English - Solé Diesel
Contents
1. Sol Diesel ENG 11 03919400 ENG rev 1 2 6 1 ENGINE DIMENSIONS SDZ165 TM170A 1400 mg A email HET i gt en DD d 3 Ay 616 Ji N yi 598 gue Ke I O oe rr Jis 1 er I O i ET R H PAN s r Ke I T 1 e B i l A W Dr mi v I i va IL 1359 1682 1271 ae ALA Hed f tD w F o o kI HYP gt E H ft MA Sim 345 Tt 1737 1 Hose Inlet seawater pump lnt 38mm 2 Hose Inlet fuel pump lnt 12mm 3 Hose return fuel pump lnt 12mm Sol Diesel ENG 12 03919400 ENG rev 1 2 6 2 GENSET DIMENSIONS G71T15 1742 SH i ik sj CZ n V P LES li raa Sr tag LES A T og CH i SG r D FAN s E HX SS 3 VEK D g T tm TF SEE AS E o kr A G 7 d WI d d L lh h q ae e elt vg Tr ul 35 115 715 35 6 Tol 621 5mm 6 Holes 821 5 mm G84T15 1776 G1 0471 5 Jugen E ANG SE TT 942 5 983 6 Tal WII man 6 Holes 221 5 mm 2 7 GEARBOX PROPULSION ENGINE AND GENERATOR GENSET VERSION Check all information attached 03919400 ENG rev 1 3 TRANSPORT HANDLING STORAGE 3 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 3 1 PAC2. a b C d Check exhaust and transmission systems g a g b 9 0 g d Sol Diesel ENG 20 03919400 ENG rev 1 5 1 1 BLEEDING AIR FROM THE FUEL SUPPLY SYSTEM On the first start up of the engine and if this has operated with the fuel tank empty air may enter the feed system and it is necessary to purge this To carry out the priming purge of the fuel system proceed as follows 1 Check fuel cock located at the tank delivery is open 2 Position fuel collection container under the filter cartridge and pressure maintenance valve B 3 Bleeder screw A and open pressure maintenance valve 4 Turn the engine over the starter read the heading 6 1 and max 20 seconds until buble free fuel escapes first from the bleeder screw A and then from the pressure maintenance valve B 5 Firmly tighten bleeder screw A and pressure maintenance valve B 6 Start the engine and make sure there are no leaks 0 warning Protect hands The fuel can harm the skin 5 2 PRELIMINARY RUNNING TESTS 5 2 1 NO LOAD RUNNING TEST Run the engine at low speed for a few minutes Keep a constant check on the oil pressure see heading 2 3 5 2 2 RUNNING IN During initial run in which lasts for the first 50 hours of duty take into account the following points 1 Dialy checking performances must be made without failure 2 Engine is to be operated at idle speed and heated up minimum 5 minutes after its starting 3 Avoid
3. When the engine is to be stopped close the sea watercock open the sea water filter cover and start the engine adding a mixture of fresh water and 30 anti freeze until the sea water circuit is filled completely Stop the engine and replace the sea water filter cover Before starting the engine again open the sea water cock Repeat this operation whenever the engine is used at temperatures below C Make sure that the lubricant oil is good quality and has a suitable viscosity SAE 10W 30 synthetic oil is recommended Protect the battery against the cold covering it with an adequate material Check that the battery is fully charged It is also advisable to use a dielectric spray on the electrical connections When starting the engine make sure that the heating plugs become hot enough Follow the instructions detailed in section 6 1 of this manual If necessary to replace the fuel with a type more suited to low temperature operation The accumulation of impurities in the fuel tank could cause faulty firing 6 5 CONSERVATION A warning All engines not in use are subject to rusting and corrosion of machined surfaces that are not protected with a paint coating The degree of corrosion depends on meteoro logical changes and climatic conditions The following recommendations are therefore of a general nature but they will help prevent orreduce the risk of damage due torusting 6 6 LONG INACTIVITY INSTRUCTIONS When the engine is not to be
4. a FILLING WITH OIL Read the page n 8 to the oil capacity b FILLING WITH COOLANT Read the page n 7 to the coolant capacity c REFUELING Read the page n 17 heading 4 2 3 Check fuel delivery cock is fully opened d OPEN SEAWATER ENTRY COCK e CONNECT THE BATTERY CONNECTOR f REMOTE CONTROL CONNECTION only for propulsion engine f a Engine control remote conection Connect control cable to the ball joint fitted to the lever A and position the cable with the clamp B Adjust in a way that gas is not delivered until the inverter gear is engaged Fig 5 1 f b Gearbox control remote conection Connect control cable to the lever by means of the ball joint provided for this purpose and position cable with the clamp When fitted adjust control in a way that it has the same forward running that rearward and gas is not delivered until the gear is perfectly engaged Fig 5 2 max 35 max 35 min 30 min 30 max 30 max 30 To check fitting is correct proceed as follows Place the gearbox lever and remote control lever in the position of forward running Adjustment is made by way of the elongated holes of the control and the elongated holes of the cable attachment support g OTHER CHECKINGS a Carefully check the engine positioning points Check all screws are correctly tightened Check all water oil and gas oil pipe nipples verifying if all them are well connected and correctly tightened
5. WARNING The level of oil never to being below the mark MIN of the oil rod Fig 4 4 lt be careful that any rod marks refer to the engine at a horizontal position Therefore check the engine inclination when the level is verified If the engine is fitted inclined the marks must be modified Read the technical annexes to modify the marks Read the technical specifications to the MAX inclination page 10 Sol Diesel ENG 17 03919400 ENG rev 1 4 2 1 2 CHANGING GEARBOX OIL Gearbox has its own lubrication independent from the engine warning the use of oil that does not conform to the technical specifications on chapter 9 will cause serious damage to the engine and invalidate the guarantee when supplying the engine never ingest oil fuel coolant liquid etc these substances are harmful to the E personal health of the user if ingested 4 2 2 FILLING THE COOLING CIRCUIT As a refrigerating liquid an anti freeze of the brand KRAFFT ACU 2300 CC 50 Ref 1325 or another one with similar specifications must be used The incorrect use of water in the refrigeration circuit is extremely harmful causing corrosion and scaling while the use of anti freeze protects the circuit from corrosion scaling and from freezing in conditions of very low temperature thus optimizing engine maintenance and reliability warning do not allow AC88 liquid to come into contact with the eyes or the skin AN warning do not ingest a
6. 2 Expansion tank 3 Heat exchanger 4 Freswater pump 5 Vibration damper 6 Fuel feed pump 7 Fuel inlet 8 Fuel filter 9 Lubrication oil filter 10 Oil dipstick 11 Conection power take off optional 12 Seawater pump 13 Conection power take off optional keel cooling 14 Inlet seawater pump 15 Fuel overflow valve 16 Governor 17 Stop solenoid 18 Fuel injection line 19 Ventilation line from turbocharger to expansion tank 20 Seawater line to air heat exchanger 21 Oil filler cap 22 Oil cooler engine 23 Fuel injection pumps 24 Starter motor 4 kW 24V 25 Oil sump 26 Oil drain pump 27 Alternator 55 A 28V 28 Exhaust manifold 29 Coolant line from charge air cooler to heat exchanger 30 Seawater outlet 31 Charge Air cooler only model SDZ 165 32 Turbocharger 34 Lubricating line to turbocharger 36 Flywheel size SAE 11 7 2 2 COOLING CIRCUIT 2 2 1 COOLING CIRCUIT COOLANT Fig 2 1 AN use anti freeze as indicated in section 4 2 2 of this manual Tuber a cebado bomba de agua Freshwater pump Oil cooler engine Cooling circuit cylinders A Cooling circuit cylinder head Expansion tank Exhaust manifold cooled Turbo charger Heat exchange anti freeze Pipe seawater Elbow wet exhaust Pipe inlet freshwater pump Thermostat 1 2 3 4 4 5 6 7 8 9 1 1 1 13 Boiler kit opcional 0 1 2 3 Thermostat valve op
