English - Solé Diesel
Contents
1. A Always change a belt that appears worn or is cracked Belts gt working in pairs must be replaced together EE 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 carelessly Said adjustment whenever is required shall be made by a SOLE DIESEL licensed service shop since precision pump monitor and skill Knowledge are required Fuse A fuse of 10A to is used to protect control panel s instruments In case the switchboard does not receive power supply check if the fuse is burnt and replace it S l Diesel ENG 33 03919402 ENG rev 0 20 Checking and cleaning turbocharger To extend turbocharger life and efficiency some basically important instructions are given below 1 Possible causes of turbocharger damaging are essentially three a Lack of lubricant causes bearing failure with consequent seizure of rotary components b Introduction of external 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 seizures 2 Turbocharger co2. 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 M18 x 1 5 1 Check that fuel intake valve located at the tank is open 2 Place a recipient under the fuel return valve B remove the plastic cap from the pipe 3 Press several times the manual fuel feed pump A until the fuel bleeds without air bubbles from fuel return valve B 4 Connect the fuel return line to the fuel tank 5 Start the engine and make sure there are no leaks 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 Daily 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 a speeded up acceleration 4 Use the engine at 100 of maximum power for limited periods 5 Carefully comply with the inspection and maintenance instructions shown in this manual Warning The longer the initial running in period with reduced loads the longer the working life time of the v
3. Fully opened at 102 C CIRCUIT CAPACITY LIT SDZ 165 SDZ 205 SDZ 280 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 sea water pump Seawater pump Intercooler Heat Exchange freshwater Elbow wet exhaust OO SIR On or gt o o NAN add V 2 3 LUBRICATION CIRCUIT Sol Diesel ENG 6 03919402 ENG rev 0 2 3 1 ENGINE Fig 2 3 1 Lubrication is forced with a lobe pump and total filtration of the oil pumped to the various lube points on the engine The oil is forced by the pump through a control valve to the filter the engine main bearings and by way of external pipelines to the rocker arms Fig 2 3 1 18 172316 12 13 10 14 15 11 9 6 Oil pan Scoop Oil pump a Valve flow control b Valve maximum pressure Oil cooler engine Oil filter element Oil pipe Bearing crankshaft Bearing connecting 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 A 9 6 8 Nr T VP VP ee 17 Pipe to turbo charger 18 Turbo charger 19 Pipe to compressor or hydraulic pump optional 23 Pipe to oil pan 24 Pipe from turbocharger
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 connection 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 connection 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 a b C d Check exhaust and transmission systems 9 a g b g C g d Sol Diesel ENG 20 03919402 ENG rev 0 9 1 1 BLEEDING AIR FROM THE FUEL SUPPLY SYSTEM
5. 4 SYMBOLS USED IN THE MANUAL 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 eee Bad 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 03919402 ENG rev 0 1 GENERAL IN
6. Weight Dry bobtail version kg 617 617 617 Sol Diesel ENG 11 03919402 ENG rev 0 942 2 6 1 ENGINE DIMENSIONS SDZ165 TM170 2 de HE i Wel i AE ME i RZ it 17 TAH z IN jj ral TA IN ae DE PIR z PU RE Clp 39 107 721 0 1218 1422 EIOBA RN x OE OU_O UO ma sde M 5 TO O JA AN ar ADA SP S y e gt ail EE ies KI a AR el ge FRE o BE ia 2 345 1 Hose Inlet seawater pump lnt 42mm 2 Hose Inlet fuel pump lnt 12mm 3 Hose return fuel pump lnt 12mm Sol Diesel ENG 12 03919402 ENG rev 0 345 SDZ280 TM265 391 6 Tal 21 6 Holes v 995 5 AS N Fig LE 2 1 GEARBOX PROPULSION ENGINE AND GENERATOR GENSET VERSION Check specific manuals for these parts S l Diesel ENG 13 03919402 ENG rev 0 3 TRANSPORT HANDLING STORAGE 3 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 3 1 PACKING 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 UNPACKING WITH PALLET
