o m - Main Pump With Engine

Mather + Platt Installation, Operating and Maintenance Instruction Manual for Split Casing Centrifugal Pumps

These instructions must be read prior to installing, operating, using and maintaining this equipment

MPPL/IM/ASCCP/2006/0

Mather + Platt

Table of Content

EC declaration of incorporation (QA02-45) for, pumps without prime mover EC declaration of conformity (QA02-46) for, pumps with CE prime mover. 1

Preface and Copyright Information

1-1

Preface Copyright Manufacturer Rights of alteration

1-1 1-1 1-1 1-1

General safety information

2-1

Safety symbols used in the manual

2-1

Guides lines used and CE certification Declaration of Incorporation or Conformity Duty conditions Safety & control devices Safety instructions Safety instruction for the operator Electrical connection and electrical work Operation with different pump fluid Sound pressure Prime mover selection Warranty Remarks

2-1 2-1 2-2 2-2 2-2 2-3 2-4 2-4 2-4 2-5 2-5 2-6

Product description

3-1

General product information Proper use and fields of application Conditions of use Construction

3-1 3-1 3-1 3-2

Handling, transportation and storage

4-1

Handling Delivery Transport Storage Returning to supplier

4-1 4-1 4-2 4-2 4-2

Installation

5-1

5.1

Introduction

5-1

5.2

Requirements for the operating area

5-1

5.3 5.4 5.5 5.6 5.7 5.8

Cleaning Foundations Bedplate Alignment of pump and driving unit Pipe work Use of diesel engine as prime mover

5-1 5-2 5-2 5-4 5-7 5-8

1.1 1.2 1.3 1.4

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13

3 3.1 3.2 3.3 3.4

4 4.1 4.2 4.3 4.4 4.5

5

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Table of Content 6

Mather + Platt

Start up

6-1

Introduction Pipe work flushing Cleaning of bearing Direction of rotation Priming Pump operating on flooded suction

6-1 6-1 6-1 6-1 6-1 6-1

Pump operating on negative suction Pump operating on hot liquid Pre-starting checks Normal starting checks Running checks Normal shut down Emergency shut down

6-2 6-2 6-2 6-3 6-4 6-4 6-4

Maintenance

7-1

Routine maintenance & frequency of inspection Overhaul maintenance Spares Lubrication

7-1 7-2 7-7 7-8

8

Troubleshooting

8-1

A

Lists, Tables & Type Plates

A-1

List of machine operators Maintenance and inspection log Type plates Leveling Records Alignment Protocol Pre-Starting checks Pump commissioning report Issue/Feed back report

A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8

Machine data sheet

B-1

Performance

B-1 B-1 B-1 B-1 B-3 B-7

6.1 6.2 6.3 6.4 6.5 6.6 6.7 6-8 6-9 6.10 6.11 6.12 6.13

7 7.1 7.2 7.3 7.4

A.1 A.2 A.3 A.4 A.5 A.6 A.7 A.8

B B.1 B.2 B.3 B.4 B.5 B.6

Pressure limits Temperature limitation Flange loads Bearing’ lubrication & gland packing data Recommended bolting & screw torques

MPPL/IM/ASCCP/2006/0

Mather + Platt

EC declaration of incorporation

EC declaration of incorporation According to annexure V of machinery directive 98 /37 /EC, We hereby state that this product (Pump without prime mover) Product designation Type designation

: :

Pump serial no Prime mover designation Type designation Prime mover (CE) serial no

: : : :

Horizontal split casing pump Refer section B5 serial No 1 to 171 of the manual & the name plate on the pump Refer the name plate on the pump Not applicable. Not applicable. Not applicable.

fulfills the following relevant legal requirements: EC – Machinery directive 98 / 37 / EC Harmonized standards used, in particular: EN 809:1998 ISO 12100-1:2001 ISO 12100-2:2002 EN 1050 Manufacturer Address

: :

Telephone Fax e-mail

: : :

Representative (within EEA) Address

: :

Telephone Fax e-mail

: : :

Mather and Platt Pumps Ltd., Mumbai –Pune Road, Chinchwad, Pune411019, India. +91 (0)20 27442100. +91 (0)20 27442211. [email protected] WILO AG, NortkirchenstraBe 100, 44263 Dortmund, Germany +49 231 4102-0 +49 231 4102-363 [email protected]

Pune, 01.07.2006

Mather & Platt Pumps Ltd Pune A. V. Joshi Deputy General Manager - Quality Assurance

QA02-45 REV 0

Mather + Platt

EC declaration of conformity

EC declaration of conformity According to annexure V of machinery directive 98 /37 /EC, We hereby state that the Mather & Platt product (Pump with prime mover), refer prime mover manual name plate, instruction manual & CE declaration of conformity Product designation Type designation

: :

Pump serial no Prime mover designation Type designation Prime mover (CE) serial no

: : : :

Horizontal split casing pump Refer Section B5 Serial No 1 to 171 of the manual & the name plate on the pump Refer the name plate on the pump Refer the name plate on the prime mover Refer the name plate on the prime mover Refer the name plate on the prime mover

fulfills the following relevant legal requirements: EC – Machinery directive 98 / 37 / EC Harmonized standards used, in particular: EN 809:1998 ISO 12100-1:2001 ISO 12100-2:2002 EN 1050 Manufacturer Address

: :

Telephone Fax e-mail

: : :

Representative (within EEA) Address

: :

Telephone Fax e-mail

: : :

Mather and Platt Pumps Ltd Mumbai –Pune Road, Chinchwad, Pune411019, India. +91 (0)20 27442100 +91 (0)20 27442211 [email protected] WILO AG, NortkirchenstraBe 100, 44263 Dortmund, Germany +49 231 4102-0 +49 231 4102-363 [email protected]

Pune, 01.07.2006

Mather & Platt Pumps Ltd Pune A. V. Joshi Deputy General Manager - Quality Assurance

QA02-46 REV 0

Mather + Platt

Preface and Copyright Information

1

Preface and Copyright Information

1.1

Preface

Dear Customer Thank you for purchasing one of our company's products. This operating and maintenance manual must be read carefully before installation & initial start-up to ensure safe and efficient use. This documentation contains all the necessary information for the product, allowing you to use it properly. In addition, you will also find helpful information, which will enable you to recognize potential dangers, reduce repair costs, down times and increase the reliability and working life of the product. The operating company is responsible for ensuring that all persons working with or on this product are at least 18 years of age and have read and understood this manual. Only qualified and trained personnel should be assigned to work on the product. All safety requirements and specific manufacturer's requirements must be fulfilled before the product is put into operation. This operating and maintenance manual supplements any existing national regulations on industrial safety and accident prevention. This manual must be made accessible to personnel working at all times and also be made available where the product is used. In a case where there is any doubt as to the functioning or adjustment of any parts of the equipment, or in the event of any trouble which cannot be remedied by reference to the information contained in this manual, MATHER & PLATT PUMPS LTD. should be consulted immediately at their Pune address mentioned below. In communicating with the Company, the Pump Serial Number should always be quoted.

