by punching at the grooves,
and fit cover 1 back in place (remembering the
seal!).

80133 0
Fig. 2 Torsional vibration absorber closure
screws
1197 0299 4664-0108 Page 1 of 2
Other components
Job Card DEUTZ MWM
B 12-1-1 TBD 645

● Send in the oil sample, stating absorber type,


Serial Number, engine data and operating data, to
DEUTZ MWM or Carl Hasse & Wrede GmbH,
Mohriner Allee 3-42, D-12347 Berlin.
The sample is so small that up to 10 samples
can be taken without risk. 3

80134 0

Fig. 3 Oil removal tube in torsional -


vibration absorber

Page 2 of 2 0299 4664-0108 1197


DEUTZ MWM Sundry
TBD 645 other instructions

10 Sundry other instructions 10

1197 0299 4663-0108 Chapter 10 - Page 1


Sundry DEUTZ MWM
other instructions TBD 645

10 This page intentionally left blank.

Chapter 10 - Page 2 0299 4663-0108 1197

You might also like