Friday, April28, 2017 L-36.com

Thornycroft 90 108 Manual




NOTE: DO NOT HIT REFRESH!!! These files are big and can take a long time to load. This file is 0.76 MB. Give it time.
If there is text in the file, you can scroll it while the image loads. Enjoy

View PDF

Image Preview



Ad by Google

PDF to Text

MARINE ENGINES
The Thornycroft 90 and 108 engines are both 4 cylinder 4 stroke high speed diesel units both engines having electrically operated heater
plugs to aid cold cast iro n crankcase with ri bbed sidewalls houses a forged steel crankshaft carried in three or five bearings full press ure wet
sump lubric ation system is emplo yed with a full element type oil filter and integrated lubricating oil cooler
The cooling system is indirect and usually employs an engine mounted heat
exchang er with a belt dr iven ra w wa ter pu mp This sy stem is known as I FWC
internal fresh water cooled
An optional system is EFWC external fresh water cooled This system utilizes the
engine fresh water pump and usually employs skin tanks attached to the hull to serve as single belt driven alternator and fresh water pump drive
include a manual
belt tensioning arrangement for low maintenance completes the package
4 Cylinder naturally aspirated
4 Cylinder naturally intermittent at 3500rpm 36BHP Power intermittent at 3500rpm 47BHP
continuous at 3000rpm 30BHP continuous at 3000rpm 38BHP
Maximum torque at 2500rpm 531bf ft Maximum torque at 2400rpm 731bf ft
Idle speed 570rpm Idle speed full load speed 1500rpm Minimum full load speed
RATINGS
The type 90 Engine may be set to develop continuous outputs from 135 to 30 BHP according type 108 Engine may be set to develop continuous outputs
from 21 to 38 BHP
according to special applications where full power will not be required for periods in
excess of 1 hour in any 12 hours consecutive running the engine can be supplied at rating as shown above
NOTE All horsepower ratings quoted are at the engine flywheel Due allowance must
be made for transmission losses which will depend on the type of gearbox fitted
For tropical use it is necessary to derate the engine by 2 for each 5C 10F
above 30C 85F air temperature at sea level In some parts of the wor ld
fur the r de rat ing for h umi dity is n ece ssar y in acco rda nce with
BS 55141
INITIAL STARTING OF Engine mounting and dipstick marking Filling engine with oil
2 Lubricant specification for engine and gearbox Filling gearbox
3 inhibitor Filling cooling system
4 Priming the engine oil system
5 Bleeding the fuel system type 90 engines
6 Bleeding the fuel system type 108 engines
7 Initial start Normal start Running in
8 Operating guidelines
9 Operating guidelines
Maintenance schedule
Engine oil and filter change
10 Engine oil and filter change
11 Fuel filter change Cleaning Type 90 engines
12 fuel lift pump Gearbox oil Type 108 engines
13 change Cleaning air filter
14 Alternator drive belt and replacement Raw water pump
16 adjustment and Checking and setting valve
clearances Procedure for
retorquing cylinder head nuts fuel injectors
19 Changing coolant
20 Draining raw water system
21 External fresh water cooled engines
22 Electrical system
23 Fault finding
24 Fault finding
25 Laying up the engine
26 CHECKING ENGINE MARKING DIPSTICK FILLING ENGINE WITH OIL
Page 1
CHECKING ENGINE MOUNTING
The maximum installed angle of the engine is 15 engine types 902 108 and 1082
10 for engine type 90 This allows for a further rise of 4 when the craft is
moving Check the angle of installation using the centreline of the mounting feet
bolts as a datum Measure vertically on the centreline of the underside of the
front mounting foot bolt to find the angle of installation Fig 1
Fig 1
Horizontal Line
Type 90 Type 902 Type 108
A 93mm 10 A 138mm 150 A 136mm 15
46mm 5 93mm 10 91mm 10
46mm 5 46mm 5
MARKING DIPSTICK FILLING WITH OIL
Your engine is despatched from the factory without engine or gearbox oil and with an
