SABB L DIESEL - traktoria.org
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1. HBN Ou o E Gearbox Cap excl Oil Cooler SABE IVPILSSeseS ec 207 xis SAPB VEZ OT i Sis oil level marks the dipstick are correct only for engines in horizontal position Check the oil level after installation and readjust the marks if necessary COOLING SYSTEM Cooling system Cap with Keel Cooler L2 093 Sus Or LET Z0 A 1963 Dui Wer 1 4 190715 Oud s Basic engine cooling system cap with no heatexchanger or pipes 1432 1 09 Zo SEES 1 593 Zt 14 186 Dod Sb 12 1950 1013 Sa Ui SEE Thermostat setting 74 C The specification of the coolant concentrate should comply with one of the following 2 x 985 MIL A ILTT7535D MIL A 46153 B To determine the amount of coolant concentrate to be added it will be necessary to calculate the total coolant capacity by adding together the engine heat exchanger keel cooler expansion tank and associated pipework capacities WARNING Anti freeze contains Monoethylene Glycol and other constituents which are toxic if taken internally be absorbed in toxic amounts under prolonged skin contact If clothing is splashed with anti freeze it should be washed before being worn again If anti freeze is swallowed accidentally medical advice should be sought immediately An anti freeze concentration of 40 should be used as an all year round coolant This concentration will give low2. Clamp Dolt CTO 2170 Nim 19559 DE 15 Hold the fuel pump delivery valve holder with a spanner and torque the fuel pipe nuts to 29 0 Nm 21 0 ft 16 Replace the injector leak off pipe 17 Fuel injector setting 240 bar WATER SEPARATOR IF MOUNTED A water separator fuel filter should always be mounted between the fuel tank and the engine Drain the separator by loosening the bottom tap PRIMING THE FUEL SYSTEM The fuel system has to be primed before initial starting after fuel filter change if it has been disconnected or if the engine has run out of fuel and stops Start the priming at the water separator if mounted e Loosen the vent plug on top of the separator and let the fuel FLOW AGEL IG vat Je OT Re tighten the vent plug d Release the bleed screws A see Figure 6 on the filter and re tighten when no further air bubbles are expelled Fig 6 Priming the Fuel Filter Fig 7 Priming a Fuel Pump oF Move the speed control to the fast position 4 Operate the fuel lift pump by hand The remaining procedure must be carried out with the engine running and to each pump in turn starting with the pump nearest the filter J3 Refer to Fig 7 and hold the delivery valve holder B with a spanner and slacken the injector pipe nut A until no air bubbles are expelled Hold the delivery valve holder and torque the injector pipe nut EO 2950 Nim WES SEES NOTE It is of the greatest i
3. Gearbox type Hurth Automatic Transmission Fluid ATE bord GGM Specification ATF DEXRON II D HVP gearbox type SABB Engine oil SAE 15W 40 STERNGLAND AND REMOTE CONTROL GREASE Following types of universal grease may be used BP BRneroregse Lo EP Fina Marson EPL Norol Universalfett EP2 Gulfpride SF Castrol Spheerol 2 Mobilux 2 or Mobilplex 47 Chevron Dura Lith Grease No 2 Shell Alvania Grease EP2 ESSO MP Grease Beacon EP2 Texaco Multifak EP2 GREASING OF ADJUSTABLE PITCH PROPELLER Following types of water resistant grease may be used Esso Cazae K2 Shell Seromous Orb 20 lexando FO 20 Smererett WVE EPZ Castrol CL grease Fina Merkan 3 CHECK OF LUBRICATION OIL LEVEL The lubrication oil level should always be checked before Shae ing The level should never be allowed to fall below lower mark Note that the marks indicate correct level when the engine has appr horizontal position The marks should be corrected accord ing to installation angle LUBRICATION OIL CHANGE The oil change should be done when the engine is warm Operate the pump handle of the engine mounted pump see fig 1 until the sump has been emptied Remove the filler cap on the top of the valve cover Fill up new us If the filler hole in the crankcase cover fig 2 is accessible the filling may be done there Run the engine after oil and filter change and check for any leaks
4. ODL Stop the engine allow the oil to settle and top up if necessary CAUTION Do not overfill with oil If a cylinder head oil filler is fitted the oil must only be poured into the filler at a rate which enables it to drain into the crankcase If the oil is poured in too quick it can flood the crankcase breather holes and escape into the inlet manifold and cylinders Fig 1 Fig 2 CHANGE OF OIL FILTER ELEMENT Precautions for Filters and Elements Used liquid filters and elements contain some of the filtered liquid and should be handled and disposed of with care After handling new or used elements the users hands should be thoroughly washed particularly before eating Use a suitable strap wrench unscrew and remove filter canister Thoroughly clean the crankcase oil filter housing face Apply a thin film of clean oil to the oil filter sealing gasket Screw on the new oil filter canister until the sealing gasket abuts the filter head and tighten a further half turn Only approved filters should be used as these have high temperature joints adequate filter paper characteristics and a rigid case Other filters may have the same external dimensions and thread as the genuine one but may fail in service HURTH GEARBOX OIL CHECK AND CHANGE Unscrew the dipstick A see Fig 3 from the gearbox Check the oil level by reinserting through hole Fill up if the oil level 1s below the mark Refill new ATF oil to corre
5. Wear protective goggles when handling liquids which are harmful to the eyes for ex battery acid If any of these substances are splashed in the eyes wash out thoroughly with clean water and OBTAIN QUALIFIED MEDICAL ASSISTANCE IMMEDIATELY ORDERING SPARE PARTS For ordering spare parts see the separate SPARE PARTS CATALOGUE for correct part name and part number When ordering always state full details 1 Engine type and Serial no Identification plate Fig 15 2 Part name and part No See page No 5 and 60 3 Quantity 4 Full address name of ship port of call marking and forwarding instructions air freight air mail by ship by mail SABB MOTOR A S BERGEN NORWAY C SERIE NR HK TURT C L3 139LB 6 NO 29 3000 SERIAL NO HP RPM
6. ll ste psel This instrument panel is just an example Single lever COMETOL TOL gearbox speed control GEARUTLOSER Double lever CGODUFOJ LOT HVP gearbox Speed control oeparate lever control for clutch HVP gearbox PRELIMINARY INSTRUCTIONS CAUTION EPFPHER BASED COLD SIART ATDS MUST NOI BE USED UNDER ANY CICUMSTRANCES WARNING EXHAUST GASSES CONTAIN CARBON MONOXIDE WHICH IS A COLOURLESS ODOURLESS AND POISONOUS GAS THAT CAN CAUSE UNCONSCIOUSNESS AND DEATH STARTING PRECAUTIONS Starting any engine can be dangerous in the hands of inexperienced people Before attempting to start any engine the operator should be fully conversant with starting procedure and controls Ensure that the batteries are in serviceable condition and correctly connected Check that the oil levels in the engine and the gearbox are COLLECT 2 Check that the fuel tank is full and that the system is primed Check that all water drain plugs and cocks are closed Check that water inlet valves if fitted are opened Check that the water level in the header tank is filled up with mixture of water anti freeze 40 Under no circumstances must the engine be started without liquid in the cooling system Ensure that the gearbox is in neutral CHECKS BEFORE STARTING Oil level in engine and gearbox Coolant level in header tank Battery main switch is ON The charge control and oil pressure lights will now be on and the
7. stainless steel clamps If water lock is fitted it should have enough capacity to collect the water which is trapped in the hose when the engine is stopped and it should be provided with a drain valve to prevent frost damage Normally the hose without water lock is drained by closing the sea cock and permitting engine to idle for max 10 seconds cr Never use hose smaller then engine exhaust outlet amp and use a 4 1 lager hose after the water lock to prevent back pressure rising the exhaust line Shown in ALT 4 4 Avoid sharp bends in the exhaust piping hose so that water dose not get traped befor the water lock WATER LINE wu 2 WATER LINE w Nm z WATER LINE eO if gt WATER LINE MIN 150 MIN 150 WATER LOCK y ie Bear er eed IL VACUM VALVE ON THE WATER PIPE RISER SILENCER WATER LOCK VACUM VALVE ON THE WATER PIPE RISER SILENCER WATER LOCK MIN 150 WATER LINE ALT 1 MIN 300 WATER LINE ALT 2 MIN 150 WATER LINE ALT 3 MIN 300 WATER LINE ALT 4 SPANNER TORQUE SETTINGS Crankcase Door Bolt see D in Fig OD Ou End Cover Nut see E in Fig 8 Fuel Filter Bracket Screw Manifold Bolts Rocker Cover Nut Fuel lift pump 2d eres Injector Clamp Nut Alternator Bolt Water Pump Bolt injec
8. L DIESELh type L2092 Lh 4 196 onc l4 190 LI based upon the LISTER PETTER engine types LPW2 LPW3 and LPWT4 and are adapted to requirements for marine use It is essential that the operators read carefully the main points in this manual before the engine is put into service Reference is made to CHECKS BEFORE STARTING STARTING OPERATION and STOP The information specifications illustrations instructions and statements Contained within Chas publication given with our best intentions and are believed to be correct at the time going to press Our policy is one of continued development and we reserve the right to amend any technical information with or without prior notice Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the Manu facturer Distributor or Dealer shall in any circumstances be held liable for any inaccuracy or the consequences thereof Users of this book are advised that the specification details apply to a range of engines and not to any one particular engine In Gases ot difficulty consult MOTOR A S BERGEN NORWAY or a local SABB MOTOR or Lister Petter Distributor for further advice and technical assistance The information given is subject to the Company s current Conditions of Tender and Sale and is for the assistance of users and is based upon results obtained from tests carried out at the place of manufac
9. buzzer will sound STARTING Ibs Before attempting to start the engine the operator Should be familiar with the safety precautions as described earlier 2 Move the speed gearbox lever into max speed position by means of the control lever with gearbox disengaged 2n Dependent on temperature turn the starter switch into the preheat position position 1 and hold at for 10 20 seconds Then turn the switch further into position 2 to energise the starter Release immediately the engine starts and it will return to position 0 The alarm light audible alarm and the changing light should mow be rtr 4 If the engine fails to start within 15 seconds despite good battery condition release the switch and investigate the cause see FAULT FINDING starter motor should be allowed to cool for at least 15 seconds before attempting to restart or In very cold weather below appr 10EC it could be necessary to increase the glowing time to appr 30 seconds and run the starter motor for up to 1 minute OPERATION If one or more alarm lamps do not go out or lights up when the engine runs the engine should be stopped at once to trace the reason When all functions are normal Engine with forward reverse gearbox engage the gearbox by pushing the control lever forward or backward Engine with SABB HVP gearbox engage the clutch Increase the engine speed and pitch simultaneously until desired level Allow the engine to warm