7. engine reaching high fete 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 03919402 ENG rev 0 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 stop solenoid will be actuated and the engine stops Maintain 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 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 method only must use in case exceptional Use the panel to stop the engine To turn
8. engine you have purchased can only be guaranteed 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 SOLE DIESEL Department If engines manufactured by SOLE S A are serviced by unauthorized technicians or non original spare parts are utilized ALL WARRANTY SPECIFICS OF SOLE S A ARE INVALIDATED 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 contact with our nearest official service for any requirements you may have 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 SOLEDIESEL department will be happy to provide you with the necessary advice and assistance This INSTRUCTION MANUAL is an integral part of the product you have acquired Please conserve it in a safe place for
9. extra equipment or for any other 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 SOLE S A such use shall be considered improper and SOLE 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 IT S STRICTLY PROHIBITED TO PERFORM MAINTENANGEWORK WHILE THERE AREENGINE PARTS MOVING WHEN THE ENGINE ISRUNNING IT IS STRICTLYPROHIBITED TO TOUCHANY PARTS OF IT IT S STRICTLY PROHIBITED TO REMOVE OR TAMPERWITH THE SAFETY DEVICES WORKING ON A HOT ENGINE
10. seconds after starting and 3 minutes before stopping Sol Diesel ENG 34 03919402 ENG rev 0 1 3 TROUBLE SHOOTINGS ENGINE FAILURE PROBABLES CAUSES FAILURE TO START C1 C2 C3 C4 C5 06 C9 E1 E2 E3 E4 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 R7 NOISYENGINE MOR UNEVEN RUNNING SPEED C4 L2 R4 M NOISY ENGINE M3 R5 R7 OIL PRESSURE TOO HIGH 3 17 M8 M9 LUBRICATION FUEL OUTLET COCK CLOSED OIL SUCTION LINES CLOGGED OR ma LOOSE ELECTRICAL SYSTEM COOLING CIRCUIT FAULTY SALT WATER PUMP CLOGGED AIR FILTER M1 WORN OR STUCK RINGS RI ENGINE OVERLOADED M2 POOR VALVE SEALING R2 TIMING TOO ADVANCED M3 STUCKVALVE R3 TIMING TOO RETARDED k GOVERNOR SPRING BROKEN OR ia kid SPRING LOW IDLE SPEED M5 WORN CON RODS OR MAIN BEARINGS RAO ALTERNATOR BELT TENSION M6 WORN CYLINDERS ORG EXHAUST BACKFIRES M7 WRONG VALVE CLEARANCE REMOTE SHIFT AND REVERSING GEAR M8 CONTROL OUT OF ADJUSTMENT CLUTCH CONE WORN me Sol Diesel ENG 35 03919402 ENG rev 0 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 SOLE S A we will provide you with the relevant instructions in relation to the laws in force
11. the full working life of the engine SOLE 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 Deliver 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 03919402 ENG rev 0 0 1
12. 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 a small 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 clearance see x in Fig 7 2 2 1 Do these operations in an authorized Sole Diesel Service Before adjusting valve clearance allow the engine to cool for at least 30 minutes The oil temperature should be below 80 C CHECK VALVE CLAREANCE WITHOUT PRESSURE WASHER SOME ENGINES MAY NOT HAVE ELEMENT NUM 4 OF Fig 7 2 2 1 THE PROCEDURE IN THIS CASE IS DESCRIPTED BELOW a Loosen ventilation valve and swing it to the side b Remove the cylinder head cover c Position crankshaft as in the figures 7 2 3 Check valve clearance of the cylinders marked in black d Check valve clearance x between rocker arm and tappet contact face with a gage 6 There should only be slight resistance when feeler blade is inserted The valve clearances are the followings Valve clearance inlet valve 0 3mm Valve clearance exhaust valve 0 5mm ADJUST VALVE CLAREANGE a Release locknut 2 b Regulate the adjustment screw 1 by using a screwdriver 7 so that alter tightening the locknut correct valve cle