unmarked engine dipstick After the boat is launched and is resting at
its normal trim angle remove the oil filler cap from the rocker box Fig 2 and pour 39
litres for type 90 45 litres for type 902 or 48
litres for type 108 of specified lubricant through the filler
hole Allow 5 minutes for the oil to drain into the sump
withdraw the dipstick and mark it for maximum oil level Fig
3 Use a centre punch for marking as filing a notch can
cause fatigue and eventual breakage while the engine is
running Then mark dipstick using the same method 127mm
below the maximum mark and this will be the minimum
level
LUBRICANT ENGINE AND GEARBOX
THORNYCRO
FT Page 2
ENGINE OIL
RUNNING IN OILS
Do NOT use special runningin lubricating oils for new or rebuilt engines Use oils specified for normal engine OIL VISCOSITY use of a multi graded
lubric ating oil h as been fou nd to impro ve and improve engine cranking in cold temperatures while at high operating temperatures A multigrade oil
conforming is recommended with the viscosity grades shown in Fig 4 The use of
single grade lubricating oil is not recommended except for synthetic oils used
in arctic conditions
Atmospheric Temperature Viscosity
Above 10C 20W50
20C to 10C 1OW30 or 1OW40
Below 10C 5W30 or 5W40
Fig 4
GEARBOX OIL
Borg Warner Automatic Transmission Fluid T ype A
Hurth Automatic Trnamsission Fluid T ype A
Newage PRM SAE 20 Engine Oil Minus 18C to 0C
SAE 30 engine Oil Above 0C
FILLING THE the oil filler plug combined dipstick from the top of the gearbox This is
in approximately the same position on Hurth Newage PRM and Borg Warner Using
a plastic bottle or funnel fill the gearbox up to the maximum mark on the
dipstick There is one level mark on the Hurth dipstick the others have high
and low marks
Fig COOLING SYSTEM
Page 3
COOLANT
Use antifreeze during all seasons to protect the engine cooling system from
corrosion as well as freeze damage Using the following antifreeze solution
25 3 3 5 0
Solution Solution Solution
Complete protection lOF12C 3F16C 4F20C
Safe protection 1F17C 8F22C In tropical climates where antifreeze availability may be limited corrosion
inhibitor to protect the engine cooling system use a
NOTE Corrosion inhibitor is NOT an antifreeze COOLANT QUANTITIES
Complete system including engine IFWC types 90 and 108 engines
51 Litres
For external fresh water cooled engines EFWC See Page 23 FILLING THE COOLING
SYSTEM
Remove the filler cap from the heat exchanger Fig 6 and fill the system
with coolant This will take approximately 5 minutes as the system self
bleeds Fill to 5mm below the filler neck level mark Refit filler cap
M Fig 8
405i
M Fig 9
PRIMING THE ENGINE OIL SYSTEM THOMYCWFT
Page 4
PRIMING THE ENGINE OIL SYSTEM TYPE 902R ENGINES ONLY
As only a residual amount of oil is present in the oil pump filter and oil
galleries of the engine it is therefore necessary to prime the system before the
engine is run Connect the engine starter batteries disconnect power to the
fuel solenoid valve on the injection pump Fig 7 and crank the engine over using
the key starter switch until pressure registers on the oil pressure gauge
Stop cranking and check the engine and gearbox for oil or water leaks Replace
power Fig 7
PRIMING THE ENGINE OIL SYSTEM TYPE 90 AND108 ENGINES
As only a residual amount of oil is present in the oil pump filter and oil
galleries of the engine it is therefore necessary to prime the system before the
engine is run Connect the engine starter batteries operate the key with the stop control out crank the engine over until pressure registers
on the oil pressure gauge Stop cranking and check the engine and gearbox for
oil or water BLEEDING THE FUEL SYSTEM TYPE 90 5
BLEEDING THE FUEL SYSTEM
Slacken the bleed valve on the injection pump Fig 8 Operate the lift pump
Fig 9 and when the fuel coming from the valve is free of air bubbles tighten the