10. fuel oil filter Check belt tension Check block heater if fitted and manifold heater plug Check electrical connections ror CL2gniness and COrrosrion Trghten Nuts DBoltS unions and Nose Clamps Change pressure oil filter in HVP gearbox LUBRICATION OIL SPECIFICATION The engines must be run on heavy duty lubricating oils meeting the requirements of API CC DEF2101D MIL L 2104B or MIL L 46152A B Straight mineral oils are not suitable neither are oils of less detergency than specified CD Series or MILb L 21040 D oils Can inhibit the running in process in new or reconditioned engines but can be recommended for engines running at high load tactor particularly in conjgunctron with high ambient temperatures Turbo charged engines type L4 186 T must be run on heavy duty lubricating oils meeting the requirements of API CD Series 3 or Ihe following tables show the correct oil viscosities at various ambient temperature ranges for cold start to maximum running Before selecting a viscosity grade refer to Notes Monograde Oils Ambient Temperature Range C ZONW ZU Between 5 C and 30 C 30 Between 20 C and 52 C For temperatures above 40 C refer to Note 3 SC ss 52 Multigrade Oils 5W 20 Between 32 25 Refer to Note 1 10W 30 Between 15 C and 52 C For temperatures above 40 C refer to Note 3 10W 40 Between 15 G and 52 C 15W 40 Be
11. temperature protection down to 525B C Additionally a 40 concentration will protect the cooling system rom COTOS LON ELECTRIC SYSTEM VIDI GEI REA KU ae 12 V isolated return Starter MOCO ede Sod 2 cyl engine 1 2 kW Starter Motor 3 and 4 cyl engine 1 7 kW Alternator qwe 55 A Lucas radio suppressed 42 V 300 W extra equipm Inlet Manifold Heater Plug 2 and 3 cyl engine 1x345 W 0 7 4 cyl engine 2x345 W GEARBOX Engine type 12 093 13 139 166 b4 186 T CECI Hurth HBW 125 Gearbox ratio forward reverse 3 63 1 95 ZAP 2y AZ hotstdo Qt DrOpeLVer se Right RH SABB HYDRAULIC OPERATED ADJUSTABLE PITCH PROPELLER Gearbox Type 1 7 2 3 1 7 2 3 Rotation of propeller Right Ihe SABB HVP gearbox has hydraulic operated clutch and pitch adjustment Operating of the gearbox is not possible when the engine is at standstill To move the propeller shaft or propeller pitch rod it is necessary to start the engine INSTRUMENT PANEL AND OPERATING CONTROLS Ihe engine is normally fitted with following instruments e Zs or Tachometer Charge Control Lamp The light will glow when the battery switch is on but must go out when the engine has started AL arms and acoustic warns 1 at too high cooling water temperature 2 at too low oil pressure Glow Starter Switch Butbon Running recorder OpPtEronal
12. CLEARANCE ADJUSTMENT ALTERNATOR BELT TENSION CHECK AND CHANGE OF ENGINE HEATER IF MOUNTED CHECK OF BATTERY CAUTION GENERAL PRECAUTIONS REGARDING ELECTRIC SYSTEM POWER TAKE OFF LIMITS PTO WET EXHAUST SYSTEM FOR SAILING BOATS AND MOTOR BOATS MOUNTING THE EXHAUST HOSE IMPORTANT TIGHTENING SEQUENCES FOR CYLINDER HEAD BOLTS CRANKCASE DOOR BOLTS AND END COVER NUTS FAULT FINDING SCHEME DIFFICULT STARTING EXCESSIVE CARBON DEPOSITS EXHAUST SMOKE ENGINE STOPS LOSS OF POWER OVERHEATING ENGINE FAILS TO BE STOPPED DESCRIPTION OF THE ELECTRICAL OPERATED STOP START SYSTEM STOP SOLENOID DESCRIPTION IMPORTANT WINTER LAYING UP RETURN TO SERVICE ORDERING SPARE PARTS GENERAL PRECAUTIONS Ensure that the engine is securely mounted Ensure that the ventilation combustion air ducts are not Ed Keep the engine and surrounding areas clean Never allow any part of the body to come into contact with high pressure fuel oil when testing injection equipment Avoid contact with exhaust pipe when the engine is or has recently been running These parts can be very hot and can Cause severe burns Keep all safety guards in position Keep the body and clothing clear of all moving or hot parts Rectify all fuel water and oil leaks as soon as possible Isolate the battery when working on the engine All drive belts must receive regular attention Keep electrical contacts fr
13. FORM 977 612 REVISED JAN 2001 SABB L DIESEL OPERATORS HANDBOOK FOR L2 093GR L3 139GR HVP L4 186GR HVP L4 186TGR HVP SABB MOTOR 5 P O Box 7170 5020 BERGEN NORWAY Telephone 47 55 348800 Telefax 47 55 348801 E mail firmapost sabb no GENERAL PRECAUTIONS LIFTING PRECAUTIONS INTRODUCTION ENGINE STARBOARD PORTSIDE VIEW DESCRIPTION OF ENGINE VIEWS GENERAL ENGINE DATA ENGINE RATING AND PROPELLER FUEL SYSTEM EXCESS FUEL DEVICE LUBRICATION SYSTEM COOLING SYSTEM WARNING ELECTRIC SYSTEM GEARBOX SABB HYDRAULIC OPERATED ADJUSTABLE PITCH PROPELLER INSTRUMENT PANEL AND OPERATING CONTROLS PRELIMINARY INSTRUCTIONS CAUTION WARNING STARTING PRECAUTIONS CHECKS BEFORE STARTING STARTING OPERATION CAUTION STOP ROUTINE MAINTENANCE WARNING INITIAL ATTENTION ROUTINE MAINTENANCE PERIODS LUBRICATION OIL SPECIFICATION Monograde Oils Multigrade Oils Notes GEARBOX OIL SPECIFICATION STERNGLAND AND REMOTE CONTROL GREASE GREASING OF ADJUSTABLE PITCH PROPELLER CHECK OF LUBRICATION OIL LEVEL LUBRICATION OIL CHANGE CAUTION CHANGE OF OIL FILTER ELEMENT HURTH GEARBOX OIL CHECK AND CHANGE SABB HVP GEARBOX OIL CHECK AND CHANGE SABB HVP GEARBOX CHANGE OF PRESSURE OIL FILTER CHANGING FUEL CARTRIDGE AGGLOMERATOR WATER SEPARATOR IF MOUNTED PRIMING THE FUEL SYSTEM REFUELING COOLANT LEVEL CHECK TO DRAIN THE COOLANT CAUTION CHECK OR REPLACE THERMOSTAT IDLING SPEED ADJUSTMENT VALVE
