Home

S i M l Service Manual T 427 Type 427

1. 222242222222222222222222722 22222222222 2 2222222222222222222222222222222222222 Ma annan aa SQ N 24 2222222222 oa gt AN aN N a HINN og o2 OG RN ez 2427227222122222712222222 E em me NG i IN 427 30120 Callesen Diesel Page 1 of 1 Sheet no 7 26 2B COOLING WATER SYSTEM TYPE 427 T FRESH WATER SUPPLY OVERFLOW OVERBORD VALVE an i 1 i 1 1 I EU FRESHWATER COOLER CIRCULATIONSPUMP oy HE NENNED NE pd OVERFLOW VALVES CLUTCH won LU osp t t COOLER 7777 1 COOLIN GWATER PUMP BILGE PUMP 1 1 1 1 1 1 1 1 4 BOTTOM VALVE 50 mm SIGNATURES Freshwater pipe 60 54 steel pipe Seawater pipe 56 50 copper r r Air relief pipe gt steel pipe Blind flange CAPACITIES Type C D Type E F Cooling water pump 9 3 m h 14 4 m h Bilge pump 9 3 m h 14 4 m h Circulation pump 14 0 m h 22 0 m h EMERGENCY COOLING In case of failure in the freshwater system seawater can be led direct on the engine by opening blind flanges A and C and closing B Callesen Diesel Page 1 of 1 Sheet No 9 11 2A OPERATION AND MAINTENANCE OF FRESHWATER AND OIL COOLER Structure The cool
2. The clutch oil should be replaced after about 5000 working hours however at least every 2 years The turbocharger oil should be exchanged every 1000 working hours The pistons should not be drawn unless the oil consumption becomes too high Then the oil control rings and probably also the compression rings should be replaced Callesen Diesel Page 7 of 12 Sheet No 7 94 2A Normally the valves should not be interfered with until they are no longer completely tight Usually this can be heard in the exhaust when the engine is idling or when starting difficulties appear Turn the pistons against top with closed compression cocks If the valves can be heard blowing in the exhaust or suction channels they need grinding To grind the valves it will be necessary to remove the cylinder covers See also sheet 7 6 The valve clearance which can be adjusted by means of an adjusting screw in the rocking lever must be 0 60 mm for the exhaust valve as well as for the suction valve The same value applies to cold and warm engine Main bearing clearance is between 0 10 mm and 0 12 mm crank bearing clearance 0 15 mm The space between piston and cylinder cover is 2 20 2 40 mm The copper packing between cylinder and cover is 1 00 mm The indicated space between piston and cylinder cover equals a compression pressure of about 38 kp cm At this pressure the engine is certain to start even at low temperatures The engine has to work on an firing pressur
3. 4 In case of hydraulic fastening the manometer should indicate a pressure of approx 250 Bar Type 427 and approx 240 Bar Type 425 Callesen Diesel Page 1 of 1 Sheet no 7 49 2B INSTRUCTION FOR VALVE GRINDING If you find that the valve seats are loose you have to check by means of a thickness gauge how much space there is between the seat and the cylinder cover If there is more than 0 05 mm you have to change the seat if less than 0 05 mm the seat has to be caulked before grinding When removing the seat the surfaces in the cylinder cover are not to be damaged and before inserting the new seat you have to examine the surface in the bottom of the hole to see if it is in order If not you have to grind it with carborundum if necessary by means of the old seat The reason is that if the seat does not bear against all over the seat will not be cooled sufficiently First the seat must be ground by a Tyrolit stone Before grinding the valve seat please observe that the valve guide is sufficiently tightened B A Face the stones for 4 Fi A 30 5 31 02 RS 15 0 NS C 45 02 Start grinding the surface A with a slight pressure so that the seat becomes round Thereafter B and C are to be faced so that the seat will get a width of 3 5 4 0 mm Before grinding with the valve and carborundum you have to examine that the valve lies hardest on the bigger diameter of the area A when you have ground af few tim
4. Distance piece 17509 is set free by putting a wrench over the ribs and turning it round The distance piece can then be removed The valve tappets 17525 and the 60 rubber ball are removed The valve seat 16515 is drawn up by means of the puller 18981 and the nozzle hammer 16978 When the distance piece 16514 has to be drawn up the puller 18981 is replaced by the puller 18982 42222202277 22 2 UN SE see SR EAS NN N NN LL NN N SER N N RE N NN NR KN PEN NLI HUN N S i Nex N Sheet 7 62 2A QUANTITY OF ANTI FREEZE MIXTURE FOR FROST PROTECTION OF CALLESEN DIESEL ENGINES Water quantity in engine Anti freeze mixture litres for protection to Type including header tank 422 425 B 422 425 422 425 D 155 37 46 57 65 72 422 CT appxi45lres 34 43 54 60 67 422 DT apprxiSOlires 42 56 66 76 427 B BT approx 17olitres 40 51 72 79 427 C CT approx230lires 54 85 97 107 427 D DT apprx290ltes 68 se 107 122 133 427 E ET 427 F FT 410 96 121 151 172 190 427 HT 203 291 NOTE When the anti freeze mixture has been filled up and the engine has been running for 30 minutes the mixture is checked by means of a hydrometre Callesen Diesel Page 1 of 1 Sheet no 7 55 2A FROST PROTECTION OF CA
5. The piston water pump of the main engine is provided with a rocking lever which actuates the oscillating lever 39 Through the actuator unit this causes the worm gear 34 to rotate in the same direction always regardless of the direction of rotation of the drive shaft Numbers on this page refer to the drawing on page 4 3 STARTING UP Installation and connection of the lubricating pump Install the pump vertically and fix it in position The oscillating lever should be connected to the rocking lever on the piston water pump of the engine Filling lubricant reservoir and piping Clean all piping carefully by tapping and purging and pre charge with clean grease prior to installation using a grease gun When starting up for the first time it is recommended to fill the grease reservoir up to the strainer with oil and the fill up with grease Otherwise the pump has to go for some time in order to bleed the system Before connecting up the piping run the pump at full output until grease issues evenly and air free from each outlet Connect the lines to the pump using the sealing rings supplied and run the pump until air free grease issues Fill the bearing to be lubricated with grease and connect the lines to the lubrication points The installation is then ready to start up as soon as the quantity of lubricant to be delivered has been preset to the required level Is a single outlet not used you could either carry it back to the reservoir o
6. and the holes respectively are worn out to such an extent that the oil leakage is becoming to large the bolts have to be replaced by new oversize bolts The following procedure must be used Cover 2 reversing cylinder 5 and clutch shaft 4 are bolted together by means of the studs 3 and the clutch cones 6 and 7 are unbolted by means of the blocking bolts 8 after having mounted only one of the catch bolts in order to control the holes in relation to each other Subsequently a single hole is drilled by an oversize drill whereafter it is reamed by an oversize reamer Now an oversize bolt is put into the new hole and the next bolt can be adjusted Callesen Diesel Page 1 of 1 Sheet No 7 69 2A BLOCKING INSTRUCTIONS FOR CLUT Two piece pipe 2 NAN 422 425 20943 427 C D 16908 2 427 E F 16956 7 Q NN 4 C c lt Z 227272272522 2222772222727 A 2 N N I 7 Zu PU NS A r HZ NN N Blocking screw S CH AND REVERSAL In case of failure of the oil pressure system in the clutch and reversal the clutch as well as the reversal can be blocked as an emergency arrangement The 6 blocking screws are to be mounted as shown on the drawing and must be tightened simultaneously to avoid jam ming of the clutch cones The blocking of the reversa
7. cyl 3 To cyl 5 From starting air pipe 10010 LL Position of the ANER 10052 disc valve with Direction of 2 2 10166 cyl 6 in start rotation NI RES position 16155 17132 SSS SSK opie SSN G m 5 N 2 S y N 52 59 N MI Nut Cover is removed 8 gt I I O CO S fa JOU S l 0 L 512 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17132 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 6 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 6 is in starting position even though the top mark for cylinder 6 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 6 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 6 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the
8. engine set the propeller pitch at zero position When dismounting the propeller head cover take care that the joint surface is not damaged When the joint bolts have been unscrewed the cover can be loosened by turning the blades When the cover has been removed the blades can be taken out by turning them around the sliding journal Thus neither pull rod nor flange coupling have to be dismantled When blades and sliding blocks have been refitted lubricate all moving parts with engine oil Do not fill up with grease until the cover has been mounted Prior to assembling the propeller head see that the joint surface is completely free from dirt and burrs and prior to mounting the cover clean the threaded holes of the propeller head carefully to remove grease and dirt otherwise the bolts may not be tightened sufficiently Lock the joint bolts by means of the stainless locking screws bored into the cover Then fill the propeller head with thin grease or sterntube oil SAE 140 as follows Place the head so that the filling hole is pointing straight downwards and the air relief hole straight upwards Fill grease into the bottom hole The head is filled when grease is beginning to run from the top hole Finally fill the joint bolt holes with tallow If the pull rod has been dismantled or when the pull rod is being mounted for the first time proceed as follows Screw the pull rod into the piston rod or the intermediate shaft sleeve by turning t
9. failure is due to a defect in the hydraulic system which cannot be remedied at sea you can manage this way Remove the cover on the starboard side of the clutch Screw the six 3 4 screws with square heads which are supplied into the aftermost clutch cone through the large openings in the clutch case Take care that they are tightened smoothly and exactly equally to avoid jamming of the cones as in this case the clutch will slip Loosen the propeller shaft flange coupling from the engine and draw it so far backwards that the two half pipe sections can be laid around the pull rod In case they cannot be fitted because the propeller shaft cannot be pushed far enough astern the sections can be sawn into pieces and laid at two or more times The flanges should then be tightened together again Take care that the flange couplings are completely together The propeller is then blocked at Ahead The propeller shaft or the propeller may be damaged The faults must be remedied and as far as possible it is recommended to have this done by a skilled expert REGULATIONS FOR FUEL OIL AND LUBRICATING OIL FUEL OIL The engine is tested on the factory s testbed with the fuel oil gas oil which is usually available on the market If the use of another type of fuel oil might be intended the factory should be asked for advice LUBRICATING OIL For lubricating of the engine a good grade diesel engine oil which is highly self purifying a so called D3
10. no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 8 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 H RUNNING CLOCKWISE To cyl 5 To cyl 3 From starting air pipe Position of th d osition disc valve with Direction of PL 10082 cyl 7 in start rototion q AED 10166 E A ae position NY 16155 55 WY Zi 40137 NMG To cyl 7 To cyl 1 NG 16157 N zal 7 SSS Ee ET FREIE N 10103 8 e L 530 20 fib EE s 19124 17132 Cover is MIO Nut removed iHi zm H 0 5 pac To cyl 6 To cyl 4 19122 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17132 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 7 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 7 is in starting position even though the top mark for cylinder 7 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 7 giving full index to the fue
11. oil should be used Such an oil can be supplied by all recognized oil companies All the year Callesen Diesel Page 11 of 12 Sheet No 7 94 2A round an oil with a viscosity equalling SAE 30 should be used It is important that the oil has a high flash point and can emulsify with water CLUTCH OIL A special hydraulic oil should be used as stated below STERNTUBE GREASE Use a thin soft special sterntube grease which can emulsify with water This grease can also be applied to the other grease cups OIL LUBRICATED STERNTUBE WITH SUBLIME PACKING GLANDS Same oil as engine GREASE FOR AUTOMATIC GREASE GUN DE LIMON As stated below THE FOLLOWING OILS CAN BE USED FOR CALLESEN MARINE DIESEL ENGINES 4 STROKE TYPES 422 425 AND 427 MAKE ENGINE OIL LUBRICATED CLUTCH STERNTUBE ESSO EXXON EXXMAR 12 TP 30 NUTO H 68 Q8 MOZART DP 30 HAYDN 68 BP ENERGOL DS 3 103 ENERGOL HLP 68 SHELL RIMULA 30 TELLUS 33 CHEVRON DELO 300 SAE 30 OC TURBINE OIL 68 MOBIL MOBILGARD 312 DTE HEAVY MEDIUM GULF SUPER DUTY SAE 30 HARMONY 68 TEXACO TARO 30 or XD 30 REGAL R amp O 68 CASTROL MARINE MLC 30 HYSPIN AWH 68 AUTOMATIC GREASE GUN TURBOCHARGER ESSO EXXON BEACON EP 2 NUTO H 68 BP ENERGREASE MM EP 2 ENERGOL THB 68 or BARTRAN HV 68 SHELL ALVANIAR 3 TURBO OIL 78 CHEVRON INDUSTRIAL GREASE HEAVY OG TURBINE OIL 68 MOBIL MOBILUX EP 3 DTE HEAVY MEDIUM GULF GOLD CROWN EP GREASE 2 HARMONY 68 TEXACO MULTIFAK EP 2 REGAL R amp O 68 CASTROL SPHEEROL AP 3 HYSP