7. 43 INSTALLATION warning N When water cooled engines must be located in an enclosed place or protected by guards or a cabinet it is important to ensure that combustion air is freely supplied and freely expelled from the area The above recommendation is of primary importance in relation to the perfect operation of the engine because the hot air that it generates must never be routed to the area of the combustion air intake cleaner If the users fails to take these precautions a hot air recirculation system will be formed thus reducing engine power output and obstructing proper cooling In these cases it is advised to take steps to avoid taking in engine combustion air from the place in which the engine is installed This is achieved by placing the suction filter or a suction prefilter outside the place in which the engine is installed 4 4 INDICATIONS FOR REMOVAL DISPOSAL OF WASTE MATERIAL warning A Disposal of waste material must be carried out in conformity with established legislation in the country of installation Sol Diesel ENG 19 03919400 ENG rev 1 5 PREPARING THE ENGINE FOR USE 5 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 5 1 INSTRUCTIONS FOR FIRST STARTING Do not alter the functioning conditions of the engine by changing the settings of factory sealed parts Tampering with such parts automatically invalidates the guarantee Proceed as follows when starting the engine for the first time
8. a speeded up acceleration 4 9 Use the engine at 100 of maximum power for limited periods Carefully comply with the inspection and maintenance instructions shown in this manual warning N The longer the initial running in period with reduced loads the longer the working life time of the various parts of the engine with consequent savings in termsof maintenance and running costs Sol Diesel ENG 21 03919400 ENG rev 1 6 USING THE ENGINE 6 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 6 1 STARTING and STOP for propulsion engine a b c d e STARTING Place control lever at the neutral point Rotate the ignition key to position ON Check oil pressure battery charge lamps are lighted and the alarm is heard refer to heading 2 5 1 for lamps position Pre heating of incandescent spark plugs This engine is dessing with a direct injection system Then this function is cancelled Turn the key directly to Start position Starting Place the remote control lever to neutral point and deliver gas up to the half position rotate the ignition key to the START position until the engine starts running H the engine does not start running even with the ignition key in the START position for10 seconds draw your hand out from the key for 30 seconds and then try again to start the engine AN warning Do not run the starter motor for more than 20 seconds at a time O
9. s country Packing materials Wood Steel nails Steel screws Plastic film Cardboard Metal or plastic straps 3 3 TRANSPORT AND HANDLING THE PACKED ENGINE When lifting and transporting the engine use EXCLUSIVELLY a fork lift or bridge crane of appropiate load capacity with chains equipped with safety hooks suitable for lifting the load in question The use of any other system automatically invalidates the insurance guarantee against possible damage to the engine 3 4 TRANSPORT AND HANDLING OF THE UNPACKED ENGINE When the engine is unpacked ready for transport use EXCLUSIVELLY the appropiate lifting eyebolts A see the picture 3 4 Choose the lifting equipement with reference to heading 3 3 Fig 3 4 3 5 STORAGE OF PACKED AND UNPACKED ENGINE If the engine is left idle for prolonged periods the client must check the possible conditions of conservation in relation to the place of storage and the type of packing system base pallet etc If the engine is unused for prolonged periods and stored observe all the relative technical specifications The treatment of the engine for storage is guaranteed for 6 months after the time of delivery if the user decides to start the engine after a longer time period this must bed one in the presence of an authorized technician Sol Diesel ENG 15 03919400 ENG rev 1 4 INSTALLATION 4 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 4 1 ASSEMBLY DATA PAR
10. the hand drive the handle of shutdown 2 in direction of shoots with an arrow until the engine pauses Once unemployed the engine ignites the lights witness of current of load and oil pressure This methode only must use in case exceotional Use the panel to stop the engine To turn the key towards position OFF and to remove it The lights switch off 6 2 STARTING and STOP for GENSET Check the Service Manual Panel Read the chapter writted before to stop the gen set not using mechanical system 6 3 USING THE ENGINE INFREQUENTLY Take special precautions in installations where the engine must cut in rapidly and suddenly after long periods of inactivity emergency power systems fire prevention systems and harsh ambient conditions For specific application conditions consult SOL DIESEL 6 4 OPERATING THE ENGINE AT LOW TREMPERATURES Whenever the atmospheric temperature drops below zero the following series of circumstances occur 1 The cooling liquids of the engine may freeze 2 The lubricating oil becomes thicker 3 There is a grop in the voltage at the battery terminals 4 The air inlet temperature is low and the engine has 5 The fuel loses fluidity difficulty in starting Sol Diesel ENG 23 03919400 ENG rev 1 To prevent the damage caused by low temperature operation the engine should be prepared as follows 1 2 Use anti freeze as indicated in section 4 2 2 of this manual
11. used for a long period of time or during the winter time certain operations must be carried out to keep it in perfect operationing condition Follow these lay up instructions carefully Carefully clean the external surface of the engine If very low temperatures are expected always use liquid anti freeze in the refrigeration circuit as indicated in section 4 2 2 of this manual In the case of low capacity fuel tanks drain completely and clean refill with a mixture of diesel oil and rust inhibitor oil For diesel oil in large capacity fuel tanks it is enough to add 2 rust inhibitor oil Close the sea water cock Connect a hose from the sea water pump to a open bucket Put 30 anti freeze mixture to the bucket Start the engine for a moment So the sea water system will be filled with anti freeze mixture Stop the engine Use a dielectric spray on the electrical connections disconnect the battery and charge it several times during the period of inactivity Sol Diesel ENG 24 03919400 ENG rev 1 6 7 RESTORATION OF THE RUNNING CONDITIONS When starting up the engine again after winter lay up certain operations must be performed Follow these steps 1 Fill the fuel tank with clean diesel oil Carry out the process for checking the fuel filter If the filter is clogged replace the filter cartridge The diesel oil rust inhibitor oil mixture placed in the tank for winter lay up can be used to operate the engine Drain the rust
12. 4 E5 M3 R1 R3 L4 STARTS THEN STOPS C1 C3 C5 C7 C9 M5 R4 R6 POOR ACCELERATION C1 C2 C3 C4 M1 M2 M4 Ri NOISVENGNE 1 MH 4 UNEVEN RUNNING SPEED C4 L2 R4 M1 NOISY ENGINE M3 R5 R7 OIL PRESSURE TOO HIGH KENE M8 M9 LUBRICATION FUEL OUTLET COCK CLOSED OIL SUCTION LINES CLOGGED OR ae bad LOOSE ELECTRICAL SYSTEM COOLING CIRCUIT FAULTY FRESH WATER PUMP FAULTY SALT WATER PUMP FAULTY SPARK PLUGS FAULTY THERMOSTAT E7 NM FAULTY ALTERNATOR REGULATOR REPAIRS CLOGGED AIR FILTER M1 WORN OR STUCK RINGS Er ENGINE OVERLOADED M2 POORVALVE SEALING R2 TIMING TOO ADVANCED M3 STUCK VALVE R TIMING TOO RETARDED Lal GOVERNOR SPRING BROKEN OR sa hal SPRING LOW IDLE SPEED M5 WORN CON RODS OR MAIN BEARINGS RS ALTERNATOR BELT TENSION M6 WORN CYLINDERS RE EXHAUST BACKFIRES Mi WRONG VALVE CLEARANCE REMOTE SHIFT AND REVERSING GEAR M8 CONTROL OUT OF ADJUSTMENT CLUTCH CONE WORN r Sol Diesel ENG 35 03919400 ENG rev 1 8 ADDITIONAL INSTRUCTIONS 8 0 ADDITIONAL INSTRUCTIONS Refer to heading 1 3 for safety information 8 1 INSTRUCTIONS FOR DECOMMISSIONING SCRAPPING AND DISPOSAL When you decide to decommission the engine please contact SOL S A we will provide you with the relevant instructions in relation to the laws in force at the time When scrapping the entire engine or components of the engine observe the LAWS IN FORCE IN THECOUNTRY OF INSTALLATION For informati
13. ENGINE INSTRUCTIONS MANUAL SDZ 165 SDZ 165G SDZ 205 Sol Diesel MARINE DIESEL ENGINES N MARINE DIESEL GENSETS This engine instructions manual is also avallable in the following languages ENG This operator s manual is available in English Part no 03919400 ENG Download from our web page www solediesel com or order to oftec solediesel com SP Este manual de instrucciones puede solicitarse en espa ol Ref 03919400 SP Descargar desde nuestra web www solediesel com o pedir a trav s mail oftec solediesel com Sol S A seeks for the constant improvement of its final products for that reason the design description dimension configuration and other technical specifications herein appear just as an informative note that can not be understood as a binding offer referred to the final product The technical specifications and presentations are subject to variations and modifications without being obliged to proceed with any previous notice NDICE GENERAL 0 INTRODUCTION 0 0 FOREWORD 0 1 USING THE INSTRUCTION MANUAL 0 1 1 IMPORTANCE OF THE MANUAL 0 1 2 CONSERVING THE MANUAL 0 1 3 CONSULTING THE MANUAL 0 1 4 SYMBOLS IN THE MANUAL 1 GENRAL INFORMATION 1 1 ENGINE MANUFACTURER S INDENTIFICATION DATA 1 2 INFORMATION REGARDING TECHNICAL ASSISTANCE MAINTENANCE OF THE ENGINE 1 3 GENRAL SAFETY NOTICIES 1 3 1 INFORMATION REGARDING RESIDUAL RISKS 1 3 2 SAFETY REGULATIONS 2 PRELIMINARY INFORMATION
14. ESDEAPRIETE spe SDZ20 1 Bot cylnderhead B B I AAA SJ JL s Bolt metal cap r Bolt conecting rod 3 3 For the Connecting Rod Bolts please read Bolts Flywheel length 30 45 mm _ the comment 1 and for the Flywheel bolts Bolts Flywheel length 50 85mm please read the comment 2 Plug oil pan Oil filter Pressure relief valve 4 5 4 5 ii Bolts to fix the Flange injections pumps 5 5 Bolt Stop solenoid 2 1 2 1 Nut for B terminal of starter 1 1 1 1 Water cooler element locknut 23 23 Reversing gear body set screw 5 Oil gearbox drain plug General tightening torque M6 1 0 M6 1 0 M8 2 5 M8 2 5 M10 6 0 M10 6 0 M12 10 0 M12 10 0 Comments 1 1st tightening angle 60 l 2nd tightening angle bolts 60 2 1st tightening angle bolts 30 85 mm lenght 60 2nd tightening angle bolts 30mm length 30 2 4 tightening angle bolts 35 85mm length 60 Bolts may be used 5x if evidence can be furnished concerning their use CYLINDER HEAD BOLTS TIGHTENING SEQUENCE When bolting the cylinder head clean throughly the contact faces and fit the head gasket Retighten one screw at a time when engine is cold as indicated in the suitable drawing Loosen must be done using the reverse sequence Do e o e e e e OO A Manifold side Cylinder head bolts may be used max 5 times If evidence can be furnished concerning their use Tightening torque 15 stage 50 Nm Tigh
15. FAGTURER S IDENTIFICATION DATA MANUFACTURER Sole Diesel 7 SOLE S A SPAIN Ctra de Martorell a Gelida km 2 08760 MARTORELL BARCELONA SPAIN MODEL TRADE DESIGNATION SDZ 165 marine and genset SDZ 205 The above data can be quickly identified in the following position Check the plaque Fig 1 1a for genset and the Fig 1 1b for propulsion engine See the Fig 1 2 to read the engine identification see fig 1 1 detail of the plaque See the fig 1 3 to read the engine serial number 1 2 INFORMATION REGARDING TECHNICAL ASSISTANCE AND MAINTENANCE OF THE ENGINE Our after sale service is at your complete disposal to solve any problems that may arise or to supply any information you may need For ANY explanations refer to the SERVICE SOLEDIESEL address booklet Optimal operation and efficiency of your new SOLEDIESEL engine can only be guaranteed if you use original spare parts For GUARANTEE terms refer to the GUARANTEE CARD 1 3 GENERAL SAFETY NOTICES The engine is designed and built as a power unit for generating mechanical energy ALL USES OTHERTHAN THE PRESCRIBED APPLICATIONAUTOMATICALLY RELEASE SOLE S A FROMLIABILITY FOR DAMAGES THAT MAY ENSUE in any event the use of products other than those agreed upon at the time of purchase RELEASES SOLE S A FROM ALL LIABILITY FOR DAMAGE TO THEENGINE OR PROPERTY OR INJURY TO PERSONS Although the engine Is built in compliance with the most recent saf
16. Fuel decanting filter drainage if equipped Check indicators After commisioning check oil pressure Control and eventual adjustment of the alternator belt water temperature and battery charge The three lamps must be switched off and the alarm must not be sounded Check cooling water is flowing and if some failure is Overhaul of the propeller shaft and positioning screw detected in the exhaust gases noise and vibrations tightening torque Check cooling water level Clean water filter for impurities EVERY 250 OPERATING HOURS EVERY 500 OPERATING HOURS Change oil engine a Check the tightening torque of the engine positioning propeller shaft screw and gas oil piping nipples Chanoe oil filter Adjust valve clearance or it there is two connections Check condition of sea water pump impeller and its eventual replacement EVERY 1000 OPERATING HOURS EVERY 2 OPERATING YEARS Change the refrigeration anti freeze liquid Change alternator belt Clean the fuel tank Check the compression pressure of each cylinder Injector checking EXHAUST PROTECCTIONS Check the protections follwing the manufacturer comments For the airvent in case of blocked passages disassemble the valves clean with freshwater and spray with silicone before resembling the unit Sol Diesel ENG 27 03919400 ENG rev 1 7 2 OPERATING DESCRIPTION 1 Change engine and gearbox oil Read heading 4 2 1 Change oil filter Fig 7 2 2 Se
17. GS 9 1 INSTRUCTIONS FOR FIRST STARTING 9 1 1 BLEEDING AIR FROM THE FUEL SUPPLY SYSTEM ENG 21 9 2 PRELIMINARY RUNNING TEST 9 2 1 NO LOAD RUNNING TEST 9 2 2 RUNNING IN 6 USING THE ENGINE ENG 22 6 0 GENERAL WARINGS 6 1 STARTING AND STOP THE ENGINE PROPULSION VERSION 6 2 STARTING AND STOP THE ENGINE GENSET VERSION ENG 23 6 3 USING THE ENGINE INFREQUENTLY 6 4 OPERATING THE ENGINE AT LOW TEMPERATURES 6 5 CONSERVATION ENG 24 6 6 LONG INACTIVITY INSTRUCTIONS 6 7 RESTORATION OF THE RUNNING CONDITIONS ENG 25 7 REPAIR AND MAINTENANCE ENG 26 7 0 GENERAL WARNINGS 7 1 TYPE AND FREQUENCY OF INSPECTIONS AND MAINTENANCE INTERVENTIONS 7 2 OPERATION DESCRIPTION ENG 28 7 3 TROUBLE SHOOTINGS ENG 35 8 ADDITIONAL INSTRUCTIONS ENG 36 8 0 ADDITIONAL INSTRUCTIONS 8 1 ISNTRUCTIONS FOR DECOMMISSIONING SCRAPPING AND DISPOSAL 8 2 DERATING OF ENGINE DUE TO FUEL AND COMBUSTIO PROPERTIES 9 TECHNICAL ANNEXES ENG 38 9 0 OIL SPECIFICATIONS 9 0 1 ENGINE OIL TO BE USED 9 0 2 GEARBOX OIL 9 1 ESPECIFICATIONS FOR ENGINE INSTALLATION 9 2 POWER TAKE OFF ESPECIFICATIONS OPTIONALS Sol Diesel ENG 03919400 ENG rev 1 0 INTRODUCTION 0 0 FOREWORD Dear client The SOL S A engine you have purchased is a product of the highest technological quality Our Service SOL DIESEL department has recently been strengthened to ensure even better service for all our clients Reliable duty and long life of the engine you have purchased can only be guarant
18. HING WHEN WORKING ON A HOT ENGINE PROTECT THE RESPIRATORY PASSAGES WHEN WORKING IN THE VICINITY OF ENGINE EXHAUST GAS Sol Diesel ENG 4 03919400 ENG rev 1 2 PRELIMINARY INFORMATION ON THE ENGINE 2 1 GENERAL DESCRIPTION 1 Direction of Rotation clockwise observing engine from side opposite flywheel Counter Clockwise observing engine from flywheel 2 Tming pushrod and rocker arm with gear driven camshaft in crankcase 3 Air Supply air clearing by jeans of a dry type air filter Turbocharger used in both models SDZ 165 equiped with an intercooler Fuel System equiped with mechanical priming pump Combusti n System Direct Injection Cycle diesel 4 stroke 4 cylinders in line for SDZ 165 and 6 cylinders in line for model SDZ 205 Cooling System liquid cooled circulation controlled by centrifugal puma with thermostatic control and heat exchanger Also 4 5 6 Injection Pumps Single puma for each nozle 7 8 the exhaust manifold is cooled 9 Lubrication torced feed lubrication by gear pump 10 Electrical System 24V 2 poles 18 19 20 21 22 23 17 1 e 2 d F i x Se 16 15 14 13 12 11 10 9 8 7 6 31 37 30 l 32 22 e 33 J 34 27 Ge hef 26 36 25 24 33 Coolant line to turbocharger 35 Flywheel housing size SAE 3 37 Elbow wet exhaust Sol Diesel ENG 5 03919400 ENG rev 1 1 Filler cap for the coolant on the expansion tank