13. ALWAYS PROTECT THEHANDS WITH SAFETY GLOVES AND HEAT RESISTANT CLOTHING WHEN PROTECT THE RESPIR TORY PASSAGES WHEN WORKING IN THE VICINITY OF ENGINE EXHAUST GAS Sol Diesel ENG 4 03919402 ENG rev 0 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 Timing 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 all models SDZ 165 SDZ 165G and SDZ 280 equipped with an intercooler Fuel System equipped with mechanical priming pump Combustion System Direct Injection Injection Pumps Single injection pump for each cylinder integrated in crankcase Cycle diesel 4 stroke 4 cylinders in line for SDZ 165 and SDZ 165G and 6 cylinders in line for model SDZ 205 and SDZ 280 8 Cooling System liquid cooled circulation controlled by centrifugal puma with thermostatic control and heat exchanger Also the exhaust manifold is cooled 9 Lubrication forced feed lubrication by gear pump 10 Electrical System 24V 4 5 6 7 1 Filler cap for the coolant on the expansion tank 2 Expansion tank 3 Heat exchanger 4 Freshwater pump 5 Vibration damper 6 Fuel feed pump 7 Fuel inlet 8 Fuel filter 9 Lubrication oil filter 10 Oil dipstick 11 Connectio
14. 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 eguipment 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 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 eguipment 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 UNPACKING WITH ENGINE MOUNTING FIXTURE AND PLASTIC PACKAGIN 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 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 operat
15. ENGINE INSTRUCTIONS MANUAL SDZ 165 SDZ 165G 5DZ 205 SDZ 280 Sol Diesel fN MARINE DIESEL ENGINES N MARINE DIESEL GENSETS This engine instructions manual is also available in the following languages ENG This operators manual is available in English Part no 03919402 ENG Download from our web page www solediesel com or order to oftec solediesel com SP Este manual de instrucciones puede solicitarse en espanol Ref 03919402 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 CONTENTS 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 ON T
16. FORMACION eee 1 1 ENGINE MANUFAGTURER S IDENTIFICATION DATA MANUFACTURER n MADE Sale Diesel Ed SOLE SA Ctra de Martorell a Gelida km 2 08760 MARTORELL BARCELONA SPAIN MODEL TRADE DESIGNATION SDZ 165 SDZ 1656 SDZ 205 SDZ 280 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 SOL DIESEL engine can only be guaranteed if you use original spare parts For WARRANTY terms refer to the WARRANTY MAUAL 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 SOL 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 SOL S A FROM ALL LIABILITY FOR DAMAGE TO THEENGINE OR PROPERTY OR INJURY TO PERSONS Although the engine is built in comp
17. HE 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 5 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 03919402 ENG rev 0 ENG 1 ENG 2 ENG 3 ENG 4 ENG 5 ENG 6 ENG 7 ENG 8 ENG 9 ENG 10 ENG 11 ENG 12 ENG 13 ENG 14 ENG 15 ENG 16 ENG 17 ENG 18 ENG 19 CONTENTS 5 PREPA
18. RING THE ENGINE FOR USE ENG 20 5 0 GENERAL WARINGS 5 1 INSTRUCTIONS FOR FIRST STARTING 5 1 1 BLEEDING AIR FROM THE FUEL SUPPLY SYSTEM ENG 21 5 2 PRELIMINARY RUNNING TEST 5 2 1 NO LOAD RUNNING TEST 5 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 03919402 ENG rev 0 0 INTRODUCTION 0 0 FOREWORD Dear client The SOLE S A engine you have purchased is a product of the highest technological guality Our Service SOLE DIESEL department has recently been strengthened to ensure even better service for all our clients Reliable duty and long life of the
19. Z 165G AN Check the panel service manual and the electrical wiring attached with the genset OP CLIVE HE TEM MIL STE CHARGE HI START Fall ECHE SIP FA RE STOP NERLDAD VOLG S07 165 60599842300 CARGA LOAD Trifasico 220 Trifasico 380v JOALINGJI 30 OaQVNo 609942730 60954380 ALTERNADOR GET SET Sol Diesel ENG 10 03919402 ENG rev 0 2 6 TECHNICAL SPECIFICATIONS dl ei kadhal ET ERE di 15 e ST 15 A Hur 15 Cylinders Number 4 Diameter mm 108 108 108 108 108 108 Compression Rato AO ME ET Type y Ratio TM 170 2 04 1 2 04 1 Gear box 25 1 25 1 Ba 1 ed 1 26 1 26 1 IE ELE 2 82 1 2 82 1 ENE e AAN NAN EN 2 311 2 311 A ae EC032 3L 4 ECP34 1S ECP34 25 ee angle Crankshaft Power 1 kW CV 118 160 145 197 200 272 871118 87 118 87 118 Propeller Shaft Power 1 kW CV 105 144 132 180 180 245 1 ISO 8665 Oil Capacity with filter Oil Capacity without filter EE LE S S pp 4 Gearbox oil Capacity liters hot engine 175 175 en Pu os BOSCH geen Bose BOSCH Bos NE NNN A O EO Mm EE N 193824 193824 Valve Timing intake open cold engine hl ll el Ed cold engine weigh Dry with Gearbox TM 170 698 88 o kg mm m m 1 TM 265 808 98 1 pp o TM 265A 808 98 1 pp o GE Ass Geis pp 1 108 1 G4Tis pp Mos
20. 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 03919402 ENG rev 0 1 REPAIR AND MAINTENANCE 7 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 7 1 TYPE AND FREQUENCY OF INSPECTIONSAND MAINTENANCE INTERVENTIONS S QOPE General Lubrication System Fuel System Intake System Cooling System 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 IT IS STRICTLY FORBIDDEN TO CLEAN THE ENGINE WITHCOMPRESSED AIR IT IS STRICTLY FORBIDDEN TO PERFORM MAINTENANCE CLEANING OPERATIONS IN THE PRESENCE OF MOVING PARTS USE GLOVES OVERALLS ETC TO PROTECT THE BODY FROM BURNS Intervals 1st 20h Every Every Every Every Every 2 W
21. arance 1 is achieved c Check and adjust the valve clearance on all remaining cylinders d Reinstall cylinder head with a new gasket if is necessary 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 03919402 ENG rev 0 Fig 7 2 2 1 EX RTAINBEX Noren IN 4 lt Tua S a k b 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 clearance WITH PRESSURE WASHER FOR ENGINES WITH ELEMENT NUM 4 OF Fig 7 2 2 1 1 Loosen ventilation valve and swing it to the side 2 Remove the cylinder head cover 3 Do these operations in an authorized Sole Diesel Service Before adjusting valve clearance allow the engine to cool for at least 30 minutes The oil temperature should be below 80 C 4 Turn
22. arious parts of the engine with consequent savings in terms of maintenance and running costs Sol Diesel ENG 21 03919402 ENG rev 0 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 A OFF ON e STOP Ze Rotate the ignition key to position ON gt M Check oil pressure battery charge lamps are lighted and the alarm is heard piii refer to heading 2 5 1 for lamps position Pre heating of incandescent spark plugs N This engine is design with a direct injection system This function is cancelled stop OFF on Turn the key directly to Start position Be AM START Starting Place the remote control lever to neutral point and deliver gas up to the half GEN position rotate the ignition key to the START position until the engine starts STOP os ere running If the engine does not start running even with the ignition key in the START START position for10 seconds draw your hand out from the key for 30 seconds and then try again to start the engine Warning Do not run the starter motor for more than 20 seconds at a time Once the engine has started release the ignition key allowing it to automatically return to the ON running position and disconnecting the starter OFF ON motor Immediately adjust the accelerator to prevent the
23. at the time When scrapping the entire engine or components of the engine observe the LAWS IN FORCE IN THECOUNTRY OF INSTALLATION For information on the materials of which individual components of the engine are made contact SOLE 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 ja E 4 4 se se gt 2 3 c c 8 0 s 0 3 3 3 2 3 2 O 4 O 4 E 6 10 20 30 40 40 amp O 0 78 0 8 0 82 0 84 0 86 01 88 0 9 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 Sal Diesel ENG 36 03919402 ENG rev 0 If the air deviates from these values correction factors in are found in the graphs below Use the correction factors in calc
24. crankshaft until both valves in cylinder n 1 overlap exhaust valve about to open 5 Locate the crankshaft as showed in the photo 7 2 3 Check valve clearance of the cylinders marked in black 6 If is necessary to adjust the clearance do as the following see photo 7 2 3 at the top a Release locknut 2 b Fix the tool Fig 7 2 4 on the adjustment screw 1 and adjust the clearance as follows Fix the magnet Turn rotating disk of the tool 7 2 4 until there is no clearance Turn 90 150 back depending on the valve see specifications below IN Inlet valve 90 EX Exhaust valve 150 tighten the locknut 2 using a torque tool torque 20 Nm c Repeat the check and adjust the clearance in every cylinder 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 S l Diesel ENG 29 03919402 ENG rev 0 6 Water filter cleaning lt is important to fit between the engine and the bottom cock a filter SD to avoid that an
25. duct 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 6 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 for normal operation for 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 for draining circuit instructions S l Diesel ENG 18 03919402 ENG rev 0 Run the engine for a few minutes until the cooling circuit is properly filled and free of air bubbles Check the coolant level and refill if necessary Warning A Never open the oil plug 1 when the engine is hot as it can release steam or splashes of hot coolant Stop the engine and wait until it gets cold to do the coolant change See fig 4 2 2 Warning A After the first 50 hours of engine duty and thereafter at six months or 1000 hours intervals add rust inhibiting agent AC88 to the coolant in the same proport
26. e If a difference of pressure in excess of 15 between cylinders is determined the cylinder unit concerned should be dismantled to establish the cause Check condition of sea water pump impeller and its eventual replacement Impeller is made of 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 cover 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 Removal and reassembly Drain the water from the seawater system Remove the pipes from the seawater pump Remove the gear rear cover Remove the screw cap Loosen the hex nut from gear of sea water pump Loosen bolts on seawater pump Loosen gear from pump shaft by using a plastic hammer Install the seawater pump 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 without 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 Die
27. fuel pump The distance L will be the maximum For the aspirations and return fuel hose interior diameters and lengths L follow these specifications 12mmwhenL lt 6m 14mm when L lt 15m 16 mm when L lt 25 m High pressure injection pumps increase the temperature of fuel An increase of temperature of 30 C measured between the injection pump inlet and fuel return line may result in a loss of 1 5 of power for each 10 C Install a fuel cooler of 2 4 kW to reduce this fact Maximum permissible fuel temperature is 75 C 2 4 1 INJECTORS Opening Pressure 275 bar Sol Diesel ENG 8 03919402 ENG rev 0 2 5 ELECTRICAL PLANT 2 5 1 ELECTRICAL PLANT INSTRUMENT PANEL SDZ 165 SDZ 205 SDZ 280 DESCRIPTION GLOW PLUG OPERATION LAMP not active ET BATTERY CHARGE LAMP R WATER TEMP ALARM LAMP D OIL PRESSURE ALARM KEY STARTER TACHOMETER VOLTIMETER GAUGE HOUR COUNTER FUSE ALARME FUSE OIL PRESSURE GAUGE COOLANT TEMP GAUGE RESISTENGE 200 Q RESISTENGE 100 O Standard Panel 24V Part no 609 94 125 60994200 SDZ 165 504 205 BLANC RUDO While Red MOTOR Started Selonced CONTACTO PRESION Od presure svilch CONTACTO TEMPERATURA Water emp s itch TRANSMISOR PRESI N sa s Pressure Transmitter TEE TRAN TEMPERATURA Hater SAMICA TEMPE U Temperalure Transmiter Sol Diesel ENG 9 03919402 ENG rev 0 2 9 2 ELECTRICAL PLANT INSTRUMENT PANEL SD
28. ified 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 S l Diesel ENG 17 03919402 ENG rev 0 4 2 1 2 CHANGING GEARBOX OIL Gearbox has its own lubrication independent from the engine warning A 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 z 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 Warning do not ingest any of the liquids utilized to fill the various circuits on the engine Open de valve plug to clean the air possible air bubbles during this process When distilled water is used in the refrigeration circuit an anti freeze pro
29. 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 03919402 ENG rev 0 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 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
30. inter storage and Inspection Item Daily 50h 250h 500h 1000h year years Preservation Screw tightening fastening Engine block CL Valve clearance Exhaust gas noise and vibrations Compression pressure Engine oil C C C C Inverter oil if applicable C C C C Oil filter C C C Fuel level Fuel tank CL E CL I Fuel filter engine C Water separator filter if applicable I E I E C Injection pump Injector Power system bleeding Air filter C Coolant C C Salt water circuit I CL Water filter VCL I CL Sea water cock Salt water pump impeller I C C I CL Zinc anode if applicable I C I C S l Diesel s l 26 03919402 ENG rev 0 Instruments Incandescent spark plug Electrical System Starter motor and alternator Alternator belt and tension C Battery level C I Inspect adjust or fill E Empty C Change CL Clean Use oil with 15W40 viscosity and no less than ACEA E5 or API CH 4 SJ quality EXHAUST PROTECCTIONS Check the protections following the manufacturer comments For the air vent in case of blocked passages disassemble the valves clean with freshwater and spray with silicone before resembling the unit Sol Diesel ENG 27 03919402 ENG rev 0 7 2 OPERATIONS DESCRIPTION 1 Change engine and gearbox oil Read heading 4 2 1 Change oil filter Fig 7 2 2 See the page n to find the filter on the engine Change the oil filter after the firsts
31. ions 3 2 RECEIPT 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 forward photographic evidence of the damage gt important After inspecting the goods if you notice damage duo to transport Have the transport company delivery note and inform SOLE S A Sol Diesel ENG 14 03919402 ENG rev 0 3 2 1 PACKING LIST 1 ASSEMBLED ENGINE 2 TECHNICAL DOCUMENTATION 13 The technical documentation contains instruction and user manual Packing material must be disposed of in compliance with established law in the user s country Packing materials Wood Steel nails Steel screws Plastic film Cardboard Metal or plastic straps 3 3 TRANSPORT AND HANDLING THE PAGKED ENGINE When lifting and transporting the engine use EXCLUSIVELLY a fork lift or bridge crane of appropriate 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 p
32. ions as indicated in the table from section 4 2 2 The cooling liquid mixture must be totally drained and replaced every 2 years Warning A To use refrigeration liquid that does not match the technical specifications causes damage to the components of the engine determining the cancellation of the warranty 4 2 3 REFUELING Use clean filtered gas oil of ASTM D 975 88 quality 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 N Warning Do not use diesel fuel mixed with water or any other foreign substances Warning A 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 4 3 INSTALLATION Warning 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 f
33. 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 drain and cleaning supplied as accessory 1 Close the fuel inlet cock 2 Loosen the bleeding screw 7 and let the fuel bleed 3 Unscrew left handed the filter armor 4 with o ring 3 and retire it 4 Clean all the elements and specially the sedimentation chamber 5 Change the filter if necessary 5 Mount the elements again Tighten the filter armor at 2 5 kgf m max 7 PET EE Sol Diesel ENG 30 03919402 ENG rev 0 10 11 12 13 14 15 Replace the fuel filter element engine and purge the circuit See the page n 5 to locate the filter The fuel filter is closed and cannot be cleaned It must be replaced at least once every 12 months To perform the filter change Close the inlet cock located at the fuel tank Unscrew cover filter with a chain spanner Screw the new filter to the cover with the hand and 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 SOLE DIESEL service If a injector testing manual pump is available monitor the calibration of injectors by verifying that the pressure are those listed in paragraph 2 6 of this manual Checking for a
34. liance with the most recent safety 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 Sol Diesel ENG 3 03919402 ENG rev 0 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 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
35. lled with the applicable fluids 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 be changed with warmed engine in order to ensure that is emptied The temperature of the oil will be approximately 80 C Stop the engine before doing the oil change This operation is done by oil drain pump see Fig 4 1 Dismount the plug A and fit the hand oil pump 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 new oil through the filling hole Fig 4 2 Oil capacity see heading 2 6 technical specifications 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 oil dipstick Fig 4 3 cleaning it with a Fig 4 2 rag and repositioning it by retightening 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 dipstick mark MAX The oil level must be between the mark MIN and MAX MIN Fig 4 3 AN WARNING The level of oil never to being below the mark MIN of the oil dipstick Fig 4 4 33 Note that dipstick marks refer to the engine at a horizontal position Therefore check the engine inclination when the level is ver