valve
Fig 8
Slacken the uni ons at the
injector ends of a ny two high p ressure pipes Fig 10 Ensure that the stop
control is in the run position and the engine speed control is in the fully
open position Crank the engine until the fuel coming from both pipes is free from air
bubbles then tighten the unions
NB After initial start procedure has been observed start the engine and allow it
to idle until it is running evenly on all four 10
BLEEDING THE FUEL SYSTEM TYPE 108 ENGINES
THE FUEL SYSTEM
Fig 11
YCROF
Fig 12
2 46
Note After renewing the
fuel filter element it will only be necessary to bleed the fuel filter as
described in 1 and 2 provided that the engine has not been cranked while the
filter is dismantled
1 Slacken the blanking plug in the unused outlet connection in the fuel
filter head Fig 12 Operate the lift pump Fig 9 page 5 until the fuel
flowing from the plug is free of air bubbles tighten the plug NB Numbers
26 refer to Fig 11 bleed points
2 Slacken the union nut at the injection pump end of the fuel feed pipe
Operate the lift pump and when the fuel flowing from the union is free
from air bubbles tighten the nut
3 Slacken the air bleed screw on the injection pump body Operate the lift pump
and when the fuel flowing from the bleed screw is free from bubbles tighten the screw
4 Slacken the air bleed screw on the injection pump governor housing
Operate the lift pump until the fuel flowing from the bleed screw is free
from air bubbles leave the bleed screw slack
5 Slacken the air bleed screw on the injection pump high pressure banjo bolt
Operate the starter motor while operating the throttle control and when the
fuel flowing from the high pressure bleed screw is free of air bubbles
tighten the bleed screw
6 Co ntinue cranking the engine with the starter motor to expel any air
trapped in th e governor and when the fuel flowing from the go vernor
housing bleed screw is free of air bubbles tighten the screw
Slacken the unions at the injector ends of any two high pressure pipes Fig
13 Ensure that the stop control is in the run position and the engine
speed control is in the fully open position Crank the engine until the fuel
comibng from both pipes is free from air bubbles then tighten the unions NB After initial
start procedure has been observed start the engine and allow it to idle until it is
running evenly on all four Fig
INITIAL START NORMAL START RUNNING IN
Page 7
INITIAL START
With all systems filled primed and checked the engine may be started Run it for
2 to 3 minutes then stop it Top up engine gearbox oil and water levels to the
high mark The engine and gearbox are now ready for use Oil pressure should be
observed within 15 seconds
NORMAL STARTING PROCEDURE
1 Put gearbox selector lever in neutral
2 Ensure the stop control is fully disengaged
3 Set the engine speed control lever fully open
4 Turn the key to H position on starter switch and hold for 30 seconds this
preheats the heater plugs This is not necessary for a warm engine
Also control level only needs to be set half open
5 Turn the key to H S position and the starter motor will crank up the
engine
CAUTION If the starter fails to crank up the engine within 10 seconds
re lea se t he s wit ch k ey a nd w ait for th e starter motor to come to a
c o m pl et e st o p T h en tu r n t h e k e y to H S po s i ti o n a ga i n D o n o t
engage the starter motor for more than 30 seconds then wait 2 minutes
between unsuccessful attempts
6 Move the throttle position to idle as soon as engine starts
7 Oil pressure should be observed within 15 seconds
8 To stop the engine pull the stop control
RUNNING IN
The care given to an engine in the first 20 hours of operation will result in
longer life better performance and more economical operation During this
period follow these 1 Warm up the engine before placing it under load
2 Do not operate the engine at idle or full load for more than 5 minutes 3 Avoid