14. R MAX 42 V TO HEATER 2x 1 5 mm J CHECK OF BATTERY The condition of the battery should be checked every third month The specific gravity of a fully charged battery depends on the ambient temperature The table below indicates the relationship between the specific gravity and the temperature Temperature Spec Gravity Temperature Spec Gravity TUE e xu iue gt 6 Ihe electrolyte level should be 6 9 mm above the separators Top up with distilled water if necessary NOTE In cold weather distilled water should be added only before charging the battery Keep the battery terminals clean and coat with petroleum jelly CAUTION The electrolyte is sulphuric acid and should be handled with great care Always wear goggles when servicing the battery If battery acid accidentally is splashed in the eyes wash with clean water and obtain qualified medical assistance immediately GENERAL PRECAUTIONS REGARDING ELECTRIC SYSTEM The following points must be strictly observed when working on the electric system otherwise serious damage can occur Never remove any electrical cable without first disconnecting the batteries Never disconnect the alternator Cables whale the engine ms Only disconnect the batteries with engine stopped end all switches in the OFF position Always ensure that cables are connected to their correct terminals before reconnecting the batteries A re
15. aust manifold the hose should run down and to its lowest point which must lay minimum 250 mm below the outlet bend Tia Further the hose should run as far as possible and then rising to the swan neck at the outlet This will permit adequate cooling of the hose and enough volume to take all water which is trapped in the hose when the engine is being stopped 23 If the outlet is not well above the deepest water level it is necessary to extend discharge hose upwards forming a loop as shown on next page The loop must be provided with a vent pipe at its crown 300 mm above the water line This vent pipe is necessary to prevent siphoning because the impeller pump sea water pump is not completely tight IMPORTANT The swan neck at the end of the exhaust line hown on next page is normally higher than standard exhaust bend fitted to the engine Thus in case the engine does not start normally after 10 sec the main valve at the sea water inlet sea cock must be closed to prevent the engine being filled up with sea water through the exhaust line The valve must be opened again immediately after the engine has started Check the function of the wet exhaust system by letting engine idle for 5 minutes and then stop Undo the exhaust hose from the exhaust bend and check that the trapped water in the line is well below the exhaust minimum 250 mm All exhaust hose connections should have two hose clamps each Use only
16. ct level If the oil is to be changed pump out the oil by means of a sump drain pump through the dipstick hole Fig 3 SABB HVP GEARBOX OIL CHECK AND CHANGE Unscrew the dipstick 3 see fig below Check the oil level by reinserting through the hole Fill up if the oil level is below the mark If the oil is to be changed unscrew the vent plug 4 on port side of the gearbox and pump out with a sump drain pump with hose extension Ensure that the hose reaches the bottom in order to drain dud contaminants Refill new engine oil appr 2 6 litres to correct level Run the engine some minutes and top up SABB HVP GEARBOX CHANGE OF PRESSURE OIL FILTER The pressure oil filter should be changed at the same time as oil change Unscrew the two bolts securing the lower filter housing to the cover and pull down Remove the filter element and the O rings Clean the filter housing and fit new element and O rings Ensure that the spring in the bottom of the housing is properly located and tighten the two bolts Start the engine and check the filter for leakage Pitch control lever 6 Pressure gauge connection Clutch lever 7 Oil pressure valve Dipstaok 8 Oil from cooler Oil filler 25 tO COOLer High pressure filter 10 Grease nipple invisible U A WN FR CHANGING FUEL CARTRIDGE AGGLOMERATOR If the fuel oil tank is installed at a level above the engine the cock must be closed before fuel filter change Water is dra
17. e If everything fails the engine is stopped manually by moving the lever A fully anticlockwise until the engine stops and so fully GLOCKWLSe again to reset 1m start position A new stop solenoid should be ordered for replacement WINTER LAYING UP Before laying up the boat for the winter protect the engine as LOU COW Se Change the oil in engine and gearbox If the boat is laid up for more than one year the HURTH gearbox should be filled completely with ATF oil Remember to drain to normal lever before starting Grease the nipple for oil seals SABB HVP Gearbox Close the sea Cock and allow the engine to idle for approx 20 seconds to expel any water from the exhaust hose For keel water cooled system there is no need to drain if antifreeze has been added If the system is drained the keel cooler must be blown through or drained See that the sea water is self drained from the tubestack in heat exchanger Does not refer to engines with keel cooler Open impeller pump cover remove impeller and replace cover drain gearbox oil cooler HVP gearbox Clean engine externally and touch up with engine paint Drain off water from fuel tank and top up with fuel Ihe battery should be recharged and stored in a dry frost proof place RETURN TO SERVICE When the boat is launched and before taking it into service again the engine prop shaft should be checked for alignment Tighten rubber mounts carefully after this check
18. e no adjustment is necessary or possible NOTE If the cylinder head and the valve gear for any reason have been removed the assembling sequence must be according to the Service Manual which may be obtained from the factory ALTERNATOR BELT TENSION It is important that the belt tension is checked after an overhaul or when new belt is fitted New belt tension A force of 3 3 5 kg to deflect belt 3 5 mm Checking and adjustment at service intervals A force of 2 2 2 4 kg to deflect belt 3 5 mm The deflection should be measured on the belt section between crank shaft pulley and the water pump pulley See fig below CHECK AND CHANGE OF ENGINE HEATER IF MOUNTED Ihe engine heater is mounted in the port side of the engine block If the heater is being continuously used the heater element is subject to burning and should be checked yearly or if the heating does not work Drain the coolant through the drain plug Disconnect the leads and unscrew the heater using a 26 mm wrench If the inner reducer should loosen reglue with epoxy glue Or Loctite If the element is badly burnt or corroded replace it by a new one If the new heater element does not work check the thermostat and replace if defective See wiring diagram inside the thermostat box see below Note The engine heater should not be tested in open air as it will be overheated and damaged THERMOSTAT TWIST CONNECTION POWE
19. ee from corrosion etc by smearing them with petroleum jelly E Batteries under charge release explosive gases therefore the battery compartment must be well ventilated at all times Never allow any smoking sparks or flames near the batteries Wear protective goggles when handling liquids which are harmful to the eyes for ex battery acid If any of these substances are splashed in the eyes wash out thoroughly with clean water Many liquids used in engines are harmful if taken internally In the event of accidentally swallowing oil fuel anti freeze or battery acid obtain medical assistance immediately LIFTING PRECAUTIONS The following points must be considered before attempting to lift the engine Ensure the lifting equipment to be used has the correct capacity to lift the engine Single lifting equipment must only be used when a single lifting eye is fitted When two engine lifting eyes are fitted suitable lifting equipment designed to give two vertical lifts from directly above the engine lifting eyes must be used Check that the engine lifting eyes are not damaged and that they are secure prevent damage to the cylinder head cover ensure that there 1s clearance between the lifting equipment hooks and the cover The lifting eyes fitted to the engine are suitable for lifting the engine and gearbox if fitted and accessory assemblies doy LBnster PebbEer INTRODUCTION The SOABB
20. iller cap on header tank Drain the coolant through tap or plug hole in front of the crankcase Close the tap securely after draining Refill the system with correct water anti freeze mixture Let the engine idle for 20 30 minutes with the filler cap off and top up CAUTION Under some circumstances an airlock can occur when filling the System causing a false level indication CHECK OR REPLACE THERMOSTAT Loosen the rubber bend between the thermostat housing and the water cooled exhaust manifold Unscrew the thermostat housing bolts and remove the housing with thermostat To check the thermostat function put it into hot water The thermostat is set to open at 73EC It should close again when put into cold water If the thermostat is defect it must be replaced Ihe gasket should also be replaced before assembling the thermo stat housing Ensure that all hose clamps are properly fixed and drain tap closed before refilling with water anti freeze mixture IDLING SPEED ADJUSTMENT The factory should be consulted before any idling speed adjustment Start the engine and run until normal operating temperature is reached Correct idling speed is 900 RPM and is factory set before despatch Adjustment should only be carried out after consulting SABB MOTOR BAD The idling speed is adjusted with the adjusting screw A see Figs Berow VALVE CLEARANCE ADJUSTMENT The engine is fitted with hydraulic tappets and therefor
21. ined from the agglomerator by unscrewing the drain tap C sufficiently to allow the water to drain See fig 4 d Using a suitable strap wrench unscrew the cartridge A from the head B 24 Screw a new cartridge onto the head and hand tighten it Fig 4 Cartridge Agglomerator Fig 5 Delivery Valve Holder Prime the fuel system after filter change see below REPLACING AN INJECTOR D Pull off the injector leak off pipe from the injector body stub pipe 2 Remove the cylinder head cover nut retaining the fuel pump to injector pipe clip and release the clip Du Hold the fuel pump delivery valve holder B with a spanner and slacken the pump to injector pipe nuts 4 Slacken the injector clamp bolt oe Remove the pump to injector pipe Os Remove the injector clamp and lift out the injector y Remove the injector sealing washer from the cylinder head taking care not to damage the seating area O4 Ensure the seating in the cylinder head is clean and smooth x Lightly smear a very small amount of high melting point grease to one side of a new injector sealing washer and place it over the injector nozzle greased side first 10 Replace the injector and clamp Hand tighten the clamp bolt 11 Replace the pump to injector pipe hand tightening the nuts 12 Fit new rubber O rings into the recesses on the cylinder head Cover 13 Replace the pipe clip and torque the nut to 9 0 Nm 6 5 IZ TOrque the