36. m for lengths superiors to 3m 9 2 POWER TAKE OFF ESPECIFICATIONS OPTIONALS A B C Ratio r 1 1 116 1 1 297 1 1 297 Npower take off 1 1297 x Nengine Rotation Non Clockwise Non Clockwise Clockwise Left Left MAX 50 kW 20 kW 20 kW OUTPUT 187 Nm 64 5 Nm 64 5 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 connection Contact to Technical department SoleDiesel Sol Diesel ENG 38 03919402 ENG rev 0 MARINE DIESEL ENGINES MARINE DIESEL GENSETS SOL S A 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 www solediesel com Ref 03919402 ENG Ed 1 rev 0
37. m please read the comment 2 Plug oil pan Oil filter Pressure relief valve 4 5 4 Bolts to fix the Flange injections pumps 9 D Glow Plugs 2 2 Bolt Stop solenoid 2 1 2 1 Nut for B terminal of starter 1 1 1 1 Bolts reversing gear flange set 12 0 12 0 Water cooler element locknut 2 3 2 3 Reversing gear body set screw Oil gearbox drain plug General tightening torque Comments 1 1st tightening angle 60 II 2rd tightening angle bolts 60 2 1st tightening angle bolts 30 85 mm length 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 thoroughly 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 A A O O O 9 9 q 69 Qe 0 0 O 9 SDZ 165 SDZ 205 SDZ 280 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 Tightening torque 2nd stage 130 Nm Tighten M8 bolt with a torque of 21 Nm Tightening angle 909 Sol Diesel ENG 16 03919402 ENG rev 0 42 ENGINE SUPPLIES The engine does not come with its circuits fi
38. n power take off optional 12 Seawater pump 13 Plug 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 28V 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 33 Coolant line to turbocharger 34 Lubricating line to turbocharger 35 Flywheel housing size SAE 3 36 Flywheel size SAE 11 7 37 Elbow wet exhaust 12 14 13 2 2 COOLING CIRCUIT S l Diesel ENG 5 03919402 ENG rev 0 2 2 1 COOLING CIRCUIT COOLANT Fig 2 1 AN Use anti freeze as indicated in section 4 2 2 of this manual Expansion tank coolant pump compensation hose 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 9 4 4 5 6 7 8 9 1 1 1 13 Boiler kit optional 0 1 2 3 Thermostat valve operating values AllEngines Start opening at
39. nstruction simplicity is only apparent in fact many of its parts are machined to 1 1000 mm tolerances It is therefore recommended that you entrust any servicing to skilled personnel having availability of special equipment provided by the Sole Diesel service network 3 Preventive maintenance will extend the life and efficiency of turbochargers Watch for loss of lubricant vibrations or abnormal noises stop engine immediately 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 Fig 7 2 20 remove it carefully 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 It 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 impregnate it with engine oil to prevent damage due to dry running N Warning for better lubrication of the turbocharger we advice to let the engine run at idling speed without load during 30
40. nti corrosion protection The anti corrosion protection is not fitted in these engines The parts of the seawater cooling system are made with materials that protect the cooling system Change air filter The engine is provided 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 according 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 03919402 ENG rev 0 16 Compression pressure checking Connect compression tester Crank engine with starter motor 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 It is recommended to use the compression pressure measurement only for comparison of compression pressures of all cylinders in one engin
41. ossible damage to the engine 3 4 TRANSPORT AND HANDLING OF THE UNPACKED ENGINE When the engine is unpacked ready for transport use EXCLUSIVELLY the appropriate lifting eyebolts A see the picture 3 4 Choose the lifting equipment with reference to heading 3 3 te PE l to En NE ze er de ay s a di F A DE fr GF N E gt ogg aS ed FEN H 17 frr Y NE 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 03919402 ENG rev 0 4 INSTALLATION 4 0 GENERAL WARNINGS Refer to heading 1 3 for safety information 4 1 ASSEMBLY DATA kgf m Ma aar N TT SDZ 165G SDZ 280 Boltcylinderhead 1 18 1 B 1 4 5 1st retightening angle 60 214 angle 30 60 mm long bolts 60 80 mm long bolts Bolt connecting rod 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 85 m
42. pen 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 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 meteorological changes and climatic conditions The following recommendations are therefore of a general nature but they will help prevent or reduce the risk of damage due to rusting 6 6 LONG INAGTIVITY INSTRUCTIONS When the engine is not to be used for a long period of time or during the winter time certain operations must be carried out to keep it in perfect operating 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
43. reely 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 user 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 Disposal of waste material must be carried out in conformity with established legislation in the country of installation Sol Diesel ENG 19 03919402 ENG rev 0 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 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
44. sel ENG 32 03919402 ENG rev 0 17 18 19 Replace the belts alternator and fuel pump Slacken V belt to allow removal 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 pump 3 to the right Remove the belt and replace it with a new one 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 belt 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 dismounted 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 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 as previously explained NP
45. 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 written 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 SOLE 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 group 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 03919402 ENG rev 0 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 When the engine is to be stopped close the sea water cock 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 filed completely Stop the engine and replace the sea water filter cover Before starting the engine again o
46. to oil pan 25 Pump oil suction Oil circuit pressure 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 1 2 Engine equipped with Standard oil pan no engine inclination and with oil filter 0 SDZ 165G 1 1 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 03919402 ENG rev 0 2 4 FUEL CIRCUIT Fig 2 4 1 Fuel tank 2 Marine hose fuel 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 It must be bigger 14 Fuel filter water separator ENGINE INJECTORS 8DZ 20 6 6 Fig 2 4 1 Fuel pump 2 Fuel filter engine 3 Marine fuel hose Read the next comment at the bottom of the page 4 Fuel filter water separator 5 Valve 6 Fuel pump manual Not supplied optional order kit 19424075 7 Fuel tank 8 Breather tank 9 Fuel cooler optional 10 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 Not surpass the 2 m of height between the tank and
47. ulation of engine output Output correction Temperature C Graph 3 Effect of intake air temperature on engine output 25 Cis reference temperature 0 NORMALLY ASPIRATED TURBOCHARGED Sol Diesel ENG 37 03919402 ENG rev 0 Output correction 1050 1000 950 900 dal S00 TAU Air Pressure mbar Graph 4 Effect of air pressure on engine output Normal value is1000 mbar 750 mm Hg 0 9 TECHNICAL ANNEXES O OOOO 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 CH 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 INT FUEL HOSE INT FUEL HOSE FROM ua OMTEKIAUST maren gy CASE TO y MMMALSEETON FROMTANKTO ECON PUM TO THE 5 24V PRIMING PUMP TANK AIRE ASPIRACION A BATERRY __ 650 700 m h A o a 160Ah 1100 1200 160 Ah Som mm MA 1 Max r p m 2 for each curve of 90 of the installation must increase 10 m
48. y impurities existing in these a water might clog the SS li ducts wien cooling conducts a Em EE Die D Filter shall be cleaned every 200 hours by loosening the wing nut and removing the filtering component Clean the filter 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 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 electrolyte level and charge Batteries require a very careful handling and frequent checks 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
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