19. KING AND UNPACKING The engine is shipped in various types of packing systems STORAGE STACKING OF PACKS Pallet with wooden crate See heading covered area only 3 1 1 Pallet with skeleton crate See heading covered area only NO 3 1 2 Engine mounting base plastic covered area only packaging See heading 3 1 3 3 1 1 PACKING AND UNPAGKING WITH PALLET AND WOODEN CRATE Remove the lower nails Lift the engine using chains with safety hooks and of suitable load capacity Attach the chain hooks to the engine eyebolts and lift using a forklift or other suitable lifting equipment as described in heading 3 3 Transfer the engine to the intended position of installation and remove the plastic wrap film Unscrew screws that secure the engine to the wooden base withdraw the base and proceed with installation operations 3 1 2 PACKING AND UNPACKING WITH PALLET AND SKELETON CRAT Remove the lower nails Lift the engine using chains with safety hooks and of suitable load capacity Attach the chain hooks to the engine eyebolts and lift using a forklift or other suitable lifting equipment as described in heading 3 3 Transfer the engine to the intended position of installation and remove the plastic wrap film Unscrew screws that secure the engine to the wooden base with draw the base and proceed with installation operations 3 1 3 PACKING AND UNPAGKING WITH ENGINE MOUNTING FIXTURE AND PLASTIC PACKAGIN Lift the engine using chain
20. L The Safety symbols and notices shown below are used throughout this publication to draw the user s attention to situations or hazardous procedures that could damage the engine or cause personal injury and to indicate suitable practices to assure the correct operation of the engine DO P PP Bad 5 GENERAL OPERATIONAL NOTE PROTECT YOUR HANDS GLOVES PROTECT YOUR EYES SAFETYGLASSES PROTECT RESPIRATORY PASSAGES MASK DANGER GENERAL DANGERSITUATION FOR THE SAFETYOF PERSONS AND PROTECTIONOF THE ENGINE DANGER DANGER OFELECTRICAL DISCHARGES FORTHE SAFETY OF PERSONS ANDENGINE DANGER DANGER FROMSOURCES OF HEAT FOR THESAFETY OF PERSONS AND THEENGINE THE OPERATION INDICATED INTHE TEXT IS STRICTLYPROHIBITED IT IS ABSOLUTELYPROHIBITED TO PERFORMMAINTENANCE WORK IN THEPRESENCE OF MOVING PARTS REMOVING OR TAMPERING WITH SAFETY DEVICES ISSTRICTLY PROHIBITED Prescription Indication notices rectangular it is obligatory to adopt the protective measures shown in the notices to perform the operation in question in total safety Danger Warning Attention Notices triangular General Attention regarding personal safety and protection of the engine Prohibition notices circular indicating potentially hazardous situations for personal safety PAY ATTENTION TO SYMBOLS AND OBSERVE THE INSTRUCTIONS IN THE ADJACENT TEXT Sol Diesel ENG 2 03919400 ENG rev 1 1 GENERAL INFORMACION 1 1 ENGINE MANU
21. L licensed service shop since a precision pump monitor and skill knowledge are required The requirements for the handling of a fuel injection pump are the following Always use fuel which is without impurities and fuel filter shall be changed at the scheduled time 19 Fuse The switchboard carries as protection a 2 fuses one with a size 10A to protect the panel s instruments and other to protect the circuit In case the switchboard does not received power supply check if the switchboard is or not fused and replaced Sol Diesel ENG 33 03919400 ENG rev 1 20 Checking and cleaning turbocharger To extend turbocharger life and efficiency some basically important instructions are given below 1 Possible causes of turbocharger trouble are essentially three a Lack of lubricant causes bearing failure with consequent seizure of rotary components b Introduction of foreing matter poor servicing of air cleaner will involve the introduction of solid particles which will damage the compressor impeller blades Fragments would be carried to the cylinders c Lubricant contamination this causes scoring of journal bearings clogs oil passages wears the seals with consequent leakages and seizdures 2 Turbocharger construction siplicity is only apparent in fact many of its parts are machined to 1 1000 mm tolerances lts therefore recommended that you entrust any servicing to skilled personnel having availability of s
22. ON THE ENGINE 2 1 GENERAL DESCRIPTION 2 2 COOLING CIRCUIT 2 2 1 COOLING CIRCUIT COOLANT 2 2 2 SEAWATER COOLING CIRCUIT 2 3 LUBRICATION CIRCUIT 2 3 1 ENGINE 2 3 2 GEARBOX 2 4 FUEL CIRCUIT 2 4 1 INJECTION PUMP 2 5 ELECTRICAL PLANT 2 5 1 ELECTRICAL PLANT AND INTRUMENT PANEL PROPULSION ENGINE 2 0 2 ELECTRICAL PLANT INSTRUMENT PANEL GENSET VERSION 2 6 TECHNICAL SPECIFICATIONS 2 6 1 ENGINE DIMENSIONS PROPULSION VERSION 2 6 2 ENGINE DIMENSIONS GENSET VERSION 2 7 GEARBOX GENERAL INFORMATION 3 TRANSPORT HANDLING AND STORAGE 3 0 GENERAL WARINGS 3 1 PACKING AND UNPAKING 3 1 1 PACKING AND UNPAKING WITH PALLET AND WOODEN CRATE 3 1 2 PACKING AND UNPAKING WITH PALLET AND SKELETON CRAT 3 1 3 PAKING AND UNPAKING WITH ENGINE MOUNTING FIXTURE AND PLASTIC PACKAGIN 3 2 RECEIPT 3 2 1 PACKING LIST 3 3 TRANSPORT AND HANLING THE PACKED ENGINE 3 4 TRANSPORT AND HANDLING OF THE UNPACHED ENGINE 3 5 STORAGE OF PACKED AND UNPACKED ENGINE 4 INSTALATION 4 0 GENERAL WARINGS 4 1 ASSEMBLY DATA 4 2 ENGINE SUPPLIES 4 2 1 CHANGING OIL 4 2 1 1 CHANGING ENGINE SUMP OIL 4 2 1 2 CHANGING GEARBOX OIL 4 2 2 FILLING THE COOLING CIRCUIT 4 2 3 REFUELING 4 3 INSTALLATION 4 4 INDICATIONS FOR REMOVAL DISPOSAL OF WASTE MATERIAL Sol Diesel ENG 03919400 ENG rev 1 ENG 1 ENG 2 ENG 3 ENG 4 ENG 5 ENG 6 ENG 7 ENG 15 ENG 16 ENG 17 ENG 18 ENG 19 NDICE GENERAL 5 PREPARING THE ENGINE FOR USE ENG 20 9 0 GENERAL WARIN
23. Push the fuel pump 3 to the left until the belt is correctly tensioned Tighten the screws Alternator To adjust loosen the screw 2 Push the alternator belt pulley 1 to the right until the belt is correctly tensioned Tighten the screws To change the blet Remove the belt for the fuel pump Loosen the screw 2 Push the alternator belt pulley 1 to the left and remove the belt Replace it with a new one Push the alternator belt pulley 1 to the right until the correct belt tension Tighten the screw 2 When the belt is unfitted check the condition of the pulley recesses they shall be dry and clean lts cleanliness is performed with soap water never use petrol gas oil or similar Fig 7 2 17 products Fit the belt taking care the belt insertion is made with the hand but without damaging it and if required pace it with a tool at least without any cutting edges since otherwise the belt could be damaged and its life shortened The belt shall be tensioned such as is previously explained A Always change a belt that apears worn or is cracked Belts working in pairs be replaced together 18 Inspect injection pump The fuel injection pump is one of the most relevant components of a diesel engine and therefore its handling requires the best care In addition the injection pump has carefully been adjusted at factory and should never be adjusted carelesly Said adjustment whenever is required shall be made by a SOL DIESE
24. RVICE di 07 165 60994200 amp Lan MW LE A i SEO Trifasico 220 Trifasico 380 JOd1NO2 30 OYUYINI 609942730 60954380 ALTERNADOR GET SET Sol Diesel ENG 10 03919400 ENG rev 1 2 6 TECHNICAL SPECIFICATIONS UNITS SDZ 165 SDZ 165 SDZ 165 grupo elect grupo elect grupo elect 70 E a 84 kVA 105 kVA CilindresNumber 4 Oo 4 4 EC Bore 130 130 130 130 130 Total Displacement CC 4764 7146 4764 4764 4764 E 16 1 M61 M61 M61 m61 r p m idingspeed rpm 800 25 800425 Max Engine Speed rpm m 20 230 Type y Ratio 2 04 1 2 04 1 Gear box 25 1 25 1 2 94 1 2 94 1 pom 2 j j 26 1 2 6 1 Bl L NA 2 82 1 Dil A suma 23 1 A A EC032 3L 4 ECP34 1S ECP34 2S Max Assembly Angle 10 10 Crankshaft Power 1 kW CV 118 160 145 197 871118 87 118 87 118 Propeller Shaft Power 1 kW CV 105 144 132 180 PAG j ep 1 ISO 8665 Gearbox oil Capacity TM 170 25 28 pp y y o liters Dm 25 25 pp TM 265 mm _ 55 pp o TM 265A 55 Dee e LSO E EY hot engine 15 A AAA Ignition Sequence 1 342 1 5 3 6 24 1 34 2 1 342 1 3 4 2 Valve Timing intake open Cd or w a ew ll cold nina cold engine Weight Dry with Gearbox TM 170 698 88 gt kg TM 170A 68 818 TM 265 TM 265A r 671115 G84T15
25. TLY FORBIDDEN TO PERFORM MAINTENANCE CLEANING OPERATIONS IN THE PRESENCE OF MOVING PARTS QOPE USE GLOVES OVERALLS ETC TO PROTECT THE BODY FROM BURNS Inspection concept Daily Every250 Every 500 Every Every 2 hour hour Screw tightening fixing akena jP Exhaust gases noise and ne gt gt gt KE E er t tetelel e amp fit EE EE It Y YO 060 2 x VA j j j j Fuelsystem D W _ j o pao j j va O Fuelfiter engin 1 1 19 04 foer WO vo vo e ep o pa pr LL j Yoo Yi Bum OO PO O j j j LL vesen mew v iv e ETC ETC AAN DAKA NANA ty IE e AE eto y ova VO two JBotomook ILL LL Warpmimee 1 v 19 I Cleaning Y Inspection adjustment or filling Change Drainage Sol Diesel ENG 26 03919400 ENG rev 1 Mepeiloneoneepi 1 PAW vw Cher Lie soonour years hour 500 hour 1000 hour years Eesen Bern Jl insan JO wT Amaradsamo fT dP wT femaiorbetandiensen fleien Eraut Prien e Cleaning Y Inspection adjustment or filling Change Drainage DAILY CHECKING BEFORE USE OF THE ENGINE AFTER THE FIRST 50 OPERATING HOURS Check oil level in the engine and gearbox Filling Filling is Change oil engine gearbox and cover fuel supply pump not required if level is near to the rod upper line Check fuel level and open fuel delivery cock Change oil filter Open the water access cock
26. ainage optional Loosen the wing nut 3 Fig 7 2 9 located at the lower side of the glass vessel and let go all the acrued water Shut again off the wing nut and check it does not drip Fig 7 2 9 Sol Diesel ENG 30 03919400 ENG rev 1 10 11 12 19 14 19 Replace the fuel filter element engine See te page n 5 to locate the filter The fuel filter is bladded and cannot be cleaned H must be replaced at least once every 12 months To perform the filter change Shut off the cock located at the tank delivery Unscrew cover filter with a chain spanner Screw the new filter to the cover with the hand and at the same time replace the rubber seals Carry out the operations at heading 5 1 1 bleeding air from the fuel system Injector checking This operation shall be made by a SOL DIESEL service If a hand pump is available monitor the calibration of injectors by verifying that the pressures are those listed in paragraph 2 6 of this manual Checking for anti corrosion protection The anti corrosion protection is not fitted in these engines The parts of the seawater cooling system is maded with materials that protect the cooling system Change air filter The engine is provived with an intake air filter The filter CAN NOT be cleaned it must be changed Read the heading 7 1 Fig 7 2 13 Check alternator and starting motor The engine has an alternator of 28V and 55 Amps accordin
27. and fit it again taking care the cover is well seated on the O ring Fig 7 4 Then the engine is started to check if water is leaking from the cover Fig 7 2 6 Coolant circuit Drain Drain off all the circuit coolant opening the drain cocks in the block and in the body heat exchange See the photo 7 2 7 When in cold climates if the engine is not to be used for a long period it is advisable to drain the water circuit Once this operation has been completed close the drain cocks and fill to the hole in the tank cap see heading 4 2 2 of this manual Checking battery electrolite level and charge Batteries require a very careful handling and frequent checkings Proceed as shown below 1 Always keep batteries dry and cleaned 2 Regularly check terminal cleanliness If dust is settled terminals should be loosened cleaned and smeared with a neutral grease layer 3 Metal objects must not be placed over the battery 4 Batteries or containers containing acids should carefully be handled 5 Monthly or every 200 hours check the acid level and supplement it with DISTILLED WATER required Level should not exceed the battery inside mark 6 Never use open flames to light battery components there is explosion danger 7 In winter batteries should be detached and placed following the manufacturer s instructions Before battery is charged with an external charger disconnect both terminals Fuel decanting filter dr
28. as the following see photo 7 2 3 at the top Fm ESOS a Release locknut 4 Fig 7 2 4 b Fix the tool 1 on the adjustement screw 5 and adjust the clearance as the following griten Fix the magnet Turn the feeler gauge of the tool 1 After turn 90 150 at the back IN Inlet valve 90 EX Exhaust valve 150 tightening the locknut 4 using a torque tool torque 20 Nm c Repeat the check and adjust the clearance in every cylinder Clearance inlet valve 0 3mm Clearance exhaust valve 0 5mm d Reinstall cylinder head with a new gasket if is necessary e Swing ventilation valve into position and fasten Control and eventual adjustment of the alternator belt tension Never adjust the belt tension with engine running An excessive tension may cause a quick wear of the belt and alternator bearings Otherwise if the belt is excessively loose or has oil and insufficient load due to the belt skidding can be caused Check belt tension by pressing on one side with your thumb Belt deflection should be about T 15mm Sol Diesel ENG 29 03919400 ENG rev 1 6 7 8 9 Water filter cleaning It is important to fit between the engine and the bottom cock a filter to avoid that any impurities existing in these a water might clog the cooling conducts Filter shall be cleaned every 200 hours by loosening the wing nut and removing the filtering component Clean the filter
29. e with hot engine 1 Oil pressure at idling speed 0 8 kg cm 2 Oil Pressure at operating speed 1100 rpm or higher 4 5 kg cm OIL CAPACITY LITERS SDZ 165 SDZ 205 A 2 Engine equiped with Standard oil pan no engine inclination and with oil filter 2 3 2 GEARBOX AN Gearbox has its own lubrication independent from the engine See fig 2 2 Only for propulsion engine Sol Diesel ENG 7 03919400 ENG rev 1 2 4 FUEL CIRCUIT Fig 2 4 1 Fuel tank 2 Marine hose luel certificated 3 Fuel pump 4 Fuel pipe to fuel filter 5 Fuel filter 6 Fuel pipe to the singles injections pumps 7 Injections pumps 8 Pipe to injectors 9 Injectors 10 Fuel pipe return 11 Valve 12 Marine fuel hose to the tank 13 Distance between inlet and outlet lt must be bigger 14 Fuel filter water separator ENGINE INJECTORS SDZ 165 SDZ 205 6 SS Fig 2 4 Fuel pump Fuel filter engine Marine fuel hose Read the next comment at the bottom of the page Fuel filter water separator Valve Fuel pump manual Not suplied optional order kit 19424075 Fuel tank Breather tank Fuel cooler optional 0 Marine fuel hose to the tank Read the next comment at the bottom of the page 11 No return valve not supplied 12 Injector 13 Fuel pump 1 2 3 4 5 6 7 8 9 1 D lt Not surpass the 2 m of height between the tank and ful pump The distance L
30. e the page n 5 to find the filter on the engine Change the oil filter after the firsts 50 operating hours and afterwards every 200 hours The oil filter being a cartridge type of easy handling shall not be cleaned Change the oil filter cartridge by unscrewing it with a commercially available oil filter wrench When fitting a fresh oil filter smear as mall quantity of oil into the annular seal and firmly tighten it with the hand When this operation is finished start the engine and check oil is not leaking Checking valve clareance MARINE ENGINE VERSION Do these operations in an authorised Sole Diesel Service Before adjusting valve clareance allow the engine to cool for at least 30 minuts The oil temperature should be below 80 C CHECK VALVE CLAREANCE a Loosen ventilation valve and swing it to the side b Remove the cylinder head cover c Position crankshaft as in the figure 7 2 3 d Check valve clareance 1 between rocker arm and tappet contact face 2 and valve steam 3 with a feeler gauge 6 There should only be slight resistance when feeler blade is inserted The valve clareances are the followings Valve clareance inlet valve 0 3mm Valve clareance exhaust valve 0 5mm ADJUST VALVE CLAREANCE a Release locknut 4 b Regulate the adjustement screw 5 by using a screwdriver 7 so that alter tightening the locknut 4 correct valve arance 1 is achieved c Check and adjust the valve clearance
31. eed if you use exclusively original spare parts and ensure that the unit is serviced by our specialized personnel We therefore recommend that you insist on having your SOLE S A engine serviced EXCLUSIVELY by our Service SOL DIESEL Department If engines manufactured by SOLE S A are serviced by unauthorised technicians or if non original spare parts are utilized ALL GUARANTEE AND TECHNICALASSISTANCE OBLIGATIONS OF SOLE S A AREINVALIDATED We are confident that you will understand the importance of these recommendations which are made for purely technical reasons and serve to defend our clients and ensure their full satisfaction with our products Please get in touch with us for any requirements you may have Best regards 0 1 USING THE INSTRUCTION MANUAL 0 1 1 IMPORTANCE OF THE MANUAL This INSTRUCTION MANUAL is your guide to the USE and MAINTENANCE of the engine you have just purchased We strongly recommend that you follow all the advice in the manual meticulously because the correct operation and lasting reliability of the engine depend on its correct use and the methodical application of the programmed maintenance operations illustrated in these pages If you run into difficulties or setbacks Service SOL DIESEL department will be happy to provide you with the necessary advice and assistance This INSTRUCTION MANUAL is and integral part of the product you have acquired Please conserve it in a safe place for the full working life of t
32. erating values AllEngines Start opening at Fully opened at 102 C AAA 2 2 2 SEAWATER COOLINGCIRCUIT Fig 2 2 1 Bottom cock 2 Intake connection with water filter 3 Oil cooler gearbox 4 Pipe inlet seawater pump For genset connect the inlet seawater Directly to the seawaterpump Seawater pump Intercooler Heat Exchange freshwater Elbow wet exhaust Sol Diesel ENG 6 03919400 ENG rev 1 2 3 LUBRICATION CIRCUIT 2 3 1 ENGINE Fig 2 3 1 Lubrication is forced with a lobe pumpand total filtration of the oil pumped tothe various lube points on the engine The oil is forced by the pump through acontrol valve to the filter the enginemain bearings and by way of external pipelines to the rocker arms Fig 2 3 1 18 17 23 16 1213101415119 6 4 Oil pan Scroop Oil pump a Valve flow control b Valve maximun pressure Oil cooler engine Oil filter element Oil pipe Bearing crankshaft Bearing conecting rod 9 Bearing camshaft 10 Pipe cooling cylinder 11 Pipe cooling cylinder 12 Tappet 13 Rod cooling rocker 14 Rocker 15 Pipe to oil pan 16 Oil pressure sender 1 2 3 3 3 4 5 6 T 8 TT ar eee 17 Pipe to turbo charger 18 Turbo charger 19 Pipe to compressor or hydraulic puma optional 23 Pipe to oil pan 24 Pipe from turbocharger to oil pan 25 Pump oil suction Oil circuit pressur
33. ety standards it is advisable to bear in mind that moving parts are always potentially dangerous Therefore never attempt to work on parts of the engine while they are in motion and make sure that there are no persons in the vicinity of the engine before starting it The standard engine can run at ambient temperatures between 18 C a 45 C The operator in charge of installing and maintaining the engine must wear suitable CLOTHING for the workplace and the situation in particular avoid loose clothes chains bracelets rings and all other accessories that could become entangled with moving parts The area in which the operator is working must be kept tidy and free of oil and other liquid spillages and solid waste metal chips etc Sol Diesel ENG 3 03919400 ENG rev 1 Before starting work the operator must be aware of the position and operation of all commands and the characteristics of the engine make a daily check of the safety devices on the engine Disabling or tampering with the safety devices on the engine is strictly prohibited Do not attempt to perform maintenance work adjustments or reset tings on moving parts on the engine before performing any of the above operations disconnect the electrical supply to ensure that no other persons can start the engine up In the meantime Do not alter any parts of the engine for example connections holes finishes etc to adapt it to the installation of extra equipment or for any ot
34. g to the model with an electric regulator incorporated and an output for the revolutions counter Regularly check the electrical connections its relevant positioning and the good terminal contact For the starting motor check brush wear and switch sour face roughness Replace if the service limitation has been reached Cleaning the fuel tank Drain out the contains of the fuel tank to remove condensate and any foreign materials Wash the tank with fuel dispose of fuel as described in heading 4 4 Sol Diesel ENG 31 03919400 ENG rev 1 16 Compression pressure checking Connect compression tester Turn engine with starter Compression pressure 30 38 bar The measured compression pressure is dependent on the starting speed during the measuring process and also on the altitude of the engine site Therefore it is difficult to specify precise limit values lt is recommended to use the compression pressure measurement only for comparison of compression pressures of all cylinders in one engine If a difference in pressure in excess of 15 is determined the cylinder unit concerned should be dismantled to establish the cause Check condition of sea water pump impeller and its eventual replacement Driving impeller is neoprene and cannot rotate dried If operated without water the impeller can be broken It is important therefore that a spare impeller is always available To change the impeller close water inlet cock remove pump co
35. he engine SOL S A reserves the right to make changes aimed at improving its products without any form of prior notification Please ensure that you enclose with the original publication of the present manual any amendments or updates that you may receive Pass on this manual to all users of the engine or future owners 0 1 2 CONSERVING THE MANUAL When using the manual make sure that it is not damaged or defaced Do not remove or rewrite any parts of the manual for any reason Conserve the manual in a dry and heat protected place 0 1 3 CONSULTING THE MANUAL This instruction manual comprises COVER PAGE WITH INDICATION OF THE FAMILY TO WHICH YOUR ENGINE BELONGS The cover page shows the model of the engine described in the manual TABLE OF CONTENTS Use the contents page to find the page containing information relative to a given argument INSTRUCTIONS AND OR NOTES ABOUT THEPRODUCT All the INSTRUCTIONS AND OR NOTES ON THE PRODUCT are designed to define safety practices proper procedures and the skills required for correct operation of the engine The annexes at the end of this manual are an integral part of the same Please note that the illustrations in the manual which have been included to help you identify the parts described in the text show standard or prototype engines and may therefore differ in some respects from the engine in your possession Sol Diesel ENG 1 03919400 ENG rev 1 0 1 4 SYMBOLS USED N THE MANUA
36. her reason THE RESPONSIBILITY FOR ANY TYPE OFINTERVENTION NOT EXPRESSLY AUTHORISEDIN WRITING BY SOLE S A IS BORNEEXCLUSIVELY BY THE PERSON OR PERSONSWHO CARRY OUT SUCH WORK SOL S A DECLARES THAT THE ENGINECHARACTERISTICS ARE COMMENSURATEWITH THE PARAMETERS PERMITED BYESTABLISHED LAW REGULATIONS REGARDINGTHE EMISSION OF AIRBONE NOISE POLLUTING EXHAUST GAS WHEN USING THE MOTOR IN A CLOSEDENVIRONMENT THE EXHAUST FUMES MUST BECONVEYED OUTSIDE 1 3 1 INFORMATION REGARDING RESIDUAL RISKS The engine must be used in compliance with the manufacturer s prescriptions technical specifications safety regulations etc Any modifications you make be previously authorized by the Manufacturer If you use the engine beyond its application limits and alter in any way the characteristics that are the responsibility of SOL S A such use shall be considered improper and SOL S A declines all liability for the consequences see notes regarding intended use in General Safety Notices 1 3 DO NOT TAMPER WITH ORMODIFY ANY MECHANICAL OR ELECTRICAL COMPONENTS OF THE ENGINE WITHOUT PIOR WRITTEN AUTHOR ISATION FROM THE MANUFACTURER 1 3 2 SAFETTY REGULATIONS ITS STRICTLY PROHIBITED TO PERFORM MAINTENANCEWORK WHILE THERE AREENGINE PARTS MOVING WHEN THE ENGINE ISRUNNING IT IS STRICTLYPROHIBITED TO TOUCHANY PARTS OF IT ITS STRICTLY PROHIBITED TO REMOVE OR TAMPERWITH THE SAFETY DEVICES ALWAYS PROTECT THEHANDS WITH SAFETY GLOVES AND HEAT RESISTANT CLOT
37. ine duty and at six months or 1000 hours intervals thereafter addrust inhibiting agent AC88 to the coolant in the same proportions as indicate dearlier The cooling liquid mixture must be topped up with identical mixture and totally drained and replaced every 2 years Sol Diesel ENG 18 03919400 ENG rev 1 warning A To use a refrigeration liquid that does not ful fill the technical specifications brings about damages to the components of the motor determining the cancellation of the guarantee 4 2 3 REFUELING Always use clean filtered gas oil Never use either kerosene or heavy oils On topping up with fuel use a funnel with a metallic mesh filter to keep out impurities or foreign bodies which may cause problems in the fuel injection circuit Whenever possible keep the fuel tank full as temperature changes may cause condensation of the damp air present in the tank so that water accumulates at the bottom giving rise to corrosion or making it impossible to start the engine if this is aspirated by the fuel pump Check all tank filling plugs located at the boat deck are sealed AN warning Do not use diesel fuel mixed with water or any other foreing substances warning N Always use top quality fuel of certified origin the use of diesel fuel that does not comply with the technical specifications indicated above will cause serious damage to the injection system and hence to the engine and also invalidate the terms of the guarantee
38. inhibitor oil contained in the crankcase and refill the engine sump with oil according to the instructions on heading 4 2 1 1 Check the condition of the fresh water cooling system rubber hoses Reconnect the battery and apply a layer of neutral Vaseline to the battery terminals Remove the nozzle supports and clean them If possible verify the setting of the nozzles at a workshop Turn the engine without nozzles using the starter motor to eliminate the rust inhibitor oil used in the winter Then install the clean nozzles Connect the cooling and exhaust system Open the sea water cock Verify whether there are any leaks in the fuel and water systems Start up the engine and try out at different speeds making sure that the water flows correctly Check again to see if the connectors leak Sol Diesel ENG 25 03919400 ENG rev 1 7 REPAIR AND MAINTENANCE 7 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 7 1 TYPE AND FREQUENCY OF INSPECTIONSAND MAINTENANCE INTERVENTIONS INCREASE THE FREQUENCY OF MAINTENANCE IN HARSH DUTY CONDITIONS FREQUENT STOPS AND STARTS DUSTY SURROUNDINGS PROLONGED WINTER SEASON NO LOAD RUNNING IF POSSIBLE CHECK LEVELS AND REPLENISH SUPPLIES WITH THE ENGINE STOPPED AND AT AMBIENT TEMPERATURE WARNING RISK OF BURNS DURING MAINTENANCE OPERATIONS CARRIED OUT WHEN THE ENGINE IS HOT WEAR SUITABLE SAFETY CLOTHING ITIS STRICTLY FORBIDDEN TO CLEAN THE ENGINE WITHCOMPRESSED AIR ITIS STRIC
39. nce the engine has started release the ignition key allowing it to automatically return to the ON running position and disconnecting the starter motor Immediately adjust the accelerator to prevent the engine reaching high speed When the engine is running do not turn the ignition key to the START position as this would seriously damage the starter motor After the starting operation check oil pressure and battery charge lamps are switched off Heating Heat the engine for approx 5 minutes allowing it to run with no load at half feed In this case directly rotate the ignition key to the START position until the engine is running Sol Diesel ENG 22 03919400 ENG rev 1 e Me eSTART stop OFF SCH NANG START STOP ON START OFF N S N OFF on START STOP Allow to run at low speed for 4 or 5 minutes and place the gearbox remote control lever in the neutral position Turn the starter key to STOP The piston will be actioned and the engine stops Mantain this position until the engine is fully stopped With the engine stopped the starter key returns to OFF position automatically If engine is not to run for a longer period it is advisable to shut fuel and water AUTOMATIC cocks and also to disconnect the battery OF STOPPING THE ENGINE not using the mechanical system Locate the handle of adjustment of revolutions 1 in low speed of turn Using
40. ny of the liquids utilised to fill the various circuits on the engine When distilled water is used in the refrigeration circuit an anti freeze product must be added otherwise the expansion of water when it freezes may produce cracks and damage to the refrigerator unit and to the block and in proportion to the temperatures expected The anti freezing agent manufacturer in the package labels is giving the instructions to be followed at each case However in the following box suitable rates a reset out in accordance with temperatures Ant freezing liquid concentration 30 40 50 60 Freezing temperature C 45 It is advisable the anti freezing agent strength is selected based on a temperature which is approx 5 C under the actual atmospheric temperature The anti freeze solution recommended can be used fora normal operation of 2 years At the end of this period of time the refrigeration circuit must be emptied and cleaned then refilled with the predetermined anti freeze see 4 2 2 Read the chapter 7 2 to air purge Run the engine for a few minutes until the cooling circuit is properly filled and free of air pockets Check the coolant level and replenish if necessary warning N Never open the oil plug 1 when the engine is hot since they can leave steam or spurts hot coolant The engine and to hope to realise the engine change with the already cold one To see fig 4 2 2 warning A after the first 50 hours of eng
41. on all remaining o D e Swing ventilation valve into position and fasten CRANKSHAFT POSITION 1 Turn crankshaft until both valves in cylinder n 1 overlap exhaust valve about to close inlet valve about to open Adjust clearance of valves marked in black on photo 7 2 3 Mark respective rocker arm with chalk to show that adjustment has been carried out Sol Diesel ENG 28 03919400 ENG rev 1 m afo nja ojo nja 0004 S sk FJ Fig 7 2 3 9 CRANKSHAFT POSITION 2 Turn crankshaft one full revolution 360 Adjust clearance of valve marked in black on photo 7 2 3 After the adjustment the rocking nut should be well tightened while the adjusting screw is locked so that it does not rotate NOTE The adjustment of the valve play must be made after the cylinder head screws are again tightened Strictly comply with the operation sequence indicated in the heading 4 1 Checking valve clareance GENSET VERSION a Loosen ventilation valve and swing it to the side b Remove the cylinder head cover c Do these operations in an authorised Sole Diesel Service Before adjusting valve clareance allow the engine to cool for at east 30 minuts The oil temperature should be below 80 C d Turn crankshaft until both valves in cylinder n 1 overlap exhaust valve about to open e Locate the crakshaft as showed in the photo 7 2 3 6 If is necesary to adjust the clearance do
42. on on the materials of which individual components of the engine are made contact SOL S A 8 2 DERATING OF ENGINEDUE TO FUEL ANDCOMBUSTION PROPERTIES FUEL PROPERTIES Output correction due to fuel properties Specified outputs presuppose the following fuel properties as per ISO 3046 Energy value 42700 kJ kg Temperature before feed pump 35 C Density 15 C 0 84 kg dm If the fuel derivates from these values correction factors in are found in the graphs below Use the correction factors in calculation of engine output B B 4 4 g g 2 2 S 5 o 0 3 3 3 2 3 2 gt O 4 O 4 6 6 10 20 30 40 40 DU 0 78 0 8 0 82 0 64 0 56 01 88 0 39 Fuel temperature C Density Kg Dm3 Graph 1 Graph 2 Effect of fuel temperature on engine output 35 C is Effect of fuel density on engine output Normal value reference temperature 0 is 0 84 Kg dm3 at 15 C 0 AIR PROPERTIES Output correction due to air properties Specified outputs presuppose the following air properties as per ISO 3046 Air pressure 1000 mbar 750 mmHg Air temperature 25 C Humidity 30 Sol Diesel ENG 36 03919400 ENG rev 1 If the air deviates from these values correction factors in are found in the graphs below Use the correction factors in calculation of engine output Output correction 9 Temperature C Graph 3 Effect of intake air temperature on engine output 25 Cis reference tempe
43. pecial equipement provided by the service network 3 Preventive maintenance will extend the life and efficiency of the turbocharges Should you notice loss of lubricant vibrations or abnormal noises stop engine immediatelly Timely servicing will avoid costly and unexpected repairs 4 When the turbocharger is not working properly or for preventive overhaul proceed as follows a Loosen the ventilation pipe 1 from the air intake 2 and remove the air filter together with the air intake b Loosen the screws on the compressor housing 3 and i remove it carefully Fig 7 2 20 c Immerse complete assy in petrol gasoline until all dirt is dissolved d Clean the housing and compressor wheel 4 from soot by using a plastic brush or scraper e Wipe and dry in air making sure that the oil ducts are perfectly clean lt is better not to use steam which might damage the bearings and the shaft f Make sure that the intake filter is perfectly clean NOTE Every time turbocharger is disassembled and before starting it make sure to prime it with engine oil to prevent damage due to dry running AN warning for better lubrication of the turbocharger we advice to let the engine run at idling speed without load during 30 seconds after starting and 3 minutes before stopping Sol Diesel ENG 34 03919400 ENG rev 1 7 3 TROUBLE SHOOTINGS ENGINE FAILURE PROBABLES CAUSES FAILURE TO START C1 C2 C3 C4 C5 C6 C9 E1 E2 E3 E
44. rature 0 NORMALLY ASPIRATED TURBOCHARGED Sol Diesel ENG 37 03919400 ENG rev 1 Output correction 1050 1000 950 300 a50 DUU DU Air Pressure mbar Graph 4 Effect of air pressure on engine output Normal value is1000 mbar 750 mm Hg 0 9 TECHNICAL ANNEXES 9 0 OIL SPECIFICATIONS 9 0 1 ENGINE OIL TO BE USED Use Sole Diesel SAE 15W 40 oil Its service classification is as follows as follows OIL VISCOSITY Select oil viscosity most suitable for the atmospheric temperatures on API CE CF 4 SG which the engine should be operated Its recommended to use Sole MIL L 2104 E Diesel SAE 15W 40 oil in all the seasons due to the minimum change CCMC D4 G4 P in its viscosity with the temperature changes This is an all season oil for temperatures ranging between 15 C and 35 C 9 0 2 GEARBOX OIL Check the gearbox service manual 9 1 ESPECIFICATIONS FOR ENGINE INSTALLATION D INT FUEL HOSE INT FUEL HOSE FROM SUPERFICIE AIR ADMISSION INT EXHAUST CABLE TO MINIMAL SECTION M NIMA ENTRADA DISPLACEMENT HOSE Bil BATTERY LENGTH coe We o AIRE ASPIRACION AE pra rd BATERRY ter dl ei A a 650 700 m lh Eeer 1100 1200 one mm2 a 1 Max r p m 2 for each curve of 90 of the installation must increase 10 mm for lengths superiors to 3m 9 2 POWER TAKE OFF ESPECIFICATIONS OPTIONALS A B C Ratio r 1 1 116 1 4 297 1 1 297 Rotation Non Clockwi
45. s with safety hooks and of suitable load capacity Attach the chain hooks to the engine eyebolts and lift using a fork lift or other suitable lifting equipment as described in heading 3 3 Transfer the engine to the intended position of installation and remove the plastic wrap film Unscrew screws that secure the engine to the wooden base with draw the base and proceed with installation operations 3 2 REGEIPT When the engine is delivered make sure that the packing has not been damaged during transport and that it has not been tampered with or that components inside the packing have been removed see information marked on covers bases and cartons Place the packed engine as close as possible to the place of installation and remove the packing material checking that the goods supplied correspond to the order specifications IS if you notice damage or missing parts inform sol diesel assistance departments and the carrier immediately and foward photographic evidence of the damage lt important After inspecting the goods if you notice damage etc write are servation on the delivery note Have the carrier countersing the note and advise SOLE S A preferably by telefax Sol Diesel ENG 14 03919400 ENG rev 1 3 2 1 PACKING LIST 1 ASSEMBLED ENGINE 2 TECHNICAL DOCUMENTATION 3s the technical documentation contains instruction and user manual Packing material must be disposed of in compilance with established law in the user
46. se Non Clockwise Clockwise c Left Left MAX 50 kW 20 kW 20 kW OUTPUT 187 Nm 64 5 Nm 64 5 multiplicate to rom engine AN warning Values must be expired B C 20 kW 64 5 Nm A B C 50 kW 187 Nm If B C 0 kW gt A 50 kW it s depending conection Contact to Technical department SoleDiesel Sol Diesel ENG 38 03919400 ENG rev 1 MARINE DIESEL ENGINES MARINE DIESEL GENSETS SOL S A Dpto Publicaciones T cnicas Ctra Martorell a Gelida km 2 08760 Martorell Barcelona Spain Tel 34 93 775 14 00 Fax 34 93 775 30 13 e mail sole solediesel com nolo www solediesel com ACREDITADO POR ENAC Ref 03919400 ENG Ed 2 rev 1
47. tening torque 2nd stage 130 Nm Tighten M8 bolt with a torque of 21 Nm Tightening angle 90 Sol Diesel ENG 16 03919400 ENG rev 1 4 2 ENGINE SUPPLIES 4 2 1 CHANGING OIL 4 2 1 1 CHANGING ENGINE SUMP OIL Use oil that corresponds to the technical specifications in chapter 9 The oil must in the heat of the moment be changed with the motor in order to assure completely that empty The temperature of the oil will be approximately 80 C To stop the motor before realizing the oil change This operation is done by oil drain pump see Fig 4 1 Mount the handle B Set the knob A under the pump housing in position for pumping the oil sump Connect a hose from the oil drain pump to a container Process the old oil in accordance with the local regulations When drained fill with fresh oil through the filler hole Fig 4 2 Ska Oil sump capacity see heading 2 6 technical specifications EE 1 Immediately operate engine at idling for some minutes until the dashboard control light is switched off Stop engine Check filter and engine sealing Check then oil level by removing the rod Fig 4 3 cleaning it with a rag and repositioning it by retightening TE EN Fig 4 2 Remove it again immediately to check oil level and if it does not reach the top sign add carefully more oil through the filler hole Fig 4 2 up to the top rod sign The oil level must be between the mark MIN and MAX MAX MIN Fig 4 3
48. ver and with two screwdrivers prize it by removing the impeller from the shaft Clean housing and replace with a new one Fit cover by placing a new seal Fig 7 2 14 Open bottom cock If the impeller is broken when it is changed be sure all the rubber residues scattered are removed from the water pipes Seawater pump Renoval and reassembly Drain the water from the seawater system Remove the pipes to and from the seawater pump Remove the connecting socket Remove the screw cap Loosen the hex nut from gear of sea water puma Loosen bolts on seawater pump Loosen gear from shaft by using an arbour Install the seawater puma with a new gasket if is necessary Fit the gear with a new hex nut Pay attention that key is fitted The cones of the gear and the shaft must be free from lubricant clean and with out damage Fit the screw cap with a new O ring Fit the connecting socket with a new gasket Install the coolant pipes to and from the seawater pump Sol Diesel ENG 32 03919400 ENG rev 1 17 Replace the belts alternador and fuel pump Fully detension old belt so that is renoval can be made easier see photo 7 2 17 Fuel Pump To adjust the belts loosen the screws 1 and 2 Push the fuel pump 3 to the left until the belt is correctly tensioned Tighten the screws To change the belts Loosen screws 1 and 2 Push the fuel puma 3 to the right Remove the belt and replace it with a new one
49. will be the maximum For the aspirations and return fuel hose lengths inferiors to 6 meters mount fuel hose with inner diameter 12mm For lengths superiors to 15 meters to mount hose with inner 14mm 2 4 1 INJECTION PUMP 1 Opening pressure 250 bar 2 Adjusting Pressure 275 bar Sol Diesel ENG 8 03919400 ENG rev 2 2 5 ELECTRICAL PLANT 2 5 1 ELECTRICAL PLANT INSTRUMENT PANEL PROPULSION ENGINE DESCRIPTION GLOW PLUG OPERATION LAMP not actived BATTERY CHARGE LAMP x D OILPRESSUREALARM G VOLTIMETER GAUGE HOUR COUNTER FUSE ALARME FUSE OIL PRESSURE GAUGE COOLANT TEMP GAUGE RESISTENCE 2000 RESISTENCE 1000 Part no 609 94 125 60994200 SDZ 165 1 SDZ 205 x Standard Panel 24V x x x l MEGA y x GA ms ROSA Ross K S Se A a I LI T L MOLETA Vis SS lA I I I I D presune swilch j CONTACTO TEMPERATURA Water tenip se toh TRANSMISOR PRESI N H in 7 Fresse Transmiter BATERIA Bater TRANSMIGOA TEMPERATURA Terpaerglur Transmitter I I Sol Diesel ENG 9 03919400 ENG rev 1 2 5 2 ELECTRICAL PLANT INSTRUMENT PANEL GENSET VERSION AN Check the panel service manual and the electrical wiring attached with the genset DP O DI NA TIM Mt SPEED HANI O CHANGE fall O START FAI HHE SIO Fall O DI SI0 O ID SPAR O vi O SE
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