22. ing the upper fuse button AUX BLACK BROWN IMPORTANT If the stop solenoid for any reason has been dismantled it should be refitted in following way Move the lever A by hand until it rests against the screw C Press the stop solenoid plunger fully until it BOTTOMS Secure the screw D xn Chas Check the function by pressing the stop button It is very important that the stop solenoid plunger is completely home otherwise the pull coil fails to be unswitched and the fuse may If the stop solenoid fails to work although the fuse is reset the reason may be loose or defect wire connections or a faulty Internal switch an solenoid Check the connections If the connections are in good order the internal switch may be sticking or corroded It may be a good remedy to remove the stop solenoid plunger and spray some contact cleaner f inst CRC 2 26 against the bottom The nylon switch pin should be loose in its bore If the stop solenoid still does not work try to interconnect the terminal and the aux terminal by means of a piece of wire See fig When doing so the pull coil is always energised as long as the stop button is pressed If the stop button is pressed for more than 4 seconds the fuse may blow but usually 4 seconds should be adequate to stop the engine If the fuse should blow the stop solenoid should be allowed to cool down for some time before resetting the fus
23. mportance for trouble free per formance that no air has access to the fuel system Make therefore sure that all connections particularly on the suction side are properly tightened REFUELING The fuel to be used is GAS OIL The fuel injection equipment is made to very accurate limits and therefore even the smallest particle of dirt entering the system will destroy its efficiency by causing scoring or premature wear on the highly finished parts Ensure that scrupulous cleanliness is observed when handling the LUG system and also the ue Take care that water is not allowed to contaminate the fuel oil Always install a pre filter water collector sedimentor in the line between the tank and the engine The pre filter must be easily accessible for inspection and draining When refueling always apply a fine gauze filter anda clean dry funnel in the tank filler neck Before moving the fuel filler cap clean well near it and replace the cap after the refueling COOLANT LEVEL CHECK The engine should be allowed to cool down for some time before coolant Level check Be careful when removing the coolant filler cap when the engine is warm Use a rag to protect against scalding If necessary fill up with clean fresh water anti freeze mixture If the engine has extra header tank the coolant level is always checked in the upper tank The coolant should be changed every two years TO DRAIN THE COOLANT Remove the f
24. s Before carrying out any maintenance work on an engine it is advisable to remove the battery The battery and alternator must be disconnected before commencing any electric welding when a pole strap is directly or indirectly connected to the engine It is essential to ensure that nuts and bolts are tightened to the torques specified When re assembling an engine lubricate all moving parts with engine oil Renew nuts and bolts that have been taken from high stress Locations In particular nuts and or bolts from ine connecting rods should be renewed The fuel injector can only be checked and set off the engine using suitable specialist test equipment WARNING On no account allow any unprotected skin to come into contact with the injector spray as the fuel may enter the blood stream with fatal results Some engines may be fitted with seals or O rings manufactured from Viton or a similar material When exposed to abnormally high temperatures in excess of 400 C 752 F an extremely corrosive acid is produced which cannot be removed from the skin If signs of decomposition are evident or if in doubt always wear disposable heavy duty gloves Fuel and new or used lubricating oil may cause skin irritation The materials used in the manufacture and treatment of some filters and elements may cause irritation or discomfort if they come into contact with the eyes or mouth and they may give off toxic gasses if they are b
25. th HVP gearbox kg Hurth gearbox kg Max Inclination Running 20 Astern Ahead Lateral ENGINE RATING AND PROPELLER Ihe engine ratings given are the ratings measured on propeller shaft and with reference to ISO 3046 DIN 6271 Deduction due to alternators extra water pumps and similar auxiliaries which are not necessary for the engine function may be done Ihe ratings are also a DIN 6270 B rating i e the engine can run on this power for one hour every 6 hour Choice of propeller When selecting the correct fixed propeller for the boat choose the propeller which permits the engine to run at full speed 3000 rpm with the lever throttle in full speed position When slowing down appr 100 rpm for continuous running the engine rating is reduced by appr 10 but the speed of the boat is nearly the same This will save fuel and extend the engine s life With controllable pitch propeller CPP the full speed at 3000 rpm should be marked on the control lever operator For continuous operation the speed control lever throttle is pulled back tor 100 rpm bus the pitch control as kept in rts full speed position This full speed position is dependant on the boat and 1s not the same as maximum pitch On a lower rpm manoeuvring trolling etc the pitch may be increased above the full speed mark Do not overload the engine with too heavy pitch Overload is noticed by the exhaust getting dark FUEL SYSTEM Inec Or Se
26. tor ens m TIGHTENING SEQUENCES FOR CYLINDER HEAD BOLTS CRANKCASE DOOR BOLTS AND END COVER NUTS FAULT FINDING SCHEME This section is intended as a guide only If in difficulty consult SABB MOTOR A S or a SABB Agent DIFFICULT STARTING H D Oe 3h Ds Stop lever not in start position Unsustable Jubricatcon Incorrect Luc No fuel in tank Choked fuel filter MOCK d Discharged battery Poor battery connections Defect heater plug or engine heater In cold weather EXCESSIVE CARBON DEPOSITS Oe Choked exhaust system Unsuitable fuel oil Unsuztable lubricating oil EXHAUST SMOKE White smoke generally as a result of water entering the cylinder Faint blue smoke generally the result of high load Heavy blue smoke caused by lubricating oil passing the piston rings due to Stuck worn or broken rings Worn cylinder blore Overfull oil sump Black smoke due to incomplete combustion can be caused by Overload Choked arr filter Inlet temperature too high Unsuitable fuel or water in it ENGINE STOPS Qo back of Lue Air or water in fuel system Choked fuel filter Overload Overheating Loss of compression Lack of orl LOSS OF POWER o Loss of compression Choked exhaust system Fuel injector dirty Choked fuel filter Worn engine OVERHEATING Thermostat Lo
27. ttings ste sie ade New Used 240 bars bet 9 toe ee Se Gas OLL Sontrorming B3952669 1999 Classo AL Or A2 Or CO USA Specification ASIM D 975 77 Grades No 1 D and 2D Or BSMA 100 class ML For marine use The fuel must be a distillate and not a residual oil or blend Vaporising oils are not suitable as fuels for Lister Petter series engines Ihe user is cautioned that although the engines may operate on fuels outside the above specifications such operation may well result in excessive wear and damage If the engine has to work in areas with extremely low ambient temperatures use fuel with good clog characteristic Clog point CEPR 25E EXCESS FUEL DEVICE This device is fitted as standard being automatically selected when the engine is intentionally stopped Should the engine run out of fuel and stop the device will not select excess fuel until the engine mounted stop lever is moved to the stop position by pressing the stop button and releasing Eey The engine will automatically disengage the excess fuel position when the engine runs up to speed LUBRICATION SYSTEM lub Pressure at rdle RPM 0y 7 bar E at 3000 RPM 2 0 bar Ord Capacity Ora Smp oap molc OSEE Soe al j EIE Ayd Dx MOOS e Db oh Or Sump Gap incl Filter cooler EPA TU IM Oro Gearbox Sump BUR TE BW 2396 24 Oo Ale
28. ture This company does not guarantee that the same results will be obtained elsewhere under different conditions When purchasing parts or giving instructions for repairs customers should in their own interests always specify GENUINE SABB MOTOR A S PARTS Parts that have not been supplied by the SABB MOTOR A S cannot be relied upon for correct material dimensions or finish This Company cannot therefore be responsible for any damage arising from the use of such parts and the guarantee will be invalidated ENGINE STARBOARD PORTSIDE VIEW 1 2 3 4 5 6 9 10 11 12 PORT SIDE 14 15 STARBORDSIDE 16 17 DESCRIPTION OF ENGINE VIEWS PrP RP FP RP p m n ARES do J E IL A Go N ES Sump oil drain pump Heat exchanger D3oStsck Oil filler cap valve cover Stop solenoid Fuel filter water cooled exhaust outlet Gearbox oea water pump Lubr1icabzng Oil utter Fuel supply Header tank w coolant filler cap Air inlet damper Fuel return to tank Relay box with connections SL aber Mover Alternator GENERAL ENGINE DATA S S Stroke _ ISO 3046 related to flywheel Temp sso 400 C 9 alli Max Exhaust Temp after BEES Max Exhaust Temp before SOC LN Boost Pressure ber wax Intake Restriction m _ Engine Dimensions gearbox m 697 sos foso Weight wi
29. tween 5 C and 57 20W 40 Between 5 C and 52 C ge ee SE a BD Notes SAE 5W 20 oils are recommended on the basis that they are fully synthetic and are technically suitable for use up to 25 C 77 F Non synthetic oils at very low temperatures will suffer from wax crystallisation Monograde SAE 5W is not normally available as a synthetic oil and therefore is not quoted In order to maintain the cold starting characteristics of any recommended grade it is essential that oil changes are made within the specified recommendations An oil change is recommended immediately if the engine fails to reach its normal cold start cranking speed due to excessive oil viscosity Fuel dilution of the lubricating oil will adversely affect Cold starting and consumption SAE 30 and 10W 30 oils may be used at up to 52 C 126 F but oil consumption may be affected 10W 40 15W 40 and 20W 40 multigrades are recommended for continuous full load operation at this temperature Monograde SAE40 oils are not recommended The temperatures mentioned in the table are the ambient temperatures at the time when the engine is started However if the running temperatures are much higher than the Seri ing temperatures a compromise must be struck and a higher viscosity 011 used Provided Starling Satisfactory Multigrade oq ls overcome the problem provided they have a suitable SpecYrrcatron GEARBOX OIL SPECIFICATION
30. up before going full speed Run engine moderately to save engine and fuel Full speed at maximum rpm only for intervals For continuous running the speed should be reduced by approx 100 rpm See Engine Rating and Propeller CAUTION On L4 186 T engines serious damage to the turbocharger bearing can result if for any reason the turbocharger housing is not full of uds It is recommended that these engines run on no load after Starting for 30 seconds to ensure an adequate oil supply to the turbocharger and 30 seconds before stopping to allow the heat from the bearing to dissipate STOP Move control lever into neutral position or if SABB HVP gearbox pitch control lever in neutral and clutch disengaged Allow the engine to idle for appr 2 minutes to cool Stop the engine by pressing the stop button max 10 seconds Switch off the battery main switch ROUTINE MAINTENANCE ES The engine should receive regular attention during the first 50 hours of its life from new and after a major overhaul Long periods of light or no load running early in the engine s life may lead to cylinder bore glazing and high oil COnSUMpPE The instructions given in Maintenance Schedule are based on average operating conditions and cover the minimum requirements to keep an engine running at peak performance with trouble free operation Decarbonising may be required more often if the engine has been running on light loads for long period
31. urnt Care must be taken to ensure that all fuel used oil filters and filter elements are disposed of in accordance with all the relevant regulations of the country concerned Ihe engine has passed Test Programme before delivery Still however the engine is not completely run in It is recommended to operate the engine moderately during the first hours after it has been put into service Full speed only for short periods during tne Ide 5 70 INITIAL ATTENTION AFTER THE FIRST 15 HOURS OF OPERATION Check and tighten all hose clamps and unions paying particular attention to the fuel system Check tighten all external nuts and bolts particularly mounting DOLES Shaft couplsng bolts and exhaust manifold bolts and amis Check belt tension see ALTERNATOR BELT TENSION Check Ol and Coolant level Change the lubrication oil and filter for the first time after 100 hours and then as specified below ROUTINE MAINTENANCE PERIODS PERLOD ATTENTION After the First 15 Hours or See INITIAL ATTENTION Che Bret 3 Mont ns Before Weekly Check engine oil level Check coolant level Check fuel level in tank Drain water and contaminants from water separator Grease Stern gland Every 3 months Check gearbox oil level or 25 Hours Check battery condition Every year or 200 hours Change engine oil and filter element Change gearbox oil Grease remote Control parts Change
32. versal of polarity Short will destroy drodes sand transistors in the alternator and regulator Never flash any connections to check the current flow Always keep the electrical connections properly tightened The battery and alternator must be disconnected before commencing any electrical welding when a pole strap is directly or indirectly connected to the engine POWER TAKE OFF LIMITS PTO 5 kW max Gear Id Axia 12 kW max God Ob ATAL wth se ow A 12 kW subject to a maximum crankshaft bending moment for drives in any direction The maximum radial force F kg which can be applied to the crankshaft is given as 41182 102 1 where L mm is the distance from the center ot the radial Bo pulley face WET EXHAUST SYSTEM FOR SAILING BOATS AND MOTOR BOATS SUITABLE EXHAUST PIPING IS IMPORTANT FOR SAFE OPERATION OF THE ENGINE Damage caused by incorrect exhaust piping is not covered by the engine s warranty or insurance MOUNTING THE EXHAUST HOSE The exhaust hose must be installed in such a way that no sea water can enter the hose from rear outlet A swan neck close to the skin fitting 1s sufficient Lor most boats For deep sailing yachts however a full way valve is recommended at the exhaust outlet This valve should be closed when the engine is stopped Starting from the outlet bend from exh
33. w coolant level Water pumped bo slack Overload Lubricating oil level too low Obstructed cooling water system ENGINE FAILS TO BE STOPPED eis ion om Automatic Luse Ls Cut Press the fuse button Stop solenoid linkage is loose Defect stop solenoid DESCRIPTION OF THE ELECTRICAL OPERATED STOP START SYSTEM The lever A has two functions d To stop the engine The engine is stopped when the lever A 15 moved fully anticlockwise until it is against the stop screw Z4 The lever is reset to start position excess fuel when it is moved fully clockwise until it is against the screw B The electrical stop solenoid takes care of those two functions When pressing the stop button on the instrument table the stop solenoid is energised and the lever A is pulled to its stop position As soon as the stop button is released the return spring inside the rubber boot moves the lever back to its start position STOP SOLENOID DESCRIPTION The stop solenoid has two coils one for pull and one for hold When the stop button is pressed both the pull and hold coil are energised and the plunger retracts As soon as it BOTTOMS the internal switch disconnects the high current winding and the plunger is kept retracted by the hold coil Ihe stop solenoid is secured by an automatic fuse circuit breaker located in the relay box If the stop function fails the reason is likely a blown fuse It should be reset by press
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