constant speed
4 Observe oil pressure and temperature gauges 5
Check the oil and coolant levels frequently GENERAL
PRECAUTIONS
1 NEVER attempt to start the engine with the gearbox control lever in any
position other than neutral
2 NEVER stop the engine without first engaging neutral
3 When changing the control lever from ahead to astern or vice versa pause in
neutral
OPERATING GUIDELINES
THORNYCROFT
I Page 8
COMPLIANCE WITH THE FOLLOWING CAN RESULT IN LONGER LIFE BETTER PERFORMANCE AND
MORE ECONOMICAL OPERATION OF YOUR perform all of the specified maintenance including the First Start of
the Day checks
Use antifreeze during all seasons to protect the cooling system from corrosion as well as
freeze operate the engine without a quality fuel that is free of water and other contaminants Monitor the oil
pressure and temperature indicators frequently AVOID FULL WHEN THE ENGINE IS COLD
When starting a cold engine bring the engine up to operating speed slowly to
allow the oil pressure to stabilise as the engine warms up
If temperatures are below 0C 32F operate the engine at moderate speeds for 5 minutes before
full loads are IDLING THE ENGINE FOR MORE THAN 10 MINUTES
Long periods of idling may be harmful to your engine because combustion chamber temperatures can
drop so low that the fuel may not burn completely Carbon can then form which may clog the
injector spray holes and also cause valves and piston rings to stick
AVOID OVERHEATING THE ENGINE
Co ola nt t emp era tur e mu st not ex ceed 99 C 210 F wi th a 70 kP a 10 p si
expansion tank cap AND A MINIMUM OF 50 mixture of and water
IDLE THE ENGINE A FEW MINUTES BEFORE ROUTINE full load operation idle the engine 3 to 5 minutes before shutting it off
to allow th e lu bricating o il and coola nt to car ry h eat away from chamber bearings shafts etc
AVOID LOW COOLANT TEMPERATURE operation at l ow coo lant temperat ure be low 60C 150F can be
harmful to the engine Low coolant temperature can cause incomplete carbon and varnish to form that can damage piston rings and
A lso th e unburnt fu el c an enter the crankcase di lut ing oil causing rapid wear to other moving
OPERATING 9
DO NOT OPERATE THE ENGINE WITH LOW OIL PRESSURE
When the engine is at normal operating temperature the minimum oil pressures
required are
Idle 570 RPM 1 bar 15 psi
Full Speed and Load 23 bar 35 psi
DO NOT OPERATE THE ENGINE WITH FAILED PARTS
Practically all failures give some warning before the parts fail Be on the
alert for changes in performance sounds and visual tipoffs that indicate
either service or repair is needed Some important clues are
Engine misfiring or vibrating severely
Sudden loss of power
Unusual engine noises
Fuel oil or coolant leaks
Sudden change in the engine operating temperature Excessive
smoke
Loss of oil pressure
SAFETY PRECAUTIONS
Saf ety i s bu ilt i nto eve r y en gin e ho wev er l ike any o the r
mechanical device it can present serious threat to life and limb if
imprudently operated and maintained Remember that the best
safeguards again st accidents are to kee p ever mindful of the
potential dangers and to always use good common sense
MAINTENANCE SCHEDULE TH0RNYCROFT
Page 10
DAILY OR EVERY 10 HOURS
Check engine and gearbox oil levels top up if necessary Check
coolant level and top up if necessary Check drive FIRST 25 cylinder head nuts
Change the engine oil and renew engine oil filter
Check valve rocker drive belt oil connections for leaks
Check water hose all electrical fuel filter and service injectors as and adjust engine idling speed as necessary Use a Thornycroft dealer Check
fuel
system for leaks
ENGINES IN REGULAR USE
EVERY 50 HOURS
Check electrolyte level in 200 HOURS OR fuel filter engine oil
Change engine oil filter
Check drive belts
Check air cleaner and clean if for oil or coolant leaks
Check fuel system for leaks
Check gearbox oil level
Check and adjust idling speed as 400 HOURS
In addition to the 200 hour maintenance schedules change the gearbox oil Remove heater
plugs and remove carbon from each 800 HOURS
In addition to the 200 hour and 400 hour maintenance schedules Adjust valve
rocker injectors for spray Use a Thornycroft dealer
Check all engine and gearbox connections Renew oil
filler cap on rocker cover
ENGINES USED OCCASIONALLY HALVE THE HOURS RECOMMENDED AFTER FIRST 25 ENGINE OIL CHANGE TYPE 90 11
CHANGE ENGINE OIL
Run the engine until it reaches normal operating temperature stop the engine then
using the hand pump Fig 14 drain the oil into a suitable Fig 14
CHANGE ENGINE OIL FILTER
Slacken the centre fixing bolt 1 Fig 15 and
withdraw the filter bowl 2 and filter element
3 together Discard the filter element and
sealing ring 4
Replace with new element and sealing ring ensuring that the ring is
correctly seated i n t he filt er head 5 and tig hte n t he centre bolt
Fill the engine with the specified amount of oil and prime the oil system
as described on Page 4
Start the engine and check for oil leaks run the engine for 2 pressure registers on the gauge Stop the engine and allow a few
minutes for oil to settle Check oil level top up if necessary
Fig 15
ENGINE OIL CHANGE TYPE 108 ENGINES THORNYCRO
FT Page 12
CHANGE ENGINE OIL
Run t he engine u ntil it reaches nor mal
operating temperature stop the engine
then using the hand pump Fig 16 drain the
oil into a suitable Fig 17
Unscrew the oil filter cartridge
Fig 17 Discard the cartridge and
its sealing smear the sealing ring with clean
engine oil Fig 18 and screw the into place using hand pressure
only until the sealing ring abuts with the
filter head face Then tighten a further
a of a turn
Fill the engine with the specified amount as
of oil and prime the oil system described on Page 4
Start the engine and check for oil leaks run the engine for 2 minutes register on the gauge Stop the engine and allow a few minutes for
Oil to settle Check oil level and top op if FUEL FILTER CHANGE
Page 13
RENE W FUE L FILTER ELE MENT
Turn off the fuel supply tap then support the filter base 1 Fig 1 9 and unscrew
the centre bolt 2 Detach the base and twist the element 3 to separate it from
the filter head 4 Remove the three sealing rings 5 from the head and base
Discard element and sealing rings Clean base and head and assemble the filter
using a new element and sealing rings Fit the element with its strengthened
rim uppermost Turn on the fuel supply tap then bleed the air from the system as
described on Page 5 or 6
Fig 19
CLEANING FUEL LIFT PUMP THORWCT
Page 14
FUEL LIFT PUMP FILTER
Turn off the fuel supply tap then remove the cap screw 1 Fig 20 Lift off the cap 2
gasket 3 and filter gauze 4 Clean the gauze in a suitable solvent usin g a
sti ff brush Clean the fuel cham ber 5 Check that the gasket is renew Assemble the components Do not overtighten the cap screw Never
clean inside fuel chamber or any other part of the fuel system with a Turn on the fuel supply tap then bleed the fuel system as described on
Page 5 or 6
Fig GEARBOX OIL 1 5
CHANGING THE GEARBOX OIL
T he gearbo x o il must be changed when the gearbox has reached operating
temperature After about 12 hour driving the craft
To help the oil drain easily from the gearbox first remove the oil filler
dipstick plug from the top of the gearbox Place a suitable container under the
gearbox and remove the drain plug from the underside of the gearbox and allow
the oil to drain completely Fig 21 The drain plug is in the same position on the underside of Hurth Borg Warner and Newage PRM
gearboxes
Refit the drain plug Fill the gearbox to the maximum mark on the dipstick
Refit the filler plug start the engine in neutral and run the engine for 1
minute to allow the oil to circulate Stop the engine and check the oil level
Top up if necessary to the maximum mark on the Fig shows PRM 160 gearbox
Fig 27
CLEANING AIR FILTER THORNYC
ROFT Page 16
CLEANING AIR the clip on the breather pipe and pull the pipe off the air cleaner
then slacken the screw Fig 22 this allows removal of the outer casing and the air filter the casing and gauze in a bath of clean paraffin or diesel
fuel agitate to remove dirt particles Shake the filter dry by hand or blow dry air then 22
CAUTION WHEN USING A COMPRESSED AIR LINE GREAT CARE MUST BE OBSERVED AND
GOGGLES MUST BE DRIVE BELT ADJUSTMENT AND REPLACEMENT
ALTERNATOR AND RAW WATER PUMP
Page 17
SAFETY BEFORE ATTEMPTING THESE OPERATIONS
DISCONNECT THE STARTER BATTERIES Adjusting
Alternator Drive Belt
Type 90 alternator is shown in the
illustration Fig 23 but procedure for
adjusting the alternator drive belt is
the same for type 108 engines
Slacken the nuts and bolts 14 Move
alternator away from the engine until the
deflection of the belt arrowed is 19mm
075 in when pressed using finger pressure
only at the longest point between pulleys
Excessive tension will cause early wear of
the belt water pump bearing and
alternator bearing While a slack belt
will slip causing overheating of the
engine and insufficient charging of the
batteries Check deflection after
Replacing Alternator Drive Belt
Slacken the nuts and bolts Fig 23 14
move alternator in towards engine Remove
old belt from pulleys and replace with new
drive belt Retighten nuts and bolts
Following the instructions above readjust
the drive belt tension
Fig 23
Adjusting Raw Water Pump Drive Belt
Slacken the nuts and bolts Fig 24 1
and 2 an d ret ens ion the b elt as
described above for the alternator
The deflection of the belt must be
1012mm 039047in Check deflection
after Replacing Raw Water Pump Drive Belt
Slacken the nuts and bolts Fig 24 1
and 2 Move pump in towards engine
Remove old belt from pulleys and
replace with new drive belt
Retighten nuts and bolts following
the instructions above readjust the
drive belt tension
Fig 24
CHECKING AND SETTING VALVE CLEARANCE
THORWCWFT
Page 18
SAFETY BEFORE ATTEMPTING THIS OPERATION DISCONNECT THE STARTER Valve Clearances Engine the rocker cover bolts and remove rocker cover Discard the
gasket Turn
the crankshaft in the normal direction of rotation and adjust as the locknut and adjust with a screw driver until the correct clearance is
obtained Fig 25 Insert the feeler blade between the valve stem and rocker arm
When correct adjustment is obtained the feeler blade is able to be removed with
slight in the following sequence
Set No 1 tappet with No 8 valve fully open Set
No 3 tappet with No 6 valve fully open Set No
5 tappet with No 4 valve fully open S et No 2
tappet with No 7 valve fully open Set No 8
tappet with No 1 valve fully open Set No 6
tappet with No 3 valve fully open Set No 4
tappet with No 5 valve fully open Set No 7
tappet with No 2 valve fully open
Rec hec k the clearance wit h the loc knu ts
tightened and readjust if necessary
Fig 25
Valve Clearance Type 90 engines
Inlet Valve 0381mm 0015in
Exhaust Valve 0381mm 0015in
Valve Clearance Type 108 engines Up
to Thornycroft Engine No 6043 Inlet
and Exhaust 043mm 0017in
Engine No 6043 onwards
Inlet and Exhaust 035mm the rocker cover using a new gasket Tighten the the battery start the engine and check the rocker cover for leaks
THORNYCROFT PROCEDURE FOR RETORQUING CYLINDER HEAD NUTS
Page 19
1 PROCEDURE FOR NEW ENGINES WHICH HAVE RUN FOR 25 HOURS
A Run engine and stop when normal operating temperature is reached
B Slacken the cylinder head nuts by approximately 16 of a turn one flat
of the nut following the sequence shown using service tool 18G 1457
to reach the nuts in the centre row
Fig 26
C Tighten the nuts in the sequence shown to 104 kgf m 75 lb ft
11 6 5 12
00 00 0o
90 0 9 0 1 0 A
14 107 3 1 4 89
Slacken the valve rocker pedestal nuts by 16 of a turn one flat of
the nut and retorque to 35 kgf m 25 lb ft Adjust valve rocker
clearances Page 18
2 PROCEDURE WHERE PART ENGINES HAVE BEEN FITTED OR WHERE CYLINDER HEADS ARE
REMOVED OR REPLACED DURING REPAIR OPERATIONS
A The cylinder head nuts should not be more than finger tight until the
rocker shaft assembly has been fitted
Tighten the nuts to 104 kgf m 75 lb ft type 108 engines 98 kgf m
71 lb ft type 90 engines in the sequence shown in procedure 1
Using service tool 18G1457 to reach centre row Fig 27
C Tighten the valve rocker pedestal nuts to 35 kgf m 25 lb ft
D Adjust the valve rocker clearance as in procedure 1
When the engine has run f or Y2 hour carr y out the operat ion descr ibed 1
Fig 27
REMOVAL AND REFITTING FUEL INJECTORS THORNY
CROFT
Page 20
REMOVING FUEL cleaning and spray testing can only be carried out with therefore this must be done by a Distributor or Dealer
Fig 28 Disconnect the feed pipe 1 and spill rail 2 Note the 3 on each side of the spill rail banjo union Remove the bolts 4 and withdraw the
injector Fit protective caps to all Fig 29
Fig 28
REFITTING FUEL protective caps Ensure the washers are fitted to the injectors as
shown in Fig 29 It is most important to tighten the injector fixings evenly and
to the correct torque of 165 kgf m 12 lbf ft or of the injector can distort the nozzle and will usually cause a
misfire to occur when normal running temperature is reached Reconnect the
injector pipes do not overtighten the unions
TO REMOVE HEATER PLUGS AND CLEAN
ORIFICES Disconnect the battery Remove
electrical leads 1 Fig29A and unscrew
each plug 2 from th e cylinder head
Insert a twist drill of 437mm
11 64 in dia 3 into t he th rea ded
holes in the head 4 Turn the drill by
han d to r emo ve car bon bui ld up
Remove the drill and clean any particles of
carbon from conical seatings in the
cylinder head Refit the heater plugs
and e lec tri cal l ead s Re connec t TAT CHANGING 21
CHANGING COOLANT
Remove filler cap from heat exchanger place a suitable container beneath the drain plug
Fig 30 Remove plug and allow to drain
Place suitable container beneath drain tap in cylinder block Fig 31
Remove
tap and allow to drain
Replace both plug and tap then refill with coolant of the correct strength for be encountered See Page 3
Fig 31
DRAINING RAW WATER SYSTEM
Page 22
DRAIN THE RAW WATER the six screws Fig32 on the raw water pump Remove end covers from
heat exchanger and drain tubes either by removing the tube stack or by blowing out
with compressed air Remove oil cooler and drain tubes or blow out air Alternatively disconnect raw water pipework before gearbox oil
cooler and pipe from oil cooler into a container of antifreeze mixture and
flush through system returning antifreeze mixture from water injection bend
back into container this ensuring that any water pockets contain CAUTION WHEN USING A COMPRESSED AIR LINE GREAT
CARE MUST BE OBSERVED AND GOGGLES MUST BE
WORN
NOTE ANTIFREEZE MIXTURE MUST BE OF CORRECT STRENGTH FOR CONDITIONS TO 32
ROUTINE MAINTENANCE OF RAW WATER SYSTEM IFWC
THESE NOTES DO NOT APPLY TO EXTERNAL FRESH WATER COOLED and clean the sea inlet strainer at regular intervals Do Not remove the
strainer when the engine is running as foreign matter can be drawn into the system and damage to the pump The sea cock must be FULLY OPEN when the
engine
is running If the sea cock is partially closed air can be drawn in with
consequ ential failure of the raw water pump and engine overheating Check the
raw water discharge pipe immediately after starting the engine to see if the raw water
pump is The engine MUST NOT run without a flow of raw water through the heat WATER PUMP the raw water pump is self priming and fitted with a
It depends on the raw water for its lubrication DO NOT run dry
M ore than 3 0 se con ds runn ing withou t wate r will b urn the impellor and to an early failure When replacing the end cover gasket it is
essential to use the correct part variation of the gasket thickness can cause loss ability or seizure
EXTERNAL FRESH WATER COOLED ENGINES ONLY 2 3
This consists of a closed circ uit fresh water system with a fre sh water
circulator combined header tank and exhaust manifold dry exhaust outlet and
watercoolant tanks normally fitted to the skin of the craft It is therefore
important when filling this system with antifreeze solution or corrosion
inhibitor that the total capacity of the tanks associated pipework and the
engine cooling system is taken into Your boat builder will
advise you on these figures
We have included the box below for you to fill in these figures for your craft
Name of Craft External Fresh Water Cooled System
Capacity Date Change Due
ELECTRICAL SYSTEM THORNYCROFT
Page System
An insulated return system is employed on the type 90 and 108 engines
The 12 volt alternator has a builtin voltage regulator which the charging rate to provide sufficient electric current to keep the
battery fully charged under normal operating alternator requires no lubrication NOT disconnect the battery leads while the engine is that the
correct battery terminal is connected to a good earth on the
starter
A coating of a good grade of petroleum jelly will protect the terminals electrolyte level should be 6 to 9mm 025 to 038in above the top of the plates
If is below the correct level add the required amount of water for battery use should be kept in clean covered In cold weather add water only
immediately before running the engine so
that the charging will mix the water and electrolyte and prevent freezing
If t he b att ery i s al lowed to sta nd at lo w tem per atu res in a p art ial ly
discharged condition there is a possibility that it may freeze causing damage to the container Take
care therefore to keep the battery as fully charged as specific gravity of the electrolyte when the battery is fully be 1275 at a temperature of 25C
77F At differing temperatures the specific gravity
of a fully charged battery will change The specific gravity of any given be calculated by subtracting 0004 from 1275 for every 6C change above 25C
and adding 0004 to
1275 for every 6C below 25C
Keep the battery filler plugs and connections tight and the top of the battery clean Wiping
the battery with a rag moistened with ammonia will counteract the effect of any
of the solution which may be on the outside of the battery Wear when carrying out this operation If ammonia is accidentally splashed in the
eyes wash out thoroughly at once with clean water and SEEK QUALIFIED MEDICAL Jumper Cables
To avoid the possibility of extensive damage to your charging system it is
important to observe the following points when using battery jumper cables to start an engine
having a discharged battery The positive terminals of the batteries must be one cable usually red and the negative terminals the other cable If
this procedure is not followed extensive damage may be
done to the charging Since explosive hydrogen gas is always present sparks or flames
should not be allowed near the battery When using jumper cables the
cables should always be attached to the booster battery FAULT 25
FAULT FINDING
ENGINE WILL NOT START
Starter does not ELECTRICAL FAULT
crank engine Battery run down
Lead disconnected
Faulty starter switch
Faulty starter motor
Starter cranks ELECTRICAL FAULT
engine slowly Battery partly run down
Terminals loose
Connections dirty Faulty
starter motor
MECHANICAL FAULT
Wrong grade engine oil
Starter cranks ELECTRICAL FAULT
engine normally Faulty glow plugs
Faulty wiring connection
MECHANICAL FAULT
Injection timing incorrect
Poor cylinder compression
Blocked air intake
FUEL FAULT
Fuel Not Reaching
Injection Pump Insufficient fuel in tank
Blocked fuel pipeline
Blocked fuel tank vent
Restricted fuel filter Air
leaks in pipeline
Fuel Reaching
Injection Pump Air in fuel system
Faulty injectors

Ad by Google

Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.