12. should only be replenished after the engine has been idling for about a quarter of an hour as unskilled people may have pumped the oil from the container down to the crankcase to which the overflow valve is leading The oil will then when the engine has run for a while appear again in the oil container as the return pump which sucks from both ends of the crank sump is larger than the forward pump Check the oil level in the clutch case for clutch and reversal Ensure that the oil is kept between the marks on the dip stick in the portside of the clutch shield This checking should be made when the engine has been started and is idling The water pumps and sterntube if not oil lubricated type sterntube are lubricated by means of grease presses fitted for this purpose the sterntube must be completely filled with grease All remaining grease cups must be filled and screwed down as well to ensure that every part is well lubricated Do not forget to grease the teleflex cables for the manoeuvring box in the wheelhouse well with graphite grease at mounting Oil lubricated sterntube Sublime see separate instruction Water level The freshwater system of the engine is filled with pure water through the cover of the expansion tank fill up with so much water that the water level is approximately in the middle of the water gauge when the engine is cold Afterwards the circulation pump has to be vented Fuel system Fill the fuel tank and see to i
13. this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 1 is in starting position even though the top mark for cylinder 1 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 1 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 1 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 10 of 10 Sheet No 7 63 2A FSSA ve ete DESCRIPTION OF CHARGING VALVE For charging of the starting air receivers there is usually placed a charging valve on each engine Mode of operation The valve is opened by turning the handle 16728 3 8 turn to the left Thereby the spindle 16716 is 7 lifted so that the ball can move up and down and at NIN the same time the air supply upwards is closed as SUN the upper breast of the spindle is pressed up N N against the union 16714 Z SN Do NSS PG Di VA 5 G Ball as well as seat and spindle are made of stain 555 less steel ZZ The valve is now automatic as the ball is lifted and air flows into the air receiver when the pressure in the cylinder of the engine is higher than the pr
14. worn The injectors should be pressure tested too Pump by means of the handpump up to 240 kp cm Exchange of lubricating oil Heavily loaded engines After about 500 700 working hours or according to oil analyses Other engines After about 1000 working hours Minimum twice a year The lubricating oil filter inserts should be replaced when oil is exchanged or when the pressure dif ference on the manometers Before filter and After filter exceeds 2 kp cm The turbocharger oil must be exchanged every 1000 working hours Every year Adjust valves and check the lubrication of the rocking levers Check the water pump valves Check the air distributor Remove the cover and lubricate the disc valve Every 2 or 3 years Change the clutch oil and the clutch oil filter If water has come into the clutch the oil must be changed immediately It may have to be changed several times until it is completely clear as new oil sThe clutch oil filter insert must be replaced at the same time as it dissolves in water Every 3 or 4 years or every 15 000 18 000 working hours 1 or 2 crank bearings must be dismounted for checking Change the turbocharger bearings after 12 000 working hours If the engine is not started for some time the opening of the exhaust pipe should be covered by a bucket or a plactic bag to prevent rain and moisture from getting into the pipe as it will loosen soot If may cause difficulties in starting the engine if this soot i
15. 1 SN N 17131 Cover is NN removed M 281 05 To cyl 2 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17131 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 4 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 4 is in starting position even though the top mark for cylinder 4 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 4 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 4 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 5 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 E RUNNING ANTI CLOCKWISE To cyl 3 From starting air pipe Direction of rotation 2 t 10018 GID 3 3 Position of the disc valve with cyl 5 in start position 8852 Sy I H3 lt 10166 222 ft SS e M
16. 33 2B DESCRIPTION OF SUBLIME STERNTUBE SEALING AFT SEALING The aft sealing consists of 1 an inner casing 9 and 14 with chromium steel bush 5 2 an outer casing 1 and 13 Inner casing The inner casing consists of two rings 9 and 14 which are exactly centered to each other The bronze ring 9 is supplied with 3 rubber sealing rings The two aft sealing rings 7 prevent the entry of saltwater and the third ring 17 is to seal against oil from the sterntube The lips of the sealing rings are pressed upon the chromium steel bush 5 by means of a spring and water pressure respectively oil pressure The water pressure corresponds to the draught of the ship the height of the overhead tank 2 3 m above the water line determines the oil pressure The rubber of the sealing rings is seawater and oil resisting The support ring 8 ensures a long lifetime and a good sealing capacity The bearing ring 14 ensures that the sealing rings follow exactly the movements of the propeller shaft This bearing ring is cast inside with white metal The chromium steel bush 5 is pushed over the shaft and fastened on the propeller so that it rotates with the shaft In case of wear of the aft end bearing the lips of the sealing rings are kept centrically in the right position by means of a bearing ring 14 which ensures a durable sealing In order to prevent any leakage of oil or water between shaft and bush a bronze and rubber ring is placed in
17. 6121 above the upper side of the crank case The height should be 5 5 mm when the cam is at its lowest position It is absolutely necessary to keep the 5 5 mm which must not be changed for adjustment purposes The index pointer of the pumps must be adjusted on test bed to secure the same pumping volume unless the pumps have been delivered ex works where adjustment has been made Now the pumps can be mounted The connecting rods between the pumps are mounted before tightening Newer engines are supplied with one through connecting rod in front of the fuel pumps When tightening take care that the pump is not twisted which will result in sticking governing rods These rods must work absolutely free Checking the timing The best way to check the timing is by means of a drip pipe Instead of the fuel pipe a bent pipe sharpened so that the drops can be counted is mounted and the valve cone and the pressure valve spring are removed On the suction side of the pump a small container holding approx 12 litre is mounted When watching the dropping from the drip pipe you will see when the cutting off takes place Correct adjustment is about 6 10 drops per minute For various specifications of adjustment please refer to sheet 7 45 Adjust the fuel cam by loosening it from the cam unit Take care that the two halves of the fuel cam are pressed firmly together before tightening the bolts After having tightened the bolts check that there is no g
18. CALLESEN DIESEL Service Manual Type 427 CALLESEN MARINE om powering marine safety Aabenraavej 13 17 DK 6340 Krus Denmark Tel 45 74 62 2088 Fax 45 74 627407 E mail bukh bukh dk INDEX FOR TYPE 427 C F OPERATION AND MAINTENANCE OF ENGINE 7 94 Directions for use of Callesen Diesel 7 95 Maintenance of Callesen Diesel 7 16 Things to remember when engine is inspected 4 68 Technical data of Callesen Diesel STERNGEAR 7 33 Relief valve 7 93 Sublime sterntube sealing 7 81 Disassembling and assembling of propeller blades and head 9 26 Pipe diagramme for sterngear CYLINDER COVER 9 gt 0 Fastening of cylinder cover Instructions for valve grinding Drawing of nozzle holder Grinding of cylinder cover and liner Adjustment of fuel pumps and valves CRANKSHAFT AND PISTON 7 14 Dismounting of crank bearing and mounting of piston support 7 230 Drawing of piston 7 32 Repair of slots for piston rings 7 26 Directions for mounting of cylinder liners COOLING WATER SYSTEM 9 11 7 10 7 11 7 12 7 62 7 55 7 56 7 115 Callesen Diesel Cooling water system Maintenance prescriptions of cooler Sketch of cooler Repair of circulation pump Dismounting of ball valve in piston water pump Coolant quantity for frost protection Frost protection of Callesen Diesel Adjustment of tooth clearance for circulation pump Page 1 of 2 Sheet No 8 49 2A STARTING AIR
19. F MOBIL SHELL TEXACO ANBEFALEDE SM REMIDLER FOR DELIMON FEDTSM REPUMPE TYPE FZ RECOMMENDED LUBRICANTS FOR DELIMON GREASE LUBRICATION PUMP TYPE FZ EMPFEHLENSWERTE SCHMIERMITTEL F R DELIMON FETTSCHMIERPUMPE TYP FZ FEDTTYPE GREASE TYPE PENETRATION FETT TYP NLGI ASTM Energrease LS2 265 295 Spheerol AP3 Lithium 235 Impervia CS Calcium 280 Industrial Grease Heavy Syntetisk natrium Gold Crown EP Grease 2 270 Mobilux Grease No 2 265 295 Alvania R3 220 250 Multifak EP2 265 295 NLGI ASTM Penetration No 000 O WP 445 475 400 430 355 385 310 340 265 295 220 250 175 205 130 160 85 115 Tilsvarende sm remidler fra andre anerkendte oliefirmaer kan ogs benyttes Equivalent grades of lubricants from other recognized oil companies may also be used Entsprechende Schmiermittel von anderen anerkannten lfirmen k nnen auch benutzt werden Callesen Diesel Side 1 af 1 Skema nr 7 98 0A LUBRICATING OIL DIAGRAMME TYPE 427 OVER PRESSURE VALVE PAA AAA V Y V V OIL COOLER OIL FILTERS De LUB OIL CONTAINER TO ENGINE BEARINGS OVERFLOW PIPE NZ Pe C D E F H Forward pump capacity m3 h 2 3 4 0 6 0 Return oil pump capacity m3 h 2 45 4 25 6 5 Hand pump capacity m3 h Normal drive Usually the engine has dry sump and the 3 three way cocks A B and C must be in the positions shown in the diagramme Forward pump out of service The engine m
20. IN AWH 68 Callesen Diesel Page 12 of 12 Sheet No 7 94 2A MAINTENANCE OF CALLESEN DIESEL ENGINES Before start Check oil level in engine turbocharger and clutch as well as water level in freshwater tank Open the seawater and fuel valves Pump pressure on the lubricating oil system by means of the hand pump Turn the engine 1 turn if necessary in starting position Before start pressure must be pumped up again so that the manometer indicates pressure During operation Immediately after starting the engine check the lubricating oil and hydraulic oil pressure The engine should be loaded gradually until normal operation temperature is attained During operation the engine must be inspected every 4 hours approximately At the same time water pumps and sterntube must be lubricated If the sterntube is oil lubricated check the oil level Before stop Check the starting air bottles The bottles must be pumped to 30 kp cm If grease lubricated the sterntube must be lubricated After each stop The sternshaft pullrod must be lubricated through the grease nipple at the flange coupling Grease must be pumped in until resistance is felt The pressure is relieved after approx 20 minutes by open ing the valve on the flange coupling Every week The Stauffer cups on the end covers at flywheel and clutch casing must be lubricated a little about half a turn The coarse fuel filter water trap should be emptied of water and sludge th
21. L DIAGRAM FOR INSTRUMENT PANEL ON ENGINE Instrument panel on engine Revolution counter H pressure switch Fly Switch Hour counter Callesen Diesel Page 1 of 1 Sheet No 9 068 2A EL DIAGRAM FOR DVERSPEED STOP Overspeed box Micro switch Stop magnet Callesen Diesel Page 1 of 1 Sheet No 9 172 2A EL DIAGRAM FOR TERMINAL BOX Pump lever position L 30 Remaining wires 15 mm Callesen Diesel Page 1 of 1 Sheet No 9 169 2A CONNECTION DIAGRAM 241 6 LLT8I peedsuaA 890 6 225 uo jeuod4uaunu4su 1941SouJ4au Go ema ang GEA GOOG EEE B XOU EE 66 pAw SME VINIT 484348AUu0j 0v IGcAI AML 404 aul jan j Seh vc EG Co oulua Page 1 of 1 Sheet No 9 168 2A Callesen Diesel Alarm device BOSCH 0 332 003 012 See Diagr 9 169 Yellow Wires 1 5 mm Callesen Diesel Page 1 of 1 Sheet No 9 077 2A 1 CHECKING THE ADJUSTMENT OF THE FUEL PUMPS Dismount the Bosch pumps and the pump lever guide 18101 with lever 17190 Check the Ona bearing 3264 1 It must be absolutely without backlash At the same time check the cam face while the engine is turned The surface must be undamaged Remount pump lever and guide Check the height of the elevating screw 1
22. LLESEN DIESEL ENGINES Data for ESSO and BP anti freeeze mixture The anti freeze mixture is an etylenglykol product mixed with special additives which can prevent the cooling water from freezing and reduce rust corrosion and foam formation in the cooling system The anti freeze mixture has a boiling point of approx 200 C and therefore does not evaporate at the engine operating temperature The anti freeze mixture is chemically stable at the engine operating temperature and neutralizes acid compounds which are produced in the cooling system The anti freeze mixture has a good thermal conductivity The anti freeze mixture is innoxious to lacquer and does not attack any of the various compo nents and materials contained in the cooling system The anti freeze mixture is not inflammable Operating instructions When filling up with anti freeze mixture the following procedure is recommended 1 2 10 11 Drain off all cooling water Rinse the cooling system through until clean water is appearing at the drain of places NEVER USE COLD WATER FOR A WARM ENGINE Check cooling hoses and connections for leaks Hoses have to be replaced as soon as cracks are beginning to show Leaks on connections must be repaired by replacement of the packings Check thermostat for correct operation Close drain off places and fill 1 3 of the cooling system with water Fill with anti freeze mixture according to the table and then fill up wit
23. SKF24156 o m m m m m m m m m m m m Axial clearance for rocking levers for valves Clearance in valve guide pump lever guide and valve lever guide ajo m m m m m m m m m m m m m m m m m m 1 m o MIN ALLOWABLE kp cm 2 0 kpm Torque for bolts for connecting rod and main bearing 114 WG kpm 76 Torque for main bearing bolt M 33 kpm 100 Drive of governor wheel mm 0 9 Exhaust and suction valve clearance Callesen Diesel Page 1 of 1 Sheet No 4 68 2C OPERATION OF RELIEF VALVE FOR LUBRICATION OF PULL ROD AND PROPELLER HEAD 1 4 Pipe 1 4 Greasen 1 4 Cock Z 2 JA y Z Z Z d 2 7 After having stopped the engine pump grease in with closed cock until resistance is felt To increase the flow of the grease you might oprerate the reversal to ahead and astern pumping The grease must draw out into the propeller head and the cock should be kept closed for about 20 minutes Then open the cock and leave it open for about 15 minutes to allow the excess pressure to leave the system If grease is not pressed out of the cock the system is not filled up and you will have to pump more in Operate the reversal to ahead and astern and close the cock again until next lubrication For lubrication use a thin soft special sterntube grease Callesen Diesel Page 1 of 1 Sheet No 7
24. SYSTEM 7 203 Repair of coked starting valve 7 63 Repair of air distributor 7 129 Description of charging valve LUBRICATION 7 102 Operating instructions of Delimon grease pump 7 98 Recommended lubricants for Delimon grease pump 9 27 Lubrication oil system 7 149 Regulations for lubricating oil CLUTCH 7 69 Replacement of worn out catch bolts 7 64 Blocking for clutch and reversal 7 67 Two step overflow valve EL DIAGRAMMES 9 68 EI diagramme for instrument box 9 172 El diagramme for overspeed box 9 169 El diagramme for teminal box 9 168 Connection diagramme 9 77 Alarm device MISCELLANEOUS 7 113 Checking the adjustment of the fuel pumps 7 75 Adjusting the revolutions of type 427 4 90 Woodward governor 7 120 Hydraulic mounting of hubs 9 31 Fuel system Callesen Diesel Page 2 of 2 Sheet No 8 49 2A FIRST START AND TRIAL RUN When the engine has been installed and everything has been properly checked the engine is ready for trial run Before the engine is started for the first time proceed as follows Oil level Check the existing quantity of lubricating oil the oil level should be seen on the oil gauge or dip stick on the side of the oil container which is cast together with the starboard side of the crankcase below the exhaust pipe In case the oil does not reach the maximum mark about 2 3 cm from the top of the gauge and while the hand pump can still pump pressure on the manometer oil
25. Y 16155 44 SN 40137 ses 16157 lt LY IR 4 iA eh N DN Win 19193 N N JHH 8 4 c o O E Lyf 2 fo gt gt tel 4 03x8 ll j 17131 removed Tm H 18198 1 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17131 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 5 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 5 is in starting position even though the top mark for cylinder 5 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 5 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 5 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 6 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE F RUNNING CLOCKWISE To
26. allesen Diesel REPAIR OF CIRCULATION PUMP 16986 OR 13x26 VG VG s 7ZZZZZZZZ2 22 SS _ S N le Sy Z ESTITA WSS Q N S EE pr m A Dismounting The rotor is dismounted by means of the puller 16986 as shown on the drawing The keyway in the rotor should be in top position during the pulling otherwise the disc key could fall down into the spiral case For dismounting of gearwheel 18561 apply puller 16986 as well Assembling O ring 17 3 x 2 4 must be remembered No grease must be found between the seal faces on the packing gland Goetze 76 12 The rotor must not be drawn higher up on the cone than before the pulling Callesen Diesel Page 1 of 1 Sheet No 7 12 2A DISMOUNTING OF BALL VALVE IN TTL IL In FIN A SS DE 4222227 C4 rd SEB Y ne 727 ne K 7 Np grees 2 N T 1 ZI A 721 227222227 3 EE SE A 22222227777 12 07 SS I 2 27272 gt lt gt Assembling The wide rib of the distance pieces should face the pistons Before mounting the air vessel on the valve housing the jack screw 17522 has to be loosened Otherwise leaks might occur in the joint Callesen Diesel Page 1 of 1 THE PISTON WATER PUMP Dismounting Remove air vessel 17503 1
27. alve does not open remember lubricating If the starting valve is sticking it can be loosened by pouring a little oil onto the piston after having removed the large fitting by means of the tools delivered operate the valve until it comes back again quite easily when being pressed downwards See sheet 7 203 7 60 under starting air system 5 The automatic starting valve disc in the air distributor may have been displaced half a turn after dismounting Perhaps the driving pin is broken Adjustment of disc valve see sheet 7 63 under starting air system 6 The valves are hanging or leaking regarding valve grinding see under cylinder cover sheet 7 6 perhaps the pistons should be drawn and cleaned because the piston rings are sticking coking This is usually the case when the engine runs 1 17 turn and then stops Instructions for drawing of pistons are indicated under crank and piston sheet 7 230 7 14a The faults have to be located and remedied When the engine at start is turning round but does not ignite the cause may be Callesen Diesel Page 9 of 12 Sheet No 7 94 2A That there is no fuel supply either because the fuel tank is empty the fuel filter clogged or the overflow valve not in order when the outlet pipe on the filter has been removed it should be possible to pump the oil through in full jet by means of the feed pump There may be air in the fuel feed pipes The injectors should squeak when the engine is turned Th
28. ap between the cam halves Normally the cams for inlet and exhaust valves must not be loosed from the cam shaft Adjustment of the cam valves will influence the adjustment of the fuel cam which must then be readjusted When the cam shaft cover is mounted again apply a form gasket outside the bolt holes to prevent leakage This gasket should be of the silicone rubber type e g Permatex Do not apply too thick a layer as this may cause superfluous sealing to drop down into the engine before it has dried up After adjustment and mounting test the engine and measure the ingition pressure The ignition pressure should be between 63 and 65 atm Check the fuel injectors which must be flawless Opening pressure 240 atm Compression pressure 58 60 atm As a guide 2 mm on the face of the flywheel equals approx 1 atm at a possible readjustment Callesen Diesel Page 1 of 1 Sheet No 7 113 2A ADJUSTMENT OF REVOLUTIONS FOR TYPE 427 C E See fig 8 page 11 in the spareparts manual showing a sectional drawing of the hydraulic governor The engine is adjusted to run 225 r p m at idle speed by means of the x 75 mm screw which pushes against the end of the piston 17115 If the screw is turned clockwise the revolutions will be increasing The adjusting screw 1 4 x 65 mm at the top of the bracket 17114 is not allowed to touch the traverse 20164 If you want the engine to run faster when idling e g 230 r p m you just have to turn t
29. as standard on all engines above 300 HP but only about 1 2 mm in the direction in which the quantity of the fuel oil is increased if the regulating rod is going completely to block there will be no control of the output of the engine However if this happens the engine is overloaded and should have the propeller pitch reduced by pulling the propeller pitch lever astern until the regulating rod is free Thereafter fasten the limiting bolts found in the reversing tower on top of the clutch shield so that the engine cannot be overloaded neither on Ahead nor on Astern The charging of the starting air receivers is carried out by means of the charging valve which is placed on the aftermost cylinder cover The valve is opened by turning the valve handle to the left until the stop about 1 2 revolution Then open the cock on the starting air receiver which has to be charged with air After having finished pumping close the valve on the starting air receiver first and thereafter the charging valve on the engine When closing the latter valve a hissing sound will be heard this is only release of air from the charging pipe Every time after having finished charging it is necessary after a little while to retighten the charging valve on the engine because the valve spindle is heated during the charging procedure and when cooling down it contracts and maybe slackens If the valve is not shut properly sooting may cause the spindle to stick Callese
30. at the regulating rods will go too tight and the engine will not regulate very well Open the decompression cocks on the cylinder heads and turn the engine to top dead centre 1 foremost cylinder ensure that the fuel pump piston is lifted at the same time if not turn the engine another revolution as it is a 4 stroke engine the camshaft is only turning one revolution every time the crankshaft is revolving twice Now check whether the vent screws on the nozzle holders are tightened up and adjust the governor handle to about 225 revolutions Thereafter advance the regulating rods in the fuel pumps to the maximum position Thereafter turn the flywheel backward and forward above Top 1 about 20 30 to each side until a crackling sound is heard from the nozzle indicating that the oil is spraying through Exactly the same procedure is carried out for each of the other cylinderes and when the fuel oil has been pumped through and the engine hereby has been turned at least about 10 turns having pumped pressure on the lubricating oil system by the handpump to distribute the lubricating oil in bearings and cylinders the engine is ready for start When the governor handle has been adjusted to lowest revolution number the regulating rods of the fuel pumps should be able to be moved quite easily backward and forward Any paint or rust protecting agent must be carefully removed and the regulating rods well greased After charging the starting air v
31. djustment of the pumps normally the starting up should be carried out with measuring glass LOADING OF THE ENGINE If the engine does not operate with its usual power the fault may be 1 2 3 Air in the feed pipes Soot in the fuel filter A defect in the injectors Injection pressure by hand pumping 240 kp cm Callesen Diesel Page 10 of 12 Sheet No 7 94 2A 10 11 12 Too low charging pressure Filter for turbocharger or the turbocharger itself should perhaps be cleaned The fuel pumps are not equally adjusted see adjustment under Idling or they might be worn The delivery valve spring of the fuel pump may be broken Leaky valves Coked piston rings Worn out pistons and cylinders Worn or cracked bearings Defective fuel feed pump the spring may be broken Perhaps the piston is hanging because the pump flanges are unevenly tightened Whether the fuel pump is working can be checked by loosening the handle of the hand pump the handle should move up and down when the engine is working The clutch is slipping because the oil pressure is too low too little oil or the clutch is worn out If the oil pressure in the clutch and reversing mechanism fails the cause may be a sticking overflow valve which must be cleaned and adjusted The overflow valve is placed in the portside under the cover on which the clutch oil cooler is mounted As to adjustment see sheet 7 67 under clutch If the oil pressure
32. driver Be sure that the screw driver fits into the shallow slot of the compensating needle valve not into the deep slot located at right angles to the shallow screw driver slot Allow the prime mover to hunt for about 30 seconds to bleed trapped air from the governor oil passages 3 Move the compensation pointer to the minimum compensation position and gradually close the needle until the hunting just stops Make sure that the needle valve is max 1 turn short of closing Then the valve is opened again at its previously noted position where the hunting stopped Check the governor stability by manually disturbing the governor speed setting The compensa tion adjustment is satisfactory when the governor returns to speed with only a slight over or under shoot The needle valve must not be closed completely normal position is between 1 3 and 3 4 turn open If the hunting does not stop open the needle valve again and move the compensating pointer up by two marks on the panel front indicator scale Again gradually close the needle valve till the hunting stops If not repeat the resetting of the compensating lever upward by two marks and retest It is desirable to have as little compensation as possible Closing the needle valve further than necessary makes the governor slow to return to normal speed after load change Callesen Diesel Page 3 of 3 Sheet No 4 90 2A HYDRAULIC MOUNTING OF HUBS In principle the method is as follows At a ver
33. e a pressure cam 7 in the pump housing each time causing the plunger to execute a compression The shaft has two sets of three vertical slots N which two by two terminate in an annular channel R During the suction stroke lubricant is drawn from the suction chamber S into the vertical slots in the plunger and from there into the annular channels R During the compression stroke the lubricant is forced out of the annular channel via a vertical slot into the pressure channel D Normally the pump can operate against a back pressure of 75 bar or 100 bar for a short period 2 CONSTRUCTION OF THE PUMP Reservoir The metal reservoir is usually available with a capacity of 6 litres The cover can be opened and if necessary secured against unwanted opening by means of a padlock The reservoir contains a feed unit 9 which consists of a scraper to scrape grease off the reservoir walls and a worm conveyor to make a slight pressure in the pump suction chamber A strainer is fitted in the basis of the reservoir to present dirt from getting into the pump suction chamber Callesen Diesel Page 1 of 4 Sheet No 7 102 2A Pump body The pump body contains a control sleeve 14 to guide the plunger and for each outlet an adjustable spindle 27 to preset the stroke of the plunger and consequently the quantity delivered The allowable number of revolutions of the feed piston is max 6 rpm when it is oscillatting lever driven Driving power
34. e cleanliness First of all avoid carrying dirt sand or the like into the engine room and avoid having cotton waste and other materials lying on the floor plates as such things are liable to be sucked in by the suction filter which will clog and cause loss of power and higher fuel consumption at worst it may even damage the engine plant The engine is constructed to be easy to keep clean which should never be neglected Before starting the engine pressure must always be pumped on the lubricating oil system by means of the handpump Then you will be sure that there is oil in all bearings and on the cylinder paths Immediately after having started the engine check whether there is pressure on the lubricating system and whether the water level can be seen on the water gauge on the expansion container When the above mentioned is in order the engine may confidently be loaded however it is re commended especially as long as the engine is new to bring load on little by little so that the various parts warm up together gradually After the engine has run for a short time under load check Callesen Diesel Page 5 of 12 Sheet No 7 94 2A the cooling water temperature As described above it must be about 65 70 C If this level is exceeded the alarm device will give a warning The oil pressure can be checked in the wheelhouse where manometers for lubricating oil and clutch oil pressure are fitted As mentioned before the lubricating oil syst
35. e engine Callesen Diesel Page 6 of 12 Sheet No 7 94 2A As mentioned before the engine has been adjusted by the factory to be able to yield about 5 above the stated output This overloading possibility is intended as a reserve for a few very special occasions and it is not wise to make use of it under normal conditions It is therefore recommended never to load the engine plant more than always to leave about 1 2 mm free before the toothed rods of the fuel pumps are fully against the blocking piece of the governor Before stopping the engine after use check whether there is sufficient air in the starting air vessels about 30 kp cm When charging the shut off cock on the air vessel should be screwed completely up against the blocking Thus air access to the spindle is being blocked thereby preventing wear The grease nipple on the propeller shaft must be filled at least once a week to keep the packing round the pull rod tight and at the same time to keep the grease in the propeller If water is coming out near the flange coupling the pull rod should be repacked During periods of hard frost or when drop of temperature may cause risk of ice formation anti freeze mixture can be filled on the freshwater system of the engine in the proportion indicated on page 7 55 Then it will only be necessary to drain the seawater system i e piston pumps and cooler with associated piping In case the freshwater system is drained make sure that all wat
36. e of about 65 kp cm To obtain this pressure the fuel must be injected as follows When the mark in the pump lever in the oval hole at the bottom of the fuel pump is in middle position the top marking on the flywheel must be 48 mm before top measured on the circumference of the flywheel for turbocharged engines and 78 mm before top for engines without turbocharger This method is only a rough checking for fine adjustment a drip pipe should be used see sheet 7 45 The adjustment of the valves should be as follows Suction opens 524 270 mm before top exhaust closes 524 150 mm after top measured on the circumference of the flywheel for engines with turbocharger and without turbocharger respectively All indicated valve and fuel pump adjustments apply to a flywheel diameter of 1000 mm The freshwater and oil cooler must be cleaned in the saltwater circuit at suitable intervals when necessary For this purpose remove the end covers and clean the cooler pipe by means of a brush Rinse the cooler Check the anodes and if necessary replace them on same occasion If the alarm device supervising the cooling water temperature is giving a signal the cause may be that the thermostat is broken if so the thermostat can be removed it is placed in the front flange on top of the cooler or that the cooler has to be cleaned It may also be due to insufficient water in the cooling system because of a leaking water or oil cooler If the water has been d
37. e re moved as stated on 7 207 NB On older engines it is necessary to dismount the cylinder head and to pull the starting valve out at the IT N bottom vg IN SSSSSSSSSSSSSSSSSSSSSENNS SG SS NN SSS WM MMHG SS WK meme N N N RI Callesen Diesel Page 1 of 1 Sheet No 7 203 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 C RUNNING CLOCKWISE To cyl 3 From starting air pipe Direction of rotation 10010 70 A Position of the disc valve with cyl 1 in start position 19952 c 1 rt 10166 yess 5 16155 Sy 227 NNNM 1 sy LA NI MN 4 ia PN y HUHBHDBDBBBB 5 m III 16157 Vi NY Zm S 7 Z D SSC AN DN SEIS TU 10103 7 2 030 20 gt 1 03 8 2 17132 Cover is removed 81 UJ z a s 8 5 9 5 gt 4 CJ u 15111 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17132 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 1 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the s
38. ead in each corner is ex actly equal Before measuring paint or putty if any must be scratched away to ensure that the measuring surfaces are completely clean After having checked that everything is in order after the first start and when the engine has been running until it has become warm about 40 C it can be loaded gradually so that full power is reached about 1 hour after having reached operating temperature which is about 65 70 C the cooling water system is normally supplied with a thermostat which is acting when the temperature becomes too high about 90 C it is connected to the same alarm device as the lubricating oil pres sure control The temperature of the turbocharger should be checked on the thermometer It should not be es sentially warmer than the water outlet pipe on the engine The marine engines are as standard equipped with hydraulical clutch and hydraulically operated re versing device for the propeller blades The propeller is engaged by pushing the clutch handle in the middle of the instrument box completely forward and the propeller is given pitch to Ahead by pushing the handle on the right hand side of the control desk forward When the engine is operating at full load which means at 425 rpm the number of revolutions is stamped on the factory s type label the regulating rods in the fuel pumps should be able to move freely in the longitudinal direction can be read on the fuel pump indicator is mounted
39. edies 1 Check whether the ventilation is in order 2 Check the filter and remove all impurities from the engine room 3 Vent the fuel system 4 Check fuel filters The oil should be able to pass through in full jet when pumping with the hand pump 5 Check the exhaust piping 6 See turbocharger instruction book Cause of working troubles During the first running of the engine under loaded condition see to it that the cooling water tem perature thermometer on the foremost cylinder head in the freshwater system is rising to about 70 C If not something is wrong with the thermostat which is built into the by pass piping of the freshwater system Should the engine get too hot it may be because of air in the system or incorrect fitting of the ex pansion container The cooling water seawater which passes through the cooler and from there Callesen Diesel Page 4 of 12 Sheet No 7 94 2A outboard does not exceed a temperature of about 30 40 C under tropical conditions a little higher which is about 25 C above the inlet water temperature During the first trial run the sterntube must be lubricated sufficiently apply a not too heavy sterntube grease better too thin than too thick and the stuffing box frequently checked for heating its temperature must not be higher than one is able to hold a hand constantly on the side of the stuffing box bearing If it heats up more than normal it is probably only because the stuffin
40. em is connected to the alarm de vice which will give a warning in case the oil pressure drops below approximately 0 5 kp cm It is recommended during daily operation to inspect the engine approximately every 3 4 hours to see if everything is in order At the same time lubricant should be applied where necessary water pumps and sterntube The small air filters on the valve covers should be cleaned every two months The starting valves in the cylinder covers should be lubricated about every three months Loosen the plug which goes down into the large fitting above the valve and pour down about 6 8 drops of oil on the valve but not more and screw the plug up again During operation the engine oil level should be checked daily the oil level of the clutch case approx every week in both cases when the engine is warm and idling A small grease cup is placed on the front end of the engine at the flywheel and on the aftermost end cover near the flange coupling This grease cup should be lubricated only little every week approximately for lubrication of the shaft packing ring In case the lubricating oil pressure before filter rises to more than 5 kp cm when the engine is warm the filter inserts should be replaced by new ones Normally the pressure is about 4 kp cm The filters can be replaced during operation as the oil filter is equipped with a conversion cock and the engine can run on one filter or the other respectively or on both filt
41. engine must be turned one revolution Callesen Diesel Page 7 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 F RUNNING ANTI CLOCKWISE To cyl 3 To cyl 5 J From starting air pipe hm Position of the VANER dise valve with rection of cul 3 in start rotation V RED position NIR ZA N 2 NE 0 161 OR To cyl 6 To cyl 1 NEE ZZ 30 20 fib S 9124 1 removed mut 281 0 5 poc To cul 2 To cyl 4 15129 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17132 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 3 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 3 is in starting position even though the top mark for cylinder 3 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 3 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 3 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If
42. er is drained off the engine as well as the cooler and centrifugal pump As long as the engine is running satisfactorily avoid disassembling anything and in case there are problems beyond what must be considered normal which might need readjustment you should call in a skilled man If the engine is cared for and attended to as mentioned above it will usually not require much maintenance but you must always be sure that you are in a position to help yourself in an emergency case requiring the use of the spare parts supplied with the engine Therefore these spare parts should always be in good order and kept in an easily accessible place where they are not exposed to rust or other kinds of damage Whenever some of the parts have been used the stock should always be completed as soon as possible for use at later emergencies INSPECTION AND CONTROL As mentioned before do not tamper with the engine as long as it is in good order and running satis factorily However it is necessary to exchange the lubricating oil about every 1500 1800 working hours or ap proximately twice a year Before draining off the oil run the engine warm until the oil is thin The draining is done by opening the large cock on the oil container at the same time empty the filters by opening the air screws and removing the bottom plugs If the filter inserts are not comparatively new they should be replaced at the same time Concerning oil quantities see sheet 4 68
43. er is made up of two parts an oil cooler and a freshwater cooler As shown on the sketch sheet No 7 11 the seawater is led through the pipes in the cooling element The freshwater is led around the pipes in the cooling element Because of the follower plates there is a transverse flow around the pipes The same applies to the oil in the oil cooler Putting into operation Normally the cooler is bled when the freshwater and lubricating oil system is being filled The same applies to the oil cooler Retighten all tightenings when normal operating conditions have been achieved Check whether the thermostat keeps the correct temperature Cleaning The seawater circuit of the cooler should be cleaned and checked twice a year Sailing in muddy waters may increase the need for cleaning Increased cooling water temperature may be caused by foul pipes If so the seawater outlet temperature drops below normal Dismantle both end covers 1 and 12 and the side cover on the spacer 5 before cleaning Clean the pipes by means of the brush supplied steel brush should not be used as it may dam age the pipe surface Push mud and sediments out of the pipes to the spacer and clean the spacer Finally the cooler is rinsed out with clean water Before fitting the covers again the entire system should be checked for damages and corrosions The soft iron anodes fitted on the end covers and side cover should be replaced if there is too much corrosion T
44. ere may be water in the fuel oil pipes The lowest cock on the coarse filter must be opened about every week to drain off any water and mud The governor may be wrongly adjusted so that the engine does not receive any fuel Perhaps you may have forgotten to open a little The feed pump may be defective spring broken The fuel pumps may be defective perhaps the pump spring is broken The cylinders and pistons of the fuel pumps are worn out so that the quantity of fuel is too small for starting Cylinders and pistons must be replaced Leaking valves Seized piston rings Clogged suction filters IDLING The engine will after having been started and still being cold run at varying revs especially at slow speed After having run for some minutes and being warmed up it should run at absolute regular revs If this is not the case there may be air in the fuel feed pipes or it may be due to the governor or perhaps the toothed rods in the fuel pumps are jamming If the fuel pumps have been adjusted uneven adjustment of the pumps may be the cause Normally there are small marking lines and numbers 10 15 20 25 etc on the toothed rods of the fuel pumps When the toothed rods are pushed forward as far as possible the marks 28 29 should stand on level with the arrows on the rear end of the pumps corresponding to max load of the engine In case the toothed rods have been wrongly adjusted these marks can in an emergency be used for new a
45. ers at the same time The latter is normal The clutch and reversal oil pressure must be 7 kp cm unloaded and 9 kp cm at full revs On newer engines a two step overflow valve is fitted in this case normal oil pressure is about 9 kp cm and during reversing the pressure rises to about 16 kp cm and drops to 9 kp cm again after the operation If the engine starts smoking after having been used for a prolonged period it may have many dif ferent reasons see Working Trouble the cause of the smoking must be identified and remedied as soon as possible as thick formation of smoke will cause great wear of the cylinders and pistons and may result in sticking piston rings damaged valves etc If under the given conditions it is im possible to correct the fault at once reduce the load until the smoke nearly disappears If the cooling or bilge pump starts leaking the stuffing boxes must be tightened up if necessary the pumps must be repacked On newer engines the stuffing boxes are equipped with special packing rings When checking the pump valves remove the air vessel under which the valves balls of synthetic rubber are placed see 7 62 Should the oil pump of the lubricating system fail for some reason the engine can be operated if the oil pressure is kept up by means of the hand pump All larger engines are equipped with by pass pipes and switchcocks so that the suction pump as well as the pressure pump can be used for lubricating th
46. es with carborundum the valve should touch all over This should be checked by means of a thin coat of China ink Please observe when grinding valves you must only grind one way The valve should be lifted at return Having finished the grinding and having cleaned the valve carefully MOLYKOTE should be applied to the valve shaft before mounting w ema Inlet valve 20700 16700 16700 16701 Exhaust valve 20701 16701 16701 16701 20707 16737 16737 16737 Callesen Diesel Page 1 of 1 Sheet no 7 6 2A DRAWING OF NOZZLE HOLDER First you have to remove the cap nut on the nozzle holder Thereafter the drawing tool 16978 for the nozzle holder should be mounted as shown on the drawing and by means of the drawing tool you can draw the nozzle holder Before you mount the nozzle holder again you have to clean the packing surfaces and grease the shaft at the nozzle holder with a heat resistant compound e g Molykote HSC Z Callesen Diesel Page 1 of 1 Sheet no 7 13 2A 422 30572 425 30571 427 30570 Seal face Y N yy SSISIISSIIIIIIIII N N IS SA N N N IH N N U N p 7 1 4 52 5 N Callesen Diesel GRINDING OF CYLINDER COVER The cylinder head is placed with the bottom upwards The seal face of the cylinder head is lubricated with carborundum The grinding ring i
47. essel to a minimum of 25 and a maximum of 30 kp cm NOTE USE ONLY COMPRESSED AIR OXYGEN MUST NOT BE USED IN ANY CIRCUMSTANCES AS AN EXPLOSION WOULD BE INEVITABLE EXPOSING EVERYBODY NEAR THE ENGINE TO GREAT DANGER turn the engine so that the mark Start on the flywheel is in top position and at the same time check whether the fuel pump piston in the aftermost pump is in top position if not turn the engine another turn Engines with 4 5 6 and 8 cylinders need no turning Before starting check whether the seacock is open and whether the clutch is free Close the decompression cocks as well as the charging valve in the aftermost cylinder cover and adjust the governor handle to about 225 revolutions Lubricating oil system Start Now pump pressure on the lubricating oil system should always be remembered before starting and start the engine by quickly turning the handle of one of the main shut off valves at the end of the starting air receivers about 1 turn to the left As the engine is supplied with automatically controlled starting valve in all cylinder heads it will go on running on air as long as the shut off valve is kept open As soon as the engine is firing the shut off valve is closed and under normal conditions the shut off valve is not kept open for a longer period than to use 2 3 atm air for each start At start a hissing sound is heard from the air distributor at the front of the camshaft This is only the air pressure which is cl
48. essure in the receiver During the suction stroke of the cylinder in question the pressure in the cylinder is lower than the pressure in the air receiver and the ball will auto matically close against the seat and prevent air from flowing from the receiver into the cylinder 16 stainless Callesen Diesel Page 1 of 1 Sheet No 7 129 2A OPERATING INSTRUCTIONS FOR DELIMON GREASE LUBRICATING PUMP The Delimon grease lubricating pump type FZ A Plunger movements is a single plunger pump with 8 outlets The pump is driven by means of an oscillating lever via an intermediate driver whereby the transmission between the drive shaft and the pumps will be 50 1 1 MODE OF OPERATION On the upper side of the worm gear 1 which is driven by the engine there are two followers in the recess of which a cross piece 2 engages A cam plate 3 engages with the cross piece The cam plate is positively connected to the plunger 4 The spring 5 located between the cross piece and the cam plate exercises an upwards force onto the cam plate On the upper side of the cam plate there is a cam which as the cam plate rotates operates six adjustable spindles arranged round the periphery of the pump and causes a suction stroke of the plunger each time The lubricant is fed under slight pressure to the pump suction chamber S On the lower side of the cam plate are six further cams which as the cam plate rotates operat
49. ewed and the base of the bearing is lowered into the oil pan The pase of the bearing is removed prodcedure see 7 14 The piston is lifted and the upper part of the bearing is turned 180 then lowered and removed The filler for piston height is removed together with the upper part Mounting of piston and bearing The piston guide is placed at the top of the cylinder lining see drawing The piston is lowered and the rings are turned into the places at the same time The ring gaps must be staggered The piston is lubricated a little with oil The top of the bearing and the filler for the piston height are lifted into their places The base of the bearing is mounted The slotted nuts are fastened and secured torque for 422 425 approx 64 kpm and for 427 approx 76 kpm The crank housing covers are mounted Page 1 of 1 Sheet no 7 230 2B REPAIR OF GROOVES FOR PISTON RINGS ME ST amp HHE Compression ring chromium plated N Compression ring Compression ring Oil control ring chamfer facing upwards Oil control ring chamfer facing downwards Acceptable wear of grooves for compression rings 6 0 4 mm versize for chromium ring 1 7 2 16 mm 2 0 16 mm Oversize forchromib 9 0 14 EE oia Callesen Diesel Page 1 of 1 Sheet no 7 032 2A DIRECTIONS FOR MOUNTING OF CYLINDER LINER Before mounting the cylinder liners must be ground in the block At f
50. g box is tightened up too hard It must be slackened and if this is not enough the cotton tallow packing or perhaps the Crane metal packing if any hamp packing or similar should rather not be used as these materials are wearing the shaft should be taken out and the rings be pushed loosely in after having been lubricated with grease whereafter the gland can be tightened quite a little Newer engines which are equipped with special stuffing boxes outside and inside the sterntube are lubricated with ordinary engine oil in the sterntube regarding oil types see page 18 When the engine has been running for about 2 3 hours at full load without any trouble the trial run can be concluded The engine is stopped by pushing the governor handle completely down to stop and thereafter the toothed bars of the fuel pumps are pushed astern n IS THE DUTY OF EVERY CUSTOMER OR HIS REPRESENTATIVE TO WITNESS THE um RUN TO MAKE THEMSELVES ACQUAINTED WITH THE ENGINE AND TO COMPLAIN ABOUT DEFECTS FAULTS IF ANY ANY COMPLAINTS ABOUT THE TRIAL RUN BROUGHT FORWARD AT A LATER DATE WILL NOT BE HONOURED LATER ON USE AND ATTENDANCE After the trial run has taken place as described the plant is handed over to the purchaser in good and proper condition and with good and proper handling the engine will render many years satis factory service It is of great importance for the user to understand that a modern engine plant demands careful attendance and absolut
51. g ring 13 The seal has to be placed on the propeller shaft before or after inserting the shaft into the sterntube After mounting the aft seal the forward seal has to be fitted oil and watertight to the sterntube by means of the packing After removing the mounting clips the clamping ring can be mounted on the shaft and against the chromium steel bush The rubber ring has to be pressed between clamping ring and bush Distance between flange of chromium steel bush 6 and sealing casing 1 has to be kept see drawing of forward seal During mounting and dismounting it is necessary to take care that the chromium steel bushes are not drawn out of the sealings as the lips could be damaged when the bush is pushed in again Mounting clips of aft and forward seal are delivered with sterngear Callesen Diesel Page 5 af 6 Sheet No 7 93 2A OPERATION INSTRUCTIONS Starting By means of a handpump the oil has to be pumped out of the tank into the sterntube and overhead tank While filling the sterntube the air escape valve 10 of the aft sealing has to be open The sterntube is fully filled if the oil in the overhead tank and the gauge glass does not drop but flows back through the overflow pipe to the tank The air escape valve is closed again After filling and de aerating the sterntube the air escape valve has to be fitted oiltight After filling the sterntube with oil you have to wait before rotating the propellershaft because a The oil
52. h water until 1 3 of the over head tank is filled See sheet 7 55 2A Ventilate the cooling system and check that the cooling water reaches 1 3 up into the overhead tank The engine is started and brought to normal operating temperature The water height in the over head tank is checked if necessary refilled The freezing point of the anti freeze mixture is to be checked by means of a hydrometre When the required freezing point has been attained the overhead tank is refilled with 5 liters of anti freeze mixture and the remainder with water If the required freezing point has not been attained it is necessary to add further anti freeze mixture If the cooling system is in order the anti freeze mixture will not be utilized but the freezing point of the anti freeze mixture should be checked at regular intervals Callesen Diesel Page 1 of 1 Sheet no 7 56 2A ADJUSTMENT OF TOOTH CLEARANCE FOR CIRCULATION PUMP TYPE 427 E F NNENNNNNNNNNNNLINNNNNN NI WP 5 g WG Nut Tightening torque 8 Kpm sy I ss AN The bearing housing 15504 can rotate and is provided with an eccentric recess for guiding of the pump Adjustment of tooth clearance The four unbraco screws 3 8 x 172 are tightened loosely so that the bearing housing 15504 can be turned on the bracket 15503 by hand The pump is put into the right place and the four bolts 1 2 x 35 mm in the outer flange are tightened The cover 16005 on the crank case jus
53. he 14 x 65 mm screw further down The maximum position of the fuel oil pump is adjusted by means of the 5 16 x 32 mm pointed screw which is placed in the governor lever 16132 You can get to it by removing the little cover on the side of the governor cover If the screw is turned clockwise the load will be reduced The screw is secured by a wire and sealed by the factory The blockings of the governor and the toothed rods of the fuel pumps should never be altered If the lead seals are broken the factory s guarantee will cease to be valid The adjustment has been made so by the factory that the engine can perform about 5 above normal load Callesen Diesel Page 1 of 1 Sheet No 7 75 2A WOODWARD GOVERNOR Oil filling Low speed stop Nu Oil gauge Terminal shaft GOVERNORS FOR PRIME MOVERS Speed adj lever High speed stop F Alignment hole for timing shut down Compensation pointer Front panel Case a Plug for needle valve s Base Description The Woodward UG8L governor is a mechanical hydraulic governor for controlling diesel engines The governor is mechanically linked through a damper to the fuel racks The maximum work output of the governor is 1 1 kom over the full 42 travel of its output shaft however recommended travel of the output shaft is 30 Normally the governor operates isochronously constant speed regardless of the load on the engine Callese
54. he hunting cannot be stopped you can try to change the lever proportion by moving the bearing journal a little against the shaft approx 1 mm at a time until steady running is achieved IMPORTANT Before the engine is started make sure that the lever on the output shaft can move enough for the fuel pumps to go to 0 or there is a risk of the engine bolting Oil supply Fill the governor with oil to a level between the lines on the oil gauge sight glass We recommend a lubricating oil with a viscosity between SAE 10 and SAE 50 depending on the temperature in which the governor is operating Recheck the oil level after the engine is started and at operating tem perature then add oil if necessary Compensation adjustments Even if it seems to be running satisfactorily at constant speed the governor may need adjustment High overspeed and underspeed after load changes and slow return to normal speed indicate the need for compensation adjustment After the oil temperature of engine and governor has reached its normal operating values make the following compensation without load on the prime mover to make sure that the governor gives opti mum control Callesen Diesel Page 2 of 3 Sheet No 4 90 2A 1 Loosen the nut holding the compensation adjusting pointer enough to set the pointer at its extreme upward position for maximum compensation 2 Remove the plug and open the compensating needle valve 3 to 5 turns anti clockwise with a screw
55. he propeller shaft Screw the pull rod home and then about 1 4 3 8 turn back so that the holes in the flange couplings are facing each other Callesen Diesel Page 1 of 1 Sheet No 7 81 2A R RDIAGRAM FOR PROPELLERANL G PIPE DIAGRAMM FOR STERNGEAR ROHRDIAGRAMM F R PROPELLERANLAGE H yjdebeholder Overhead tank Hochbeh lter Oliestandsviser Gauge glass a lstandanzeiger Normalsti lling Normalstellung Normal position Gennempumpning Durchpumpen Pumping Vandaftapning Wasserablassung Waterdrainage p H ndpumpe Hand pump Luftskrue Air cock Luftschraube Luftskrue Air cock Luftschraube en alt f Nr 222227177 Pakboks Stuffing box Stuffing box Stopfbuchse Stopfbuchse Vandaftapning Wasser ab lassung Waterdrainage Sm remiddel Motor olie SAE 30 Lubricant Engine oil SAE 30 Schmiermittel Motor l SAE 30 Callesen Diesel Side 1 af 1 Skema Nr 9 26 0A FASTENING OF CYLINDER COVER 1 For mounting of cylinder cover the distance between cylinder cover and block should be identical in all 4 corners The distance must be controlled by a feeler gauge 2 In case of fastening by means of a ringstriker wrench the direction indicated under item 1 should also be observed 3 In case of fastening by means of a torque wrench the direction indicated under item 1 should also be observed Torque Type 427 300 kpm Type 425 255 kpm
56. he same applies to the dividing plate 10 It is very important not to interchange the end covers The end cover 12 with the dividing plate should be positioned in such a way that the dividing plate is horizontal and above the centre of the cooler as shown on the drawing Cleaning of the freshwater side is rarely necessary If it is to be done the freshwater element 8 must be removed When refitting it take care that the element is positioned in such a way that the cuts in the edge of the dividing plates 7 are facing downwards The spacer 5 side cover must be vertical Callesen Diesel Page 1 of 1 Sheet no 7 10 2A SKETCH OF OIL AND FRESHWATER COOLER Jojo Musa 91002 J9jD UusaJ ay uo edid Ajddns 15 ay u si 6 JDISOWJaU ay 5 Bumoo H LZY adAy 104 DId 2 491002 JSJDMUYSSJ io 8 8 481002 JO lu ul l3 7 e eid ejpjd 4 4 481002 0 JO doo ayp d Buipiaig or 481002 4 5 8405 9 92eid pug t ypisouij ul 6 5 O 43409 pug CL 9 6 YO OO 481009 0 NY o G Noc ee ee need 22 aE 55355 SS IE IN 2 g ZA Cz J91D UuS21J 110 qni 110 qn3 J9 DMDO EA gt gt Sheet 7 11 2A Page 1 of 1 C
57. irst a smooth coat of medium fine carborundum must be applied to the horizontal part of the liner take care that the carborundum does not get on the cylindric guiding piece Then grind with fine carborundum Now the packings must be fitted on the top of the crankcase in a thin coat of oil If the original coat ing was double the packings must be double coated again The block can be positioned Before moutning the cylinder liners new o rings must be fitted They should be inserted with a little silicone or stiff grease e g Dow Corning MS4 Silicone Compound Then mount the pistons and check the height of the pistons when in top dead centre Distance from piston to cylinder head 2 2 2 4 mm Distance from upper edge of liner to piston 1 8 2 0 mm applies to type 427 only see also 7 45 Mounting of piston See 7 14 and 7 14a Tightening of cylinder cover See 7 49 427 TK G 7 202 WARNING If incorrectly fitted the liner could be deformed and may be the cause of damage It is important to apply a thin layer of grease to the entire surface of the o ring The parts must be completely clean Dismounting of cylinder liner Grinding of cylinder liner 30123 Turning rod 422 liil 30119 MN 30112 NO RUBBER RING DURING GRINDING Cylinder liner LRT EET IE D NA Cylinder block lt 2 RN SR 30131 422 425 30133 30132 SIS
58. ketch the position of the disc valve is shown with cylinder 1 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 1 is in starting position even though the top mark for cylinder 1 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 1 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 1 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 3 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 D RUNNING ANTI CLOCKWISE To Cyl 4 From starting air pipe Direction of k od 77 N N SS 10010 Position of the disc valve with cyl 2 in start position Dy 872 18852 SSS 19166 SSX 722 SSN lt H NNN 16155 5555 m SSS 40137 16157 4 41 N RON 222 DN T W 227 T 78 VM NN C Ls 19124 1 N ER Cover is N removed N m gp T For maintenance of the starting air distributor the co
59. l consists of a two piece pipe which must be laid between the two flange couplings after having removed the flange coupling on the sternshaft from the engine flange When these 422 425 21422 ZI WS EZ two flange couplings 427 C D 18980 E tightened together again the E reversal is blocked in Ahead 427 E F 18963 lt SJ N SA AA R 1 VIN RR SN a 7 En Z 2 ZZ GRINE Rath EN q SEN VAR iZ TFF RV SS SS N N NY 2 Z KA 114 N Callesen Diesel Page 1 of 1 SIES NI AS 71 22 Z 7 NNN N Sheet No 7 64 2A TWO STEP OVERFLOW VALVE A GEN ASS 26 pcs 28 142x1 25 E ELHA 4 MS SKANSEN ICH or gt Q 4 g p H Kr i ANY id 7 DAN 7 2 __ W 07727 ZZ 4 2 Mode of Operation The valve is a two step overflow valve It is functioning by means of the pressure available in the hydraulic system which rises when the oil is fed into the cylinder head This is done during the reversing manoeuvre Step 1 is used to supply the clutch with oil and the pressure is dimensioned to be able to hold the clutch The pressure should be 9 kp cm Step 1 is adjusted by turning the cylinder 19434 Step 2 is used during the reversing process and the pressure should be 16 kp cm The pressure can be adjusted by turning the nut 19470 Callesen Diesel Page 1 of 1 Sheet No 7 67 2A E
60. l pumps and turning the engine past the top position for cylinder no 7 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 9 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 H RUNNING ANTI CLOCKWISE From starting air pipe 2 H 10010 Position of the disc valve with cyl 1 in start position 10052 10166 WNNNNNNN 222 NG sy gt us 724 SSS Li 4 Mr Bit 5 16155 Direction of rotation 40137 A 16157 Mor diock 10 V S l H ol n TS D 4 4 N SN SN g A 2 iv MIO Nut 10103 74 24 17132 Cover is removed e i m fo 2 9 In i A 5 5 cyl 8 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17132 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 1 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When
61. ling into the oil pan the crank should be turned to port side and the upper part of the bearing can be removed together with the filler for the piston height The bearing and the crank pin are to be checked Before mounting the parts again they should be cleaned carefully Callesen Diesel Page 1 of 1 Diagram No 7 14 2A DRAWING OF PISTON AND DISMOUNTING OF CRANK BEARING N 7222222222222222222222222222222 2 AN 55 222222022222222222222277 I S PELLE 7242772772 22 Callesen Diesel 7 2 N N lt 2 SS EM MP 2222277222 27722222722222222 ANN NN N I N VO a ZNN N aN BER Pe pe Sp ia Sa SACRA CAS N SSA ANNA The pistons should not be drawn until oil consump tion is too great Then the oil control rings and probably also the compression rings have to be re placed Dismounting of piston and bearing The cylinder cover is dismounted The uppermost 5 cm of the cylinder lining are cleaned from soot The lifting tool is fastened to the piston see drawing on recent engines type 427 use an M 12 eye bolt The crank covers are dismounted The forelocks in the connecting rod studs are removed and the slotted nuts are loosened The nut in starboard side is unscrewed The crank is turned to top for the piston in question The last slotted nut is unscr
62. n Diesel Page 1 of 3 Sheet No 4 90 2A Mounting instructions Make sure the governor drift shaft rotates freely before installing the governor Mount and fasten the governor squarely on its mounting pad on top of the gearbox taking care that the connection between the governor and the prime mover drive is in order It is most important to make sure that there is no binding excessive side loading of the drive shaft or looseness in the coupling There must be no force pushing the drive shaft into the governor Improper alignment or too tight a fit between any of the parts can result in excessive wear or seizure and may also couse undesirable jiggle in the governor output When mounting the remote control to the wheelhouse Teleflex be sure that the motion on the Teleflex tower is corresponding with the deflection on the governor lever First you should start the engine and block up at idling 220 rpm and maximum number of revolutions 425 rpm before the Teleflex connection is made A lever with a slotted hole in which the telescope link is fastened is mounted on the output shaft i e that shaft which is connected with the governor shaft of the fuel pump The lever is fastened so that the shaft is turned to impact at the same time as the fuel pumps stand on O If necessary you could adjust further on the connecting rod after the telescope link First place the telescope link in the outer slot and then follow the instructions below If t
63. n Diesel Page 3 of 12 Sheet No 7 94 2A Never alter the blocking of the governor and the toothed rods of the fuel pumps In case the lead seals are broken the factory s guarantee will cease to be valid The adjustment has been made so by the factory that the output of the engine can be about 5 above normal full load When the engine is working at full load and the governor rod is free as described above the ex haust should be nearly smokeless It is important to check this as too much development of smoke means that the engine is not in order and that it should not be operated before the defects have been repaired At full load the exhaust temperature should be about 450 500 G for turbocharged engines up to 525 C Smoky exhaust after the first start may be due to defects or faults arising during installation for in stance 1 The engine does not get sufficient air for combustion because the engine room is too tightly closed and the necessary ventilation is lacking there should always be one or several ventilating ducts having total area at least equalling the size of the suction pipe of the engine 2 The suction filter on the suction manifold turbocharger of the engine may be clogged 3 Air in the fuel system 4 Dirt in the fuel system filter clogged 5 The exhaust piping partly clogged or a too small dimension is used Use always the same pipe dimensions as the exhaust manifold 6 Loading pressure too low Rem
64. n the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 3 is in starting position even though the top mark for cylinder 3 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 3 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 3 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 2 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 D RUNNING CLOCKWISE To Cyl 3 To Cyl 4 From starting air pipe 10010 Position of the I 0052 disc valve with Direction of AULI cyl 1 in start rotation dU 10166 position X NAT NINE 40137 16157 a 2 N nd SN V amp 5 EN NM LT N Leid Li ox re it 10103 IN 9724 Va N RNF N 930 20 52 Cover is I NT 03x8 pin removed N GE i 6165 1 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17131 to be lubricated on the sealing face Mounting of new disc valve or journal On the s
65. ng order clockwise running 3 cyl 1 3 2 4 cyl 1 2 4 3 5 1 3 5 4 2 6 1 5 3 6 2 4 8 1 3 5 7 8 6 4 2 Firing order anti clockwise running 3 cyl 1 3 2 4 cyl 1 2 4 3 5 1 2 4 5 3 6 1 4 2 6 3 5 8 1 3 5 7 8 6 4 2 Adjusting screw for fuel pump 422 2 2 mm 425 2 2mm 427 5 5mm Clearance from upper edge of liner to piston 422 1 4 1 6 mm 425 1 6 1 8 mm 427 1 8 2 0 piston 17247 16 8 17 0 mm piston 18230 Callesen Diesel Page 1 of 1 Sheet No 7 45 2B DISMOUNTING OF CRANK BEARING AND MOUNTING OF PISTON SUPPORT NB ill Agr 1 Ue E A pens eg HM der y Par Piston support 425 20905 427 16915 HS VE mu SERIE OE er lt Slotted nut The crank covers are dismounted The slotted nut on the operating side is to be loosened while the slotted nut on the opposite side is dismounted The crank should be turned to top for the cylinder in question The remaining slotted nut is removed and the base of the bearing is lowered down into the oil pan Be careful of the filler If the crank is turned approx 30 towards starboard the base of the bearing can be removed through the opening in the crank case Subsequently the crank should be turned to top and the piston support 16915 placed as shown on the drawing While holding the bearing in order to prevent it from fal
66. o be applied to the other grease cups OIL LUBRICATED STERNTUBE WITH SUBLIME PACKING GLANDS Same oil as the engine GREASE FOR AUTOMATIC GREASE GUN DE LIMON As stated below THE FOLLOWING OILS CAN BE USED FOR CALLESEN MARINE DIESEL ENGINES 4 STROKE TYPES 422 425 AND 427 MAKE ENGINE AND CLUTCH OIL LUBRICATED STERNTUBE ESSO EXXON EXXMAR 12 TP 30 NUTO H 68 STATOIL MARWAY 1230 HYDRAWAY HM 68 Q8 MOZART DP 30 HAYDN 68 BP ENERGOL DS 3 103 ENERGOL HLP 68 SHELL RIMULA 30 TELLUS 33 CHEVRON DELO 300 SAE 30 OG TURBINE OIL 68 MOBIL MOBILGARD 312 DTE HEAVY MEDIUM GULF SUPER DUTY SAE 30 HARMONY 68 TEXACO TARO DP 30 or XD 30 REGAL R amp O 68 CASTROL MARINE MLC 30 HYSPIN AWH M 68 TOTAL DISOLA M 3015 TURBINE T 68 TURBOCHARGER AND AUTOMATIC GREASE GUN WOODWARD GOVERNOR ESSO EXXON NUTO H 68 BEACON EP 2 STATOIL HYDRAWAY HM 68 UNIWAY 2 ENERGOL THB 68 or BARTRAN HV 68 ENERGREASE MM EP 2 SHELL TURBO OIL T 78 ALVANIAR 3 CHEVRON OG TURBINE OIL 68 INDUSTRIAL GREASE HEAVY MOBIL DTE HEAVY MEDIUM MOBILUX EP 2 GULF HARMONY 68 GOLD CROWN EP GREASE 2 TEXACO REGAL R amp O 68 MULTIFAK EP 2 CASTROL HYSPIN AWH M 68 SPHEEROL AP 3 TOTAL TURBINE T 68 CERAN WR 2 Callesen Diesel Page 1 of 1 Sheet No 7 149 2D REPLACING WORN OUT CATCH BOLTS IN CLUTCH fue xe Aller Lc Ber Se N is EE PIN I QU F If the catch bolts 1
67. osed by the starting valve As soon as the engine has been started check immediately whether there is pressure on the lubri cating oil system Normally the engine is equipped with a pressure control which has to be con nected to an alarm device bugle bell lamp or the like which gives a warning when the lubricating pressure for some reason is dropping below 0 5 kp cm or fails to appear Callesen Diesel Page 2 of 12 Sheet No 7 94 2A The alarm device should be connected to generator not to the batteries with handswitch by a contact relay which will cause only a faint current to pass through the contacts of the pressure control and the thermostat as otherwise the contacts here would soon be destroyed If the alarm device is giving signal the engine must of course be stopped immediately and the fault must be found and corrected The grease cups must be tightened up and of course it should be checked whether all pipings and other connections are tight and that the engine is getting cooling water If there is a leakage between cylinder and cylinder head which may be due to some nuts having been loosened when mounting stiffeners on the engine the engine must be stopped and the nuts of the cylinder heads be retightened by means of the ring striker wrench supplied and a heavy blacksmiths s hand hammer To ensure that the cylinder heads are tightened straightly check by means of a feeler if the free space between the cylinder and the cylinder h
68. r assemble it with another outlet Not used pipe connections must never be closed as in such a case leakages could arise in the pump On pumps which is delivered with closed outlets there are not to be made any changes changing of fittings etc Adjustment of the quantity delivered At maximum delivery equalling 0 1 cm lubricant per outlet and plunger stroke the mark on the outlet number plate is facing the figure 4 stamped on the head of the adjustable spindle 27 Turning the spindle clockwise reduces the quantity Avoid reducing below 1 5 of maximum quantity On pumps having 7 to 12 outlets each adjustable spindle controls the quantity of two outlets one above the other The arrow on the outlet number plate indicates the outlet ports associated with the adjustable spindle Callesen Diesel Page 2 of 4 Sheet No 7 102 2A By changing the drive speed or the internal transmission ratio of the pump or by changing the angle of the oscillating lever the quantity by each outlet and consequently the total quantity can be varied 4 MAINTENANCE Filling the grease reservoir As soon as about three quarters of the contents of the reservoir have been used up the reservoir should be refilled The level of grease should never be allowed to drop so low that the feed worm is exposed otherwise air may get into the lines When filling ensure that clean grease only is used and that no dirt gets into the reservoir when the cover is opened otherwi
69. rained off for repair of the engine it may be impossible to replenish enough water usually because the expansion tank piping has clogged for which reason the pipes must be cleaned Should the oil cooler leak it will be indicated by rising oil level because water is running out into the lubricating oil this will only happen when the engine is not running When the engine is running and there is pressure on the lubricating oil the oil may possibly be seen in the cooling water outboard If there is a leakage in the freshwater circuit of the cooler it is indicated by too little freshwater which however cannot normally be seen until the engine has been stopped when the engine is running there is pressure in the cooler for which reason the volume of freshwater does not decrease Should the latter happen the cooling water system will only have to be replenished preferably with freshwater but otherwise with seawater Then you can run the engine safely until arriving in harbour where the cooler can be repaired The coarse filter water trap must be emptied of water and mud about once a week by opening the lower cock until pure fuel oil is running out Callesen Diesel Page 8 of 12 Sheet No 7 94 2A The fuel filters should be cleaned at suitable intervals about every six months or when necessary and when the inserts are too poor they should be replaced set of filters should always be kept in reserve This is very important as poor filters ma
70. rough the bottom cock at least once a week or when necessary Inject cleaning water into the turbocharger at full load If the turbo pressure drops considerably the turbocharger must be dismounted for cleaning Check the Hynautic remote control and bleed it if necessary see the Hynautic instructions If the upper and lower movements are not synchronized move the handle to both extreme positions a few times Lubricate the Jet pumps if any by turning the Stauffer cups approximately half a turn Every month Check the lubrication of the rocking lever Check also the oil under the rocker covers If this oil is black and thick exchange the system oil Every second month Clean the small air filters on the valve covers and the air inlet filters If very dirty the filters should be cleaned at shorter intervals Lubricate the starting valves with a few drops of oil Callesen Diesel Page 1 of 2 Sheet No 7 95 2A Check and exchange if necessary all corrosion anodes If corroded away the anodes must be checked and exchanged at shorter intervals Empty the starting air bottles of water Clean the fuel filters at the front of the engine at suitable intervals Exchange the inserts if they are in a poor state Every six months or more often Clean the seawater side of the cooler the inner side of the pipes If the engine is smoking and the cause cannot be found in the fuel filters or the feed pump check whether the injector holes are
71. s jammed in the valves Callesen Diesel Page 2 of 2 Sheet No 7 95 2A TO BE REMEMBERED WHEN ENGINE IS INSPECTED Cylinder Covers and Cover Fittings If the covers have been dismounted it must always be checked whether they are leaking Press the fuel pumps to the bottom when engine is idling if there are any leakages a whistling sound will be heard which is caused by the explosions going through the copper packings In this case the cylinder cover must be retightened or the cylinder head gasket must be exchanged Cylinder cover mounting instructions see 7 49 Valves Check and adjust the valves see 7 45 As to grinding of valves and valve seats see 7 6 Starting Valves Check whether the starting valves are leaking If there have been starting difficulties and one or more starting valves have coked see to it that all pipes in the starting air system and all air distributor cover ducts are open if necessary dismount the pipes for annealing and cleaning If it is impossible to tighten all starting valves completely blank off the valve in question by mounting a copper disc or a coin without hole between the fitting and the cylinder head hole to avoid getting coke into the other valves Repair instructions see 7 60 Charging Valve Check whether the valve shaft is tight against the fitting in top Adjust if necessary Maximum turn of the spindle is 3 4 of a turn see 7 129 Filters Check fuel and lubricating oil filters as
72. s of the clamp ring 13 runs around with the shaft The lips of the sealing rings are pressed firmly on the chromium steel bush by means of a spring and the oil pressure from the sterntube The sealing against oil from the sterntube is always guaranteed In order to ensure a long lifetime the foremost ring is used first and afterwards the adjacent one simply by shutting the needle valve 9 The second sealing ring which has constantly been uncharged and well cooled takes over the sealing immediately In order to avoid leackages between the propeller shaft and the chromium steel bush a rubber ring 7 is pressed in between the clamping ring and the shaft Repair of the chromium steel bush In case of repair the chromium steel bush of the fore and after packing gland can be ready machined and polished to a minimum diameter A P the spring in the sealing rings can then be shortened in length by max 5 Type A P max ee Min 155 1 5 0 2 170 15 190 1 5 200 1 5 0 4 Callesen Diesel Page 3 af 6 Sheet No 7 93 2A AR dei Z DI NE yA FIR SS fi a LAN x x x x x MM Un Z lt lt OF PP CE m ER SEN SE Aye MM E 1 6 4 7 Sheet No 7 93 2A Callesen Diesel Page 4 af 6 MOUNTING INSTRUCTIONS Mounting of the seals takes place as a whole unit The seals are built together in the work shop and the bushes moun
73. s placed as illustrated on the drawing The ring is turned backwards and forwards while at suitable intervals the ring is moved 4 revolu tion The grinding is continued until the seal face is without marks and grooves After grinding the cylinder head is cleaned care fully against carborundum GRINDING OF CYLINDER LINER The grinding is made with the liner mounted in the cylinder block The seal face of the liner is lubricated with carbo rundum The grinding ring is placed as illustrated on the drawing The ring is turned backwards and forwards while at suitable intervals the ring is moved 4 revolu tion The grinding is continued until the seal face is without marks and grooves After grinding the liner is cleaned carefully against carborundum Regarding mounting of cylinder liner see page 7 26 Page 1 of 1 Sheet no 7 38 2A FUEL PUMP AND VALVE ADJUSTMENT OF ALL TYPES ADJUSTMENT OF VALVE AND PUMP MEASURED IN MM ON FLYWHEEL Tw FEYWHEEL DIAMETER 1000 960 sso sr smm Emaste ____ m f l 17 mm Exhaust closes after Suction opens before top rasant Fuet pump wnae je 95 eomm Exhaust closes eo 5 af element Fuel pump with drip pipe sis 69 bar ignition pressure 23 20 19 18 74 bar ignition pressure 40 38 36 ee ea Suction Fauna 87584 Sucton opensbetoretop e Firi
74. se it may result in operating problems Always use a EP2 grease with a consistency of 00 0 1 2 Recommended lubricants see sheet no 7 98 Cleaning of strainer and lubricating pump The strainer should be cleaned at equal intervals as dirt from the grease might have settled After loosening the nut and lifting the grease scraper it is easy to dismount the strainer It is recom mended to clean all parts of the pump thoroughly in kerosene once a year After cleaning all parts should be lubricated in oil before refitting Parts list 1 Container with neck ring 26 Label 3 Label 27 Adjusting spindle 4 Cheese head screw 30 Cylinder tightening 5 Cheese head screw 31 Pressure spring 6 Spring ring 32 Gear housing 7 Packing 33 Pressure cams 9 Feeder 6 litre 34 Worm wheel i 54 1 10 Catch bolt 36 Spring ring 11 Hexagon nut 37 Hexagon nut 12 Disc 38 Hexagon headed screw 13 Strainer 39 Steering knuckle arm 14 with bush and piston 40 Screw plug 15 Cheese head screw 41 Drive shaft i 2 54 1 16 _ Tightening ring 42 Burst ring 17 Spacer bushing 43 Disc 18 Slotted nut 44 Distance bush 19 Spacer bushing 45 Disc 20 Slotted pin 46 Slotted nut 21 Tightening ring 47 Spacer bushing 22 Stud 48 Woodruf key 23 Pressure spring 49 Catch housing 24 Ball 54 Conical tightening ring 25 Semi circular slotted pin 55 Filister screw head Callesen Diesel Page 3 of 4 Sheet No 7 102 2A FABRIKAT MAKE BP CASTROL CHEVRON ESSO GUL
75. t above the pump is removed and the bearing housing turned through the whole until a 0 05 mm feeler gauge can be placed between the gear wheels The engine is turned and the tooth clearance of the small wheel is checked for every 90 Afterwards the engine is turned further so that the big wheel can also be checked for every 90 When the adjustment is correct i e when the minimum clearance is 0 05 mm the pump is removed again and the unbraco bolts tightened and secured by a wire A guide pin is bored into the 8 mm hole in the eccentric flange The guide pin is knocked entirely in and secured with a burr Callesen Diesel Page 1 af 1 Sheet No 7 115 2A REPAIR OF COKED STARTING VALVE Remove the upper part of the starting valve where by the tool 16977 1 and the drawing tool for nozzle holder 16978 can be mounted as shown on the drawing For loosening of the valve Caramba or equal is used By means of the tool for drawing of nozzle holder the starting valve can be stroken loose When the valve is sufficiently loose to be moved by hand the drawing tool should be removed Now the starting valve must be moved up and down by means of the tool 16977 1 until the spring can draw the valve back to its position Finally lubricate the valve with oil NB The motion of the valve is only 2 5 mm Dismounting of starting valve If the starting valve is to be repaired or exchanged the whole starting valve arrangement can b
76. t that the shut off cocks on tanks and coarse filters which may close for the inlet pipes to the engine are open whereafter air relief of the fuel system is undertaken First the coarse filter water trap is vented by means of the cock in the top This cock should always remain open because the overflow piping from the filter is led to the water trap From the cock a pipe should be led upwards to minimum 1 m above the top of the tank Thereafter the inlet piping must be vented by loosening it on the feed pump until the oil is flowing through without air bubbles Then loosen the air cocks above the fuel filter fitted on the frontside of the engine and by means of the handpump pump oil through until all air has escaped the handpump is operated by turning its handle anti clockwise until it can be moved up and down The air cock in the aftermost end of the heavy inlet pipe on the fuel pumps should be loosened and not retightened until all air has escaped Thereafter loosen the air cocks on the upper frontside of the fuel pumps and move the regulating rods in the fuel pumps forward and backward while at the same time pumping by hand until the fuel is running through completely free of air bubbles only then the air cock should be retightened Callesen Diesel Page 1 of 12 Sheet No 7 94 2A In case the unions in the top of the fuel pumps have been loosened these should not be retightened too hard as the pumps may hereby be deformed with the result th
77. tarting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 1 is in starting position even though the top mark for cylinder 1 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 1 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 1 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 1 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 C RUNNING ANTI CLOCKWISE To cyl 3 To cyl 2 From starting air pipe An Position of Direction of VETT disc valve with tati 2 pe gate cyl 3 in start bikini AG 19168 yl 3 WALT position NIS sS A NU Ko s N A 77 SW 30 20 fib NN 4 4 9124 1 N NZS Cover I SS over is removed H 151111 For maintenance of the starting air distributor the cover 16155 has to be dismounted and the disc valve 17132 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 3 in start position There has to be an overlap of 0 5 1 0 mm betwee
78. ted All you have to do at dock or slip is to push the bushes with the seals over the shaft Aft sterntube sealing After mounting the propeller shaft the aft sterntube sealing with chromium steel bush which is fixed by mounting clips to the sealing case is pushed as a whole unit over the shaft and fastened to the sterntube oil and water tight The stainless steel bolts 11 have to be secured two by two by chromium steel wire 19 The measuring bolt 2 has to be in top position During the erection the aft sealing filling plug 10 in the outer casing 13 can be changed temporarily by a hoisting bolt When refitting the filling plug 10 do not forget the copper washer 20 After fitting the propeller the pressure ring 16 and rubber ring 6 have to be put into the propeller boss Now the chromium steel bush 5 can be fitted against the propeller boss The stainless steel bolts 4 have to be secured two by two by chromium steel wire 19 After removing the mounting clips you have to measure by means of a slide gauge the distance from the measuring bolt 2 to the chromium steel bush This dimension is written down for checking the wear of the aft end bearing When dismounting the sealing you have to use the same procedure Forward sterntube sealing The forward seal with chromium steel bush 6 which is fixed to the sealing casing by mounting clips can be placed on the propeller shaft as a complete set with rubber ring 7 and clampin
79. the propeller boss Between bearing ring 14 and ring 9 a sleeve 3 of oil and seawater resisting rubber is pressed The rubber sleeve ensures a flexible and durable sealing between the inner casing 9 and 14 and the outer casing 1 and 13 and makes it possible for the inner casing with sealing rings to follow the shaft Outer casing The outer casing 1 and 13 is mounted on the sterntube by means of stainless steel screws 11 The ring 13 is precisely fixed by a recess against the sterntube The bearing ring is notched to prevent any axial or rotary movement and wreckage of the flexible rubber sleeve By any damage of the rubber sleeve a stop on the bearing ring is serving as an emergency sealing All the screws 4 10 and 11 which are placed in the water are made of stainless steel By means of a sliding gauge with a depth gauge and the measuring device on the ring 1 it is easy to check the wear of the aft end bearing Callesen Diesel Page 1 af 6 Sheet No 7 93 2A FORWARD SEALING The forward sealing has the same construction as the aft sealing however instead of the rubber sleeve simple sealing rings are used as it is known from experience that the front end bearing is never worn worth mentioning The forward sealing consists of a casing 1 In this casing two sealing rings 2 and two supporting rings are retained by means of a seeger circlip 5 The two sealing rings are running on a chromium steel bush 6 which by mean
80. tween the hub and the pressure disc so that the hub can move freely this length WARNING Repeated hydraulic mountings and dismountings or if the hub is drawn too high up on the shaft cone by mistake may result in permanent shape changes of the hub Consequently the connection may not be able to transmit the projected torque In that case the hub flange coupling will have to be replaced Callesen Diesel Page 1 of 1 Sheet no 7 120 2A FUEL OIL SYSTEM TYPE 427 C F 9 nss di AO jan ITEM s qnop sedid s nsssid jan V AN yue OPL 3 3 4 196 i lt 612 229 edid AGIIH AO s jzzou Joyesedas sajsueiy N YUE SIA19S we uiu IsyeM V N Sheet No 9 31 2A Page 1 af 1 Callesen Diesel
81. ure valve No oil must leak during reversing manoeuvres Check the reversing mechanism before calling at a port especially after prolonged journeys Reduce the engine revs to 250 rpm and reverse from ahead to astern Lubricating Oil Analyses While engine is running drain off approximately 2 litres of oil at the flange under the lubricating oil filter Then drain off the oil sample Callesen Diesel Page 2 of 2 Sheet no 7 16 2A TECHNICAL DETAILS FOR CALLESEN DIESEL TYPE 427 AND 427 T Engine type C D E __ Lubricating oil filling 220 260 Hydraulic oil filling liter 50 50 55 Freshwater filling 410 FE e 4 0 posee Capacity PP 2x475 Cooling and bilge pump m h 93 93 144 144 Circulation pump 22 0 Fuelfeedpump 96 96 146 146 50 50 Lubricating oil pump mh 23 23 40 40 60 Return oil pump 4 25 9 3 9 3 2 ALLOWABLE 90 500 525 IO Oro 3 N IE olnlolw S m o m m ojo aJo Clearance in piston pin bush Distance between piston and cylinder head njo AID O o Axial clearance for bush in intermediate wheel Clearance in camshaft bearing olo o O m m o o Clearance between piston and piston pin olo NIN Oo m Axial clearance of thrust bearing in clutch 427 SKF22236 m Axial clearance of thrust bearing in clutch 427 H
82. ust now run with wet sump and the necessary oil is led down from the oil container to the oil pan through three way cock C Three way cocks A and B should be placed in a position enabling the return oil pump to send oil through both three way cocks to the oil cooler Return oil pump out of service In this case too the engine must run with wet sump and the oil is led from the oil container to the oil pan through cock C When the necessary quantity of oil has been led down cock C is placed in a position enabling the forward pump to suck direct from the oil pan Cocks A and B remain in the positions shown in the diagramme Callesen Diesel Page 1 of 1 Sheet No 9 27 2A LUBRICATING OIL REGULATIONS LUBRICATING OIL For lubrication of the engine a good grade diesel engine oil which is highly self purifying a socalled D3 oil should be used Such an oil can be supplied by all recognized oil companies All the year round an oil with a viscosity corresponding to SAE 30 should be applied It is important that the oil has a high flash point and can emulsify with water The TBN figure must not exceed 15 depending on the sulphur contents of the fuel CLUTCH OIL A special hydraulic oil should be used as stated below PROPELLER HEAD AND PULL ROD Water emulsifying oil e g sterntube oil ESSO 460 Kinematic viscosity 400 cSt at 40 C STERNTUBE GREASE Use a thin soft special sterntube grease which can emulsify with water This grease can als
83. ver 16155 has to be dismounted and the disc valve 17131 to be lubricated on the sealing face Mounting of new disc valve or journal On the sketch the position of the disc valve is shown with cylinder 2 in start position There has to be an overlap of 0 5 1 0 mm between the bore for the starting air pipe and the recess in the disc valve When this is in order the breaking pins can be bored in NOTE As the engine is a four stroke engine one cannot be sure that cylinder no 2 is in starting position even though the top mark for cylinder 2 is at the top as it may be one revolution wrong The easiest way to check this is by dismounting the pressure pipe on fuel pump no 2 giving full index to the fuel pumps and turning the engine past the top position for cylinder no 2 If fuel gets out of the pump it is the correct position for adjusting the starting air distributor If no fuel gets out of the pump the engine must be turned one revolution Callesen Diesel Page 4 of 10 Sheet No 7 63 2A REPAIR OF STARTING AIR DISTRIBUTOR TYPE 427 E RUNNING CLOCKWISE Z A Le 40137 To cul 5 To cyl 3 From starting air pipe sis m ies Position of the 19052 disc valve with Direction of 4 PEE cyl 4 in start rotation position N SA 16155 157 lt SS B SS H SS hy er N Lb Az S N AJ n To cul 4 PT SSE T 4 8 NN led 9124
84. well as air filters frequently see Maintenance of CALLESEN diesel engines 7 95 Crank Bearings When dismounting the crank bearings for inspection see 7 14 check also whether all crank plugs are tight Camshaft Check the adjustment and lift of the fuel pumps see 7 45 If the adjustment is incorrect call in skilled assistance Check the adjustment of the air distributor see 7 63 Callesen Diesel Page 1 of 2 Sheet no 7 16 2A Water Pumps Check the valves of the cooling and bilge pump see mounting instructions 7 62 Circulation Pump Check the circulation pump On the lower side of the bracket are two holes One of them is con nected to the shaft packing ring which is blocking the engine oil and the other is connected to the carbon ring packing gland which is blocking the water When the engine is running ensure that nothing comes out of the holes and that the holes have not been blocked Check whether there are cracks in the hose connections As to withdrawal of rotor see 7 12 Cooler Check and clean the oil and freshwater coolers in accordance with maintenance directions 7 10 Clutch and Reversal Check the crossbar bolt for pull rod for wear and tear Check and if necessary replace the corrosion anodes in the clutch oil cooler When failure of clutch pressure is experienced Check clutch filter and oil level of the clutch The oil level must be sounded when the engine is idling disengaged Check the over press
85. will penetrate slowly between shaft and sterntube bearings The oil level in gauge glass has to be observed continuously especially during the first operation hours b With oil pressure on the sterntube you can test the oiltight fitting of the forward sealing against afterpeak and after sealing against sternpost and propeller If you acted as under a or b and if the needle valve 9 is opened the sterntube bearings and sealings are ready for operation The needle valve is delivered in open condition Normal operation Normal maintenance is limited to observing the oil level in the overhead tank by means of the oil gauge and if necessary to refill the tank Operation troubles Leakage in the piping sterntube forward or aft seals will be visible when the oil level in the overhead tank and the oil gauge drops Should any damage of the rubber sleeve occur a stop on the bearing ring serves as an emergency seal If the forward seal is leaking you only have to shut the needle valve the other sealing ring which was always uncharged and well cooled guarantees a perfect and immediate sealing Changing the sealing rings If you have to mount new sealing rings you have to remove the chromium steel bush and dismount the seals After mounting the new rings the chromium steel bush has to be put into the seals very carefully Callesen Diesel Page 6 af 6 Sheet No 7 93 2A DISMANTLING AND ASSEMBLING OF PROPELLER BLADES AND HEAD Before stopping the
86. y damage pumps and injectors Normally the injectors are checked once a year provided that the engine is running satisfactorily and the pressure adjusted at the same time They are to be adjusted at 240 kp cm by hand pumping At the same time the injector filters must be cleaned If the engine has been disassembled for inspection a trial run is necessary to ensure that everything is in good order When the engine is installed in a wooden vessel the alignment of the engine should be checked every year and in any case when heating begins at the inner stern bearing Alignment is very easy to carry out There are four threaded holes in the foundation one in each corner The engine can be set up here and alignment plates placed below the engine WORKING TROUBLES START If the engine does not work after having been put in starting position and the starting valve has been opened the cause may be 1 There is no air or insufficient pressure in the starting air receiver the pressure should be at least 22 25 kp cm Maybe the valve is opening too slowly or too little The manometer readings may be wrong 2 The air pipes from the receiver starting valve to the engine starting valve may be clogged or dis connected Maybe the starting air pipe to the air distributor cover or the air distributor ducts are clogged by soot 3 Water in the starting air receiver Water should be drained off the receiver about twice a year 4 The starting v
87. y high oil pressure approx 3000 atm the hub is expanded so that the hub can be drawn up on a conical shaft with a slim cone 1 50 by a small axial pull This method can be used both when mounting and when dismounting the hub As mentioned the shaft has a slim cone with oil distribution traces and oil distribution channels as well as a threaded hole where a drawbolt can be placed To obtain the pressure an SKF oil pressure pump with built in oil reservoir and relief valve is used Use a clean engine oil SAE 30 To reduce friction during mounting a thrust bearing has been placed between drawbolt and pressure disc Mounting Before assembling the parts which are to be pumped together it is important to make sure that traces and channels are in connection and the the parts are absolutely clean and free of burrs Before placing the auxiliary tools according to the sketch the parts are lubricated with oil to prevent friction during mounting When pumping take care that oil is running out at both ends before you tighten the nut When the hub has been pulled into its place the drawing tool should be kept on the shaft for approx 15 minutes so that the oil can leak out Do not load the connection during the first 4 6 hours Dismounting The same method is used However the drawing tool is used as holder on as a lot of power is set free Do not use a thrust bearing There must be a distance equalling the shrinking length approx 17 mm be

S i M l Service Manual T 427 Type 427

Contents

Download Pdf Manuals

Related Search

Related Contents