1.2

Copyright

This operation and maintenance manual has been copyrighted by, the manufacturer. The operation and maintenance handbook is intended for, the use by assembly, operating and maintenance personnel. It contains technical information and diagrams which may not be reproduced or distributed, either completely or in part, or used for any other purpose without the expressed consent of the manufacturer.

1.3

Manufacturer

Mather and Platt Pumps Ltd Mumbai-pune Road Chinchwad, Pune-411019 India. Tel.: +91 (0) 20 27442100 Fax: +91 (0) 20 27442111 Internet: www.matherplatt.com e-Mail: [email protected]

1.4

Rights of alteration

The manufacturer reserves the right to make technical alterations to systems or components and technical contents of the manual.

This operating and maintenance manual refers to the product indicated on the title page.

MPPL/IM/ASCCP/2006/0

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Mather + Platt 2

General Safety Information

General Safety Information

This operation and maintenance manual contains basic information, which must be strictly observed during operation and maintenance. Not only the safety instructions listed in this chapter must be followed but also those contained in other chapters, which refer to specific parts and procedures. The operator is responsible for ensuring that personnel follow these instructions and guidelines.

2.1

Safety symbols used in the Instruction manual This symbol indicates danger from general causes where noncompliance with safety instructions would affect personnel safety. This symbol indicates danger from electrical causes where noncompliance with electrical safety instructions will involve a high risk to personnel safety or loss of life. This note symbol refers to safety requirements or notes that are of critical importance to the user where non-compliance could damage the pump or installation or cause it to malfunction.

2.2

Guidelines used and CE certification

Our products conform to the following EU guidelines: -

Machinery directive 98 / 37 / EC.

In addition, several harmonized standards have been applied, e.g. EN 809, ISO 12100-1& ISO 12100-2, EN 1050 (Risk assessment). Please consult the EU Declaration of Conformity for the precise information and the guidelines in effect The EU Declaration of Conformity is issued in accordance with EU Directive 98/37/EC, Appendix II A. The CE symbol is found on the pump nameplate and motor & electrical panel nameplate when in M&P’s scope of supply.

2.3

Declaration of Incorporation or conformity.

Since Mather & Platt does not manufacture prime mover, following conditions will apply. It is recommended that customers should opt for CE marked prime mover. When customer takes only bare pump, or pump with accessories without prime mover, Declaration of Incorporation will be applicable. For unitized pumps with CE prime mover, Declaration of Conformity will be applicable. Where customer opts for pumps with prime mover without CE, or supplies his prime mover for unitization, which is not CE, Declaration of incorporation will be applicable.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

General Safety Information 2.4

Duty conditions

This product has been supplied as per specifications in your purchase order/ approved data sheet & drawings. A copy of these specifications / approved data sheet should be kept with these instructions.

The product must not be operated beyond the parameters specified for the application. In case of any doubts, contact Mather & Platt for advice, quoting Pump serial number. If the duty conditions of pump are going to be different than the specifications in purchase order / approve data sheet (e.g. liquid pumped, temperature or duty) it is requested the user seeks the written agreement of Mather & Platt pumps Ltd., before start up.

2.5

Safety & control devices

Direct controls are applicable when pump is supplied along with motor/panels. When motor/panel are in end user’s scope, it is advised to go for CE approved motors/panels.

These devices whether on pump/motor/electrical panels must never be dismantled or disabled. They must be checked by an authorized technician for proper functioning before, start-up. Refer to motor & Electrical panel instruction manuals for electrical safety & control devices information.

2.6

Safety instructions -

Installation & service should be done by, qualified personnel only.

-

The installation / removal of the product must not be performed by one person alone.

-

Failure to comply with safety precautions could result in personnel injury or damage to the equipment or installation. Failure to comply with safety precautions could also invalidate any claim for warranty.

-

The operator is required to know mechanical/electrical specifications of the machine and how to cut off the supply.

-

The operator must inform his/her superior immediately should any defects irregularities occur. This applies to both the electrical and mechanical devices.

-

If fastening devices are separated from the pump after use, they should be marked as fastening devices. Otherwise they should be carefully stored.

-

It is of vital importance that the system is shut down immediately by the operator if any problems arise which may endanger the safety of personnel and/or plant. Problems of this kind include: -

or

expressly

Failure of the safety and/or control devices. Damage to critical parts. Damage to electric installations, cables and insulation.

-

Main controls for the pumps should be located for easy view of the operator from the control position.

-

The removable and/or mobile equipment for lifting loads should be used in a manner that ensures the stability of -the equipment during operation.

-

Measures should be taken to bar persons from standing beneath a suspended load. Furthermore, it is also prohibited to move suspended loads over exposed workplaces where people are present.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

General Safety Information

-

The fastening devices should be adapted to the conditions at hand (weather, hooking system, load, etc.) If these are separated from the pump after use, they should be expressly marked as fastening devices. Otherwise they should be carefully stored.

-

Only fastening devices, which are legally designated as such and officially approved, may be used.

-

When using mobile working equipment for lifting non-guided loads, measures should be taken to prevent them from tipping, sliding, slipping etc.

-

If mobile working equipment is used for lifting loads, a second person should be present to coordinate the procedure if needed (for example, if the operator's field of vision is blocked).

-

While unloading the pump from the truck lift the pump by passing wire rope beneath the box containing the pump or pump assembly.

-

The load to be lifted must be transported in such a way that there is no danger of injury in the event of a power failure. Additionally, when working outdoors, such procedures must be interrupted immediately if weather conditions worsen.

-

When working in enclosed spaces care should be taken to provide sufficient fresh air. Provide sufficient ventilation.

-

When welding or working with electronic devices, ensure that there is no danger of explosion.

-

When working with pumps using hot liquid appropriate care should be taken. It is advised to use PPE irrespective of warning signs on pump/insulation provided depending upon the temperature of liquid handled.

-

Environmental safety: Disposal of any unwanted/scrap material should be disposed in appropriate way so as not to cause any harm to the environment. No hazardous material is used in M & P pumps.

These instructions must be strictly observed. Non- compliance can lead to serious personal injury and/or damage to the machine.

2.7

Safety instructions for the operator -

Local regulations for the prevention of accidents must be observed. Dangers resulting from electrical energy are to be prevented. National/local energy supply company regulations must be followed.

-

Guards for moving parts (e.g. coupling) must not be removed from the machine while in operation.

For safety reasons, safety and control devices must not be removed without authorization. Personnel must have the requisite specialist knowledge. Use Standard Personnel protective equipments against sharp corners for protection of hands, for eyes when using grinders, Special PPE against electrical shocks, against sound (Cl 2.8) etc.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

General Safety Information 2.8

Electrical connection and electrical work

Refer to the motor & panel instruction manual at the time of installation and connection. Motors or electrical control panels are operated with alternating or industrial high-voltage current. It is recommended to use CE marked motor and / or electrical panel if they are not in M&P’s scope of supply. The local regulations must be adhered to. The "Electrical connection" data sheet in the respective motor and panel instruction manual must be followed when connecting the product. The technical specifications on the nameplate and in the machine data sheet must be strictly observed. Ensure that there is a provision for isolation of all energy sources and locking. If the machine has been switched off by, a protective device, it must not be switched on again until the error has been corrected. The electrical system (machine including protective devices and operating position) must always be grounded. Refer pump GA drawing & respective manuals of motor/electrical control panel for connecting earthing suitable as per motor rating and relevant regulations and standards including proper earthing lug size and fasteners. If there is a possibility that people can come into contact with the machine and the pumped liquid (e.g. at construction sites), the grounded connection must be additionally equipped with a fault current protection device.

Electrical work (connection, maintenance and repair work) may only, be carried out by a qualified electrician. Any unused wires must be disconnected! The cable ends must never be immersed in the pumped liquid! Refer instruction manual of respective equipments like motor, panels etc for safety instruction to be followed when connecting these equipments to the pump and power supply and for the operation.

2.9

Operation with different pumped fluids

The pump supplied is intended for specific fluid. Refer pump data sheet and order confirmation. For any change in pumped fluid refer M&P before hand.

2.10

Sound pressure

Depending on the size and capacity (kW), the products produce a sound pressure of approximately 75dB (A) to 110dB (A). The actual sound pressure, however, depends on several factors. These include, for example, the installation type, fastening of accessories and pipeline, operating site condition, background noise, etc. Once the product has been installed, we recommend that the operator make additional measurements under all operating conditions.

In accordance with the laws in effect, guidelines, standards and regulations, ear protection must be worn if the sound pressure is greater than 85dB (A). The operator is responsible for ensuring that this is observed! For actual values on sound level & vibration at the time of pump testing on test bed refer to the Pump performance test certificate submitted along with other certificates.

MPPL/IM/ASCCP/2006/0

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Mather + Platt 2.11

General Safety Information

Prime mover selection

When prime mover is in M&P’s scope of supply, Electrical motors/diesel engines/steam turbines etc. are selected mutually with the customer/end user depending upon his requirements & absorbed power by the pump at duty point. (Refer Cl. 2.3 on page 2-1 for applicable CE declaration). When pump is supplied along with prime mover and/or with control panel when in M&P’s scope, manufacturers’ instruction manual for respective equipment will be provided to the customer/end user along with the pump instruction manual.

2.12

Warranty

This chapter contains the general information on the warranty. Contractual agreements have the highest priority and are not superseded by the information in this chapter! The manufacturer is obliged to correct any defects found in the products it sells, provided that the following requirements have been fulfilled:

General information -

The materials used caused the defects or the way the product was manufactured or designed.

-

The defects were reported in writing immediately to the manufacturer within the agreed warranty period.

-

The product was used only as prescribed.

-

All safety and control devices were connected and inspected by authorized personnel.

Warranty period If no other provisions have been made, the warranty period applies to the first 12 months from the date of delivery / installation or 18 months from the date of dispatch from the works which ever is earlier. For details refer the warranty certificate provided. Other agreements must be made in writing in the order confirmation.

Spare parts, add-ons and conversions Only original spare parts as supplied by the manufacturer may be used for repairs, replacements, add-ons and conversions. Only these parts guarantee a long working life and the highest level of safety. These parts have been specially designed for our products. Self-made add-ons and conversions or the use of non-original spare parts can seriously damage the product and/or injure personnel.

Maintenance The prescribed maintenance and inspection work should be carried out regularly. This work may only, be carried out by qualified, trained and authorized personnel. The maintenance and inspection log supplied must be properly updated. This enables you to monitor the status of inspections and maintenance work. Quick repairs not listed in this operation and maintenance manual and all types of repair work may only be performed by the manufacturer and its authorized service centers.

List of machine operators The machine operator list must be filled out completely. By signing this list, all persons working on or with the product confirms that they have received, read and understood this operating & maintenance manual.

Damage to the product Damage as well as malfunctions that endanger safety must be eliminated immediately by, authorized personnel. The product should only be operated if it is in proper working order. During the agreed warranty period, the product may only be repaired by, the manufacturer or an authorized service workshop. The manufacturer reserved the right to recall the damaged product to the factory for inspection.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

General Safety Information Exclusion from liability

No liability will be assumed for product damage if one or more of the following points apply: -

Incorrect design on our part due to faulty and/or incorrect information provided by the customer.

-

Operation of product different/beyond the parameters specified in purchase order/approved data sheet.

-

Non-compliance with the safety instructions, the regulations and the requirements and this operating and maintenance manual.

-

Improper installation & pipe work.

-

Faulty construction site and/or construction work.

-

Chemical, electrochemical and electrical influences.

-

Improper assembly/dismantling.

-

Improper maintenance.

-

Unqualified repairs.

-

Wear.

This means the manufacturer’s liability excludes all liability for personal, material or financial injury.

2.13

REMARKS

To avoid ambiguity in the use of the word `replace' the words `replace' and ‘renew' are used in this manual in the following context: Replace - To put back, in its existing state, a part or component that has previously been removed. Renew

- To substitute a new part of component for a worn or damaged one.

MPPL/IM/ASCCP/2006/0

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Mather + Platt 3

Product description

3.1

General product information

Product description

The machine is manufactured with great care and is subject to constant quality controls. Trouble-free operation is guaranteed if it is installed and maintained correctly.

3.2

Proper use and fields of application

Horizontal Split case pumps are used in Water supply, Water-circulating systems, Injection water, Spray Pond, Air conditioning, Water treatment, Sprinkler & drip irrigation, Fire fighting, juices etc.

Precise information about this can be found on the order confirmation and on the pump data sheet.

3.3

Conditions of use All axially split casing models are for use in non-hazardous area. For precise details about the model of the pump and design operating conditions, see Pump nameplate, motor nameplate & panel name plate when in supply scope and the pump data sheet. Do not operate the pump away from specified operating range. Operating beyond duty point may not pose a risk to the operator but will reduce the efficiency of the pump or damage the pump itself. Operation more than 5 minutes, at close valve condition is not recommended. For hot liquids this is not recommended at all. Please also note that these pumps are not self-priming, which means that the impeller & casing must always be fully filled with fluid to be handled before putting in operation. A dry run must be avoided at all cost. Ensure that always site NPSH-A is more than NPSH-R.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

Product description 3.4

Construction

3.4.1

General description

Split casing pumps are either single, two or three stages. They are of relatively simple construction, the casing being split along the pump axis so that normal maintenance work can be carried out without disturbing the position of either the pumping set or pipe work. The flow of liquid passes through the suction pipe & enters suction branch and reaches the eye of impeller or center of the impeller. The rotating impeller transfers liquid at high pressure and velocity in to the pump casing where the specially designed volute brings about a reduction in the velocity of the liquid. In this way the kinetic energy to the liquid by the rotating impeller is converted into additional pressure energy and the liquid is discharged through the delivery pipe.

3.4.2

Detailed description

3.4.2.1 Casing The pump casing is of volute form, cast in halves, which are bolted together along the pump axis. Gasket paper is provided between the split flanges of top and bottom casing. The suction and delivery branches of the pump are cast integral with bottom half casing, which also incorporate the mounting feet. Tapings are drilled in suction and delivery branches for connecting the pressure gauges and providing casing drain. Bores of bottom half casing are grooved to provide location for neck rings and stuffing box bushes. Tapings are provided in the top of casing for taking liquid seal connection on both stuffing box regions. The top half casings of certain pumps are drilled internally to provide liquid supply between discharge volute and stuffing box. In other cases, alternative arrangements as shown in figure 17 are provided. Tapings are also provided on the top half casing for mounting air cock for venting. Sometimes the pump is installed with vertical shaft. In such installation if the pump is of large size, the top half of pump casing is provided with runner at bottom. These runner slides on rails horizontally. So during overhauling, the top casing can easily moved in to & fro direction.

3.4.2.2 Internal wear allowance To prevent the pumped liquid from the delivery side of the impeller the pump casing is designed with fine running clearances around the impeller eye. These fine running clearances are essential for the satisfactory performance of the pump and their periodic restoration is necessary.

3.4.2.3 Neck Rings To minimize the amount of leakage between high and low-pressure areas of the pump, neck rings are fitted into the casing. Running clearance is provided between neck rings and impeller neck. Neck rings are renewable to allow this fine clearance to be restored periodically as wear takes place. These rings are located in the bottom half casing by a half-spigot/locking pin and are prevented from rotating with the impeller since locked by the face of split flange of top casing.

3.4.2.4 Location & doweling For accurate location casing halves, bearing housings / brackets etc. are located with dowel pins.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

Product description

3.4.2.5 Rotating element The rotating element consists of a shaft on to which is keyed the impeller or impellers. Renewable shaft sleeves abut the impeller hub and protect the shaft from corrosion and erosion. The impeller is locked by sleeve nuts, which have their threads left/right handed as per direction of rotation to prevent them from unscrewing by the rotation of the shaft. The rotating element may be carried in deep groove ball bearings or in split-bush journal bearings, in which case ball thrust bearings or thrust discs and nuts are provided to restrict – axial movement. Bearings are located in housings, which are attached to the ends of the pump casing. When the rotating element is carried by two ring oiled journal bearings, lubrication of the bearings is by oil contained within the housings. These bearings may be in plain leaded bronze or in bronze/CI lined with white metal and are split along centerline. Diametric clearance should be 0.25 mm to 0.3 mm. To permit the journal bearings to be overhauled without completely removing the bearing housings, each bearing housing and bearing bush is split along the axis. In each bearing the top half bearing bush is slotted to accommodate an oil ring, which rests on the shaft and dips into the oil contained by the housing. Rotation of the pump shaft induces rotation of the ring, causing it to pass through the oil. Oil adheres to the ring and is carried up with it to be distributed on the journal surface of the shaft. Non-driving side, journal also supplies oil to anti friction thrust bearing. Stuffing box bushes (stationary part) are provided on either side over the sleeve and located in bottom half casing. This helps in proper guiding of the liquid to impeller eye. Where as back face of stuffing box provides support to gland packing. Logging rings (stationary part) are provided on either side over the sleeve, sandwiched between gland packing located in stuffing box below sealing arrangement. Logging ring provides proper stuffing box sealing arrangement. For 2 stage pumps instead of logging ring leak-off ring / bush is provided at second stage stuffing box. For some of the models the shaft also carries water thrower, oil thrower. Please refer cross section drawing.

3.4.2.6 Gland Sealing To prevent leakage along the shaft at the point of emergence from the pump casing, gland packing or mechanical seals may be fitted in the stuffing box situated at each end of the casing.

3.4.2.7 Driving coupling Flexible coupling is used to transmit the power from motor to pump shaft. The type of coupling used is indicated in the G.A. drawing.

3.4.2.8 Intermediate shafting if applicable For vertical execution pumps, Where the motor is mounted on separate floor away from pump, it is coupled with pump shaft by intermediate shafting. Solid or hollow tube shafting is provided as per the requirement. Intermediate bearings are provided, when the distance is large. The position of intermediate bearings and support plate details are shown in the General Arrangement Drawing. Rigid supporting structure has to be provided at each intermediate bearing location. Alignment of connecting shafts and rigidity of intermediate bearing support structure are important to restrict vibrations within acceptable limit.

3.4.2.9 Bearings- intermediate shafting (if applicable) The solid intermediate shafting is supported by antifriction thrust bearing assembly is provided in the motor stool. If the distance between pump and motor shaft is very large, intermediate bearings are provided at intervals shown in G.A. drawing.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

Handling, Transport & storage

4

Handling, transport & storage

4.1

Handling

In order to prevent damage or serious injury when handling & transporting the product, the following points must be observed: -

Handling & transport work may only be carried out by, qualified personnel. The safety instructions must be followed at all times.

-

Only suitable lifting gear and load carrying equipment with valid test certificates and adequate lifting capacity for the loads involved (such as belts/wire ropes/slings) should be used for lifting & transporting the product. If chains are used, they should be secured against slipping along with protective cover to prevent damage to the product, paint and/or injury to personnel.

-

When lifting the pump in combination with the bedplate, the lifting tackle should be attached to the lifting lugs provided on the base plate side member. To lift the pump the lifting slings should pass beneath the pump body at suction and delivery flanges. See lifting diagram.

-

See also "General Safety Information" in Section 2.

Fig. 1 Lifting diagrams Pumps should never be lifted with slings engaged below the bearing housing. Eyebolts on pump top casing are only for lifting top casing during maintenance. Do not lift complete pump with this. Safe working load of wire ropes reduces with increase in included angle of wire ropes as shown below. Reduction of lifting Capacity with increase in included angle between legs Included 0° 30 60 90 120 angle Lifting 100% 95% 75% 70% 50% Capacity

4.2

Delivery

On arrival, the delivered items must be inspected for damage and a check made that all parts are present. If any parts are damaged or missing, the transport company or the manufacturer must be informed on the day of delivery. Any claim made at a later date will be deemed invalid. Damage to parts must be noted on the delivery or freight documentation.

MPPL/IM/ASCCP/2006/0

4-1

Handling, Transport & storage 4.3

Mather + Platt

Transport

Only the appropriate and approved fastening devices, transportation means and lifting equipment may be used. These must have sufficient load bearing capacity to ensure that the product can be transported safely. The product is delivered by the manufacturer / shipping agency in suitable packaging. This normally precludes the possibility of damage occurring during transport and storage. The packaging should be stored in a safe place if the location used is changed frequently.

4.4

Storage

Short-term storage The equipments as shipped have adequate protection for short-term storage in a covered, dry and ventilated location at the job site prior to installation.

Long-term storage If the equipment will be subject to extended storage condition prior to installation, then the manufacturer must be informed about storage duration, so that special protection can be recommended. The following should be taken into consideration for storage: -

Place the product on firm foundation and secure it against falling. HSC pumps, End suction pumps and multistage pumps should be stored horizontally and Vertical pump assemblies vertically.

Never put down or pick up the product when it is not secured. Bending the product should be avoided at all costs. It can cause major damage to the product and/or serious injury to persons. -

Any suction or delivery pressure connections on products should be closed tightly before storage to prevent impurities.

-

The machine must be protected from direct sunlight, heat, dust, and frost.

-

The rotors or propellers must be turned at regular intervals. This prevents the bearing from locking and the film of lubricant on the mechanical shaft seal is renewed.

If product is to be stored for a longer period, contact M&P for preservation measures to be taken.

4.5

Returning to the supplier

Products, which are delivered to the plant, must be clean and correctly packaged. In this context, clean means that impurities have been removed and decontaminated if it has been used with materials, which are hazardous to health. The packaging must protect the product against damage. If you should have any questions please contact M&P.

Products, which are not suitably packaged on delivery, are no longer covered by guarantee!

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4-2

Mather + Platt 5

Installation

Installation

In order to prevent damage to the machine or serious injury during installation the following points must be observed:

5.1

-

Installation work – assembly and installation of the machine – may only be carried out by, qualified persons. Any errors in fitting or refitting will not pose risks to persons but pump will malfunction or performance of pump will be affected or internals will be affected. The safety instructions must be followed at all times.

-

Before any installation work is carried out, the machine should be inspected for damage that may have occurred during handling, transport & storage.

-

See also “General Safety information”, section 2.

Introduction

This section provides instructions on the recommended methods of installing pumping sets on to concrete foundations. Careful attention must be paid to the customer and contractor’s installation drawings during the installation procedures to ensure that the pumping set is accurately positioned on the correct datum levels. The installation of the pump set may be divided into five stages, namely preparing the foundations, installing the pump, installing the drive unit, alignment, connecting the pipe work and coupling the drive.

5.2

Requirements for the operating area Pumping machinery should have adequate access and working room for maintenance operations. Adequate overhead space for lifting devices and working clearance must be provided.

5.3

Cleaning

Clean any anticorrosive protection from the mounting surfaces using a rag moistened with white spirit.

Do not use any chlorinated solvents such as carbon tetrachloride and trichloroethylene. Bearings, shafts etc should be cleaned and coated with lubricant till such time they are actually taken for installation.

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Mather + Platt

Installation 5.4

Foundations

Installation of the pump cannot be done in continuous sequence because two time periods are required to permit to grout to set. The first period occurs after bedplate has been leveled and foundation bolts half grouted. The second time lag occurs after full grouting of bedplate, which is after final alignment of pump and driving unit after piping. A suitable foundation for the pump must be prepared with pockets to accommodate the foundation bolts. The strength of the foundations must be adequate for the static & dynamic loads imposed and depend upon the local soil conditions. The top surface over which the bedplate rests must be left rough to assist in keying of the final grout and sufficient allowance must be made for the thickness of the steel packing and leveling shims beneath the bedplate, the requirement being approximately 25 mm. Foundation work is usually completed before the pump arrives on site but it is mentioned here because it is logical to begin the installation procedure sequentially.

Indicative drawing for foundation For detail dimensions refer General Assembly drawing. Fig. 2

5.5

Bedplate Pumps and drivers that are received with both machines mounted on a common bedplate are checked for alignment before shipment. However during shipment, storage it may get disturbed. Also bedplates are flexible to some extent and may get distorted during transport and storage. Therefore it is necessary to remove the pump and driver from the bedplate and adapt procedure as given in section 5.5.1, 5.5.2 & 5.6.

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Mather + Platt

Installation

5.5.1 Bedplate checks It is insufficient to check level on the machined pads of bedplate with a spirit level because it is possible that some types of errors will not be revealed or will be accepted as being within acceptable limits. These distortions as showed in figs. 3, 4, 5 & 6. Therefore it is necessary to use I beam straight edge along with engineers master level.

5.5.2 Installation & leveling of bedplate 5.5.2.1

If the base frame is installed directly on the uneven surface of foundation, it could distort. To avoid this distortion and to provide suitable base for leveling, the packer plates should be provided on mother concrete. Minimum requirement being one on each side of foundation bolts. Intermediate packers should be placed at 250 mm center to center. Thickness of MS plates can be between 25 and 35 mm.

5.5.2.2

Once the packer plates are positioned and leveled, place the base frame on them. Insert foundation bolts through hole in the base frame and insert nut. Ensure that bolts protrude sufficiently to accommodate lock nut and they are centrally disposed in the holes.

5.5.2.3

Level the bedplate as follows.

a.

Use “I” beam straight edge and an engineers master level (with accuracy of 0.02 mm / meter) for leveling the bedplate. I-beam should rest on the machined surfaces of the bedplate, or on the leveling pads if provided.

These machined surfaces where level is being checked must be clean and free from paint, burrs etc. b.

Check datum position of base frame as given in G.A. Adjust the level of the bedplate by inserting shims between the bed plate and the packer plate until the bed plate is leveled and supported on all the packing plates at the height required for the connection of suction and discharge branches. For checking the levels across two pads, I-beam type straight edge should be used extensively in conjunctions with engineer’s master level. Level should be achieved within 0.05 mm per 250 mm.

5.5.2.4

When the bedplate is leveled, grout the foundation bolts only. Care should be taken so as not to disturb the verticality of foundation bolts. For grouting use rich mix of 1: 1:2 of cement, sand and gravel below 12 mm. Alternatively quick setting grout mix can be used.

5.5.2.5

When the grout has set, gently but firmly tighten the foundation bolts. Care must be taken not to distort the bedplate or loosen the foundation bolts in the grout by excessive tightening.

5.5.2.6

Carefully re-check the level of the bed and make adjustments that are necessary by fine shimming

5.5.2.7

Position the pump and motor on the bedplate.

5.5.2.8

Refer instruction manual of coupling & motor manufacturer.

5.5.2.9

When the bedplate is leveled and the satisfactory-alignment is completed, proceed with connection of suction & delivery piping. Recheck the alignment after piping and run the final grout beneath the bedplate. Allow minimum seven days time for curing. Grout mix in the proportion specified earlier for foundation bolt grouting should be used. It is further recommend that All hollow pockets in the bedplate shall be filled after curing of earlier grout.

5.5.3 Pumps operating at high temperature Pumps, which operate at high temperature, e.g. boiler feed duty, are supported on feet machined in line with the center of the shaft, which prevents expansion causing misalignment. Transverse and longitudinal keys are provided to locate the pump on the bedplate. The holding down bolts securing the pumps to the bedplate are arranged to allow the feet to slide during expansion either by using spring washers or by locating the nuts on the bolts without nitting the feet.

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Installation 5.6

Alignment of pump and driving units:

The following procedures outline recommended practice given in BS-3170 in 1972 (Appendix A) for checking shaft alignment. This method is independent of the truth of the coupling or shaft and is therefore not affected by canted coupling faces or eccentricity of the outside diameter of the coupling. Before commencing the alignment, rotate each shaft independently to check that the bearings run freely and that the shaft is true to 0.1mm or better. Check that no damage can be caused when the shaft of the driven unit is turned. Coupling should be loosely coupled and the halves must be free to move relative to each other, otherwise gauge Indicators can be incorrect. Where, tightly fitting pins or spring prevent loose coupling, the springs or pins should be removed and a line scribed across both half couplings and readings taken only when the two marks are aligned.

Before proceeding for alignment please ensure: a. For bush bearing protective paper between bearing and shaft is removed, bearing housing is cleaned and flushed with oil. b. Bearings are properly lubricated. c. Pumps with stainless steel internals shaft should be rotated only after taking pump liquid inside the casing. Any dry rotation may cause severe damages to pump internals.

5.6.1 Angular alignment After isolating the driven unit from its power supply, clamp two dial indicators are dramatically opposite points on one half coupling or to the shaft behind it with the plunger resting on the back of the other half coupling. (See figure10) Rotate the coupling unit the gauges are in line vertically and set the dial to read zero. Rotate the coupling by 180 and record the readings on each gauge. The readings should be identical, though not necessarily zero. Either positive or negative readings are acceptable provided they are equally positive or negative. Adjust the position of one of the units if necessary. Rotate the couplings unit the gauges are in the line horizontally and adjust the dial to zero. Repeat the operation outlined above by rotating the coupling by 180°.

5.6.2 Radial alignment Clamp a dial gauge on one of the couplings or to the shaft as shown in figure 11 with the plunger resting on the rim of the other half coupling. Set the dial zero. Rotate the coupling and note the reading at each quarter revolution. Any variation in the readings indicates the deviation from alignment and the position of one of the units must be adjusted until the readings at each quarter revolution are identical or within the tolerances given below.

5.6.3 Alignment tolerances a b c

Pump speed < 1000 rpm > 1000 rpm to 1800 rpm 1800 rpm to 3000 rpm

Angular alignment 0.15 mm TIR 0.1 mm TIR 0.05 mm TIR

Radial alignment 0.15 mm TIR 0.15 mm TIR 0.1 mm TIR

TIR- Total indicated reading The above tolerances are general guidelines since it may very with different types of coupling and its manufacturer’s standards. However it is recommended that for higher speeds greater degree of accuracy must be observed. If the pumps are used for hot liquid or there is chance of disturbance in the alignment due to piping temperatures, hot alignment should be carried out. All the alignments (angular as well as radial) have to be carried out by using 3 dial indicators, simultaneously. MPPL/IM/ASCCP/2006/0

5-4

Mather + Platt

Installation

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig.7

MPPL/IM/ASCCP/2006/0

Fig. 8

5-5

Mather + Platt

Installation Couplings Flexible couplings

Pin Bush Coupling

Spacer coupling

Fig. 9

Alignment of Coupling

For detecting this type of error

To check the parallelism of axis (Angular alignment)

Fig. 10

For detecting this type of error To check intersection of axis (Shafts inline at coupling end)

Fig. 11

MPPL/IM/ASCCP/2006/0

5-6

Mather + Platt 5.7

Installation

Pipe work

No stress must be imposed on the pump casing by the pipe work; either by the weight of the pipes or by the tightening of badly fitting pipes (figure 12). Experience has showed that such stress can seriously affect the alignment of the pump unit. All pipe worked attached to the pump must be fully supported and the mating faces of the pipe flanges must be parallel and all bolt holes coinciding with each other. It is important therefore that alignment of the pump and motor should be re-checked after the pipes are finally fitted. Resetting or supporting the pipes must correct any deviations in the alignment.

Alignment of pump casing with pipe work Fig. 12

5.7.1 Suction condition Intake design Pump intake by way of open channel, tunnel, sump or a tank should supply evenly distributed vortices free flow with adequate submergence of pump suction pipe. A centrifugal pump can perform properly only if it is supplied with a steady flow of liquid at the suction flange with sufficient pressure to provide adequate NPSH to the pump and with a uniform, non-swirling velocity profile. The failure of suction piping to deliver the liquid to the pump in this condition can lead to noisy operation, random axial load oscillations, premature bearing failures, cavitations damage to the impeller and casing inlet portion. It may also damage discharge side due to liquid separation. Suction pipe velocity Suction pipe velocity should not exceed the velocity in pump suction nozzle. Pipe velocity may need to be reduced further to satisfy pump NPSH requirements and to control suction pipe losses. With pipe velocity in the 5 to 10 ft/sec range, and with suction piping containing valves fitting and bends, straight pipe length of minimum five diameters may be required to ensure uniform flow to pump suction. Use of strainer in suction piping If strainer is used it should have opening area which is three times the area of the upstream pipe. Differential pressure gauge / switch should be fitted across strainer to monitor any chocking and resultant pressure drop. It is advisable to connect this to operation logic of pump. The suction pipes should be as short as possible and when dealing with cold liquids, the total suction including friction should not normally exceed 15 feet. Mather & Platt pumps will deal with a suction lift as great that dealt with by similar pump of any other make but extensive experience has proved that it is not advisable to exceed 15 feet suction lift under working conditions without the approval of Mather & Platt design department. MPPL/IM/ASCCP/2006/0

5-7

Mather + Platt

Installation

An arrangement of suction pipe work, which is common to two or more pumps operating on suction lift, is not recommended. If such an arrangement is unavoidable, any possible points of air ingress, such as valve and glands should be liquid sealed and isolating valves should be fitted at the appropriate points. The arrangement of a pump, which is to handle hot liquids, should be such that the liquid flows into the pump under pressure. The pressure must be increased with temperature of the liquid. When the diameter of the suction pipe is bigger than that of pump suction branch, the form of taper pipe used must not allow the formation of air pocket. To avoid the formation of air pocket, the installation of suction pipe work must be arranged under the following conditions: a b c

With as few bends as possible. Suction pipe work must be perfectly air tight There must be a gradual rise in the suction pipe work.

Typical good and bad arrangements are shown in figure 13. The inlet of the suction pipe must lie well below the lowest possible water level and it must be fitted with a foot valve and strainer. The strainer must be clear of the bottom and sides of the well or sump, so that deposits of sediments or grit are not drawn into the pump. The foot valve should be of the free opening type preferably of the hinge flap design to work in a horizontal or vertical position. Velocity of water should not be greater than 6 feet per second for a 6" bore valve, 7 feet per second for valves between 6" and 14" bore and 8 feet per second for valves above 14" bore. The strainer should be of rugged construction with holes in the sides, suitable for the type of the liquid to be passed. For clean liquid the cumulative area of these holes should not be less than twice the area of the bore of the pump suction branch. Where the liquid is known to contain a high percentage of solids, the area of the holes should be much greater. It may even be necessary to provide special apparatus, such as traveling screens, to ensure that the pump is kept free of solid foreign matter. When pumps are expected to operate on positive suction head, foot valve is not necessary. However, at site, if liquid level falls below the minimum water level mentioned in the drawing, the pump should not be started.

If required suction sump model study should be done.

5.7.2 Delivery conditions A suitable sluice valve should be fitted in the delivery pipe as near to the pump as possible, along with non-return valve. Pump casings have sometimes been cracked by pressure surges imposed on them through the absence a non-return valve. It is often an advantage to provide these valves with by-pass connections, although these are not always required.

5.7.3 Stuffing box packing Pumps are dispatched from our Works with the stuffing boxes unpacked; otherwise, packing will be aged. The packing is packed with greaseproof paper and dispatched with the pump. The softest possible packing i.e. plaited cotton impregnated with oil and colloidal graphite is recommended for most duties. Required number of lengths of packing should be cut off so that each length will pass once round the shaft sleeve line and meet to end. The ends of packing must be cut square. After cleaning the stuffing box and shaft sleeves the packing should be inserted into the stuffing box. Each ring should be pushed into position individually using the glands joint of each ring must be positioned 180° from joints of its neighbor. If a logging ring is included in them arrangement should be inserted into the stuffing box at the appropriate time during the packing sequence so that it is aligned with the cooling water connection. The gland should now be fitted square with the pump casing and the nut should be screwed up to little more than finger tightness.

Packing should be handled with care and it should not be allowed to pick up the dust or abrasive matter by coming into contact with floors or dirty benches. It is bad practice to hammer packing to facilitate the insertion.

5.8

Use of diesel engine as prime mover The location of installation should have facility for disposal of exhaust gases and supply of continuous air. Pump house should have acoustic design.

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5-8

Mather + Platt

Installation

Examples of good & bad suction layout

Fig. 13

MPPL/IM/ASCCP/2006/0

5-9

Mather + Platt 6

Start-up

6.1

Introduction

Start-up

This chapter covers the commissioning and operation of pump only. For commissioning of motor, engine, turbine & electrical panels respective instruction manuals should be referred. This procedure also should be adapted after each major overhaul. See also “General Safety information”, Section 2.

6.2

Pipe work flushing

Before the pumps are brought into service, either on initial commissioning or on re-commissioning after overhaul, the pipe work associated with the pumps must be flushed through. This will clear deposits or scales which may have accumulated in the pipes, and which could damage the internal components of the pumps.

6.3

Cleaning of bearings

Where possible, especially if the unit has been in store for a long period before commissioning, the bearings should be cleaned and flushed out with clean white spirit or good quality paraffin. Waste should not be used for this purpose, as particles of foreign matter may be left behind which would cause damage when the bearing is in service. Bearings should be then filled with recommended grade and quality of fresh lubricant to the level. Refer list of lubricants at the end of this manual. Ball and roller bearings are given an initial charge of grease before leaving Mather & Platt Works and do not require any attention beyond the normal greasing routine before the first servicing period. Only greases selected from the table at the end of the manual or their equivalent should be used. Bearings should never be over greased.

Pumps fitted with prelubricated, sealed bearings do not require external lubrication for life.

6.4

Direction of rotation

Disconnect the drive coupling and run the motor to check its direction of rotation. A directional arrow is provided on the pump unit.

6.5

Priming

These centrifugal pumps are not self-priming type. The efficient operation of a centrifugal pump depends upon fine running clearances, which are lubricated by the pumped liquid. Priming can be done either by running vacuum pump or by external water supply.

Any attempt to run the pump dry or partially full may result in seizure of the rotating internal components. These pumps must therefore be properly primed before starting, with venting of all the air, gases, vapor etc.

6.6

Pumps Operating on Flooded Suction Head

When these pumps operate on a flooded suction head, all that is required to prime them is to open the air release valve situated on top of the pump casing, open the pump inlet isolating valve and vent the air out of the casing. When the liquid issues from the air vent, free of air, the pump is properly primed. The air vent must be closed after priming and before the pumping set is started.

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Mather + Platt

Start-up 6.7

Pumps Operating on Negative Suction Head

There are two methods of priming pumps that draw their liquid from an elevation lower than the pump inlet branch: 6.7.1

If the inlet pipe work is fitted with a non-return foot valve, the pump casing and inlet pipe work can be filled with liquid from an external source under pressure. The pressure imposed on the pump by this method must not exceed that for which the pump is designed. In certain cases priming can be achieved by flooding back from the delivery side of the pump.

6.7.2

By exhausting air or gas from the pump casing. To enable this method to be used, the gland arrangement must be sufficiently gas-tight or they should be liquid sealed from an external supply. For operation details of gas exhausts reference should be made to the manufacturer’s instructions. Some form of priming indicator is usually fitted to indicate when the priming operation is complete.

6.8

Pumps operating on hot liquids

As stated in Section 5.5.1, pumps operating on hot liquids are usually so arranged that the liquid flow into the pump under pressure. If the saturation pressure of such liquids is above atmospheric pressure, any attempt to prime the pump will result in the liquid "flashing" from the air cocks. For these reasons, the air cocks at the top of the pump casing should be left slightly open when priming boiler circulating pumps until all air has been driven out of the casing. The cooling water services of a pump handling hot liquids should be turned on before the pump is primed. These services may supply cooling water to the bearings and / or stuffing boxes. Where the services are functioning, open the inlet valves and start warming the pump throughout. Never cut off the water services while the pump is "on temperature". Where bearings are water-cooled, adjust the cooling water supply until the bearings have a running heat. Over-cooling may lead to condensation of moisture from the atmosphere inside the bearing with consequent contamination of the oil. The suction sluice valve, if provided, must be fully open and the delivery sluice valve must be closed.

6.9

Pre-starting checks

6.9.1

Ensure that sufficient fluid is available at the pump suction for satisfactory operation of the pump. Efficient operation of the pump depends upon the running clearance, which are lubricated by pumped liquid. Any attempt to run the pumps dry or partially full will result in seizure of internal rotating components.

6.9.2

Check that the inlet isolating valve is open and that the delivery valve is closed.

6.9.3

Ensure that bearings have been filled with proper grade of lubricant.

6.9.4

Check that there is no blockage in the strainer at the end of the suction line.

6.9.5

Check for free rotation of the unit when coupled.

6.9.6

Check that suction and delivery pressure gauges are connected. Test and make available any alarm, signals, interlock systems and any of the protective devices incorporated in the auxiliary and main pumping control system.

6.9.7

Ensure that all electrical checks on motor, relay setting in panel etc have been carried out in accordance with the instructions of motor manufacturer.

6.9.8

Ensure that stuffing box sealing water seal connection is provided as shown in GA Drawing.

6.9.9

Check that priming procedure detailed in 6.5 has been carried out.

Refer checklist A.6 for recording the data.

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Start-up

6.10

Normal Starting checks

6.10.1.

When all the foregoing pre-start checks are satisfactory, depress the appropriate `START' button on the control panel and run the pump at its rated speed.

6.10.2.

Check that the pump is rotating in the correct direction. This is indicated by, a direction arrow on the pump casing.

6.10.3.

Check the ammeter reading to ensure that the motor is not being

6.10.4.

Check that the pumping unit is generating not less than its rated delivery pressure indicated in the data sheet/name plate.

overloaded.

If the pumping unit fails to generate at least it’s rated delivery pressure it must be stopped immediately, the cause ascertained, the fault rectified and the pumping unit re-primed before restarting. 6.10.5.

Ensure that the stuffing box is not overheating and that there is slight leakage from the gland. There may be at first a tendency for the stuffing boxes to run warm because of the high viscosity lubricant in the packing. During the first few minutes of running with new packing, a small quantity of very viscous fluid will be extruded, but the flow should cease when the packing has settled down.

6.10.6. Check that the oil is being carried to the bearing bushes by the oil rings in case of bush bearing. 6.10.7.

Check that the bearing is not overheating. The ideal running temperature of bearings is 40 ˚C to 60 ˚C for ball bearings and 40 ˚C to 55 ˚C for bush bearings. This ideal figure may be extended provided the temperature is steady and not rising, but on no occasion should the temperature exceed 82 ˚C for all bearings and 75 ˚C for bush bearings. Overheating of ball and roller bearings is frequently caused by over packing them with grease. An Increase in the running temperature after adding grease is normal, but the temperature should return to its previous level, as the grease is distributed.

If the bearings are overheating its cause should be investigated immediately. 6.10.8.

If the foregoing checks are satisfactory, open the delivery valve slowly and bring the pump gradually up-to its rated parameters based on pressure gauge and ammeter readings. Unless the pump is fitted with a special leak-off device, it should not be run for a long period against a closed delivery valve.

6.10.9.

Check that the driving unit is not being overloaded during valve

opening.

Overloading may occur if the pump is discharging into an empty system when the delivery head will be temporarily lower than that for which the pump is designed. Careful regulation of the discharge valve until the system is fully charged will prevent this. 6.10.10.

Check vibration of pump set and ensure that vibration level is within limits specified in Hydraulic Institute Standard of America. Check that noise level is within stipulated limits.

6.10.11.

Check the pump and motor for overheating, excessive vibration and noise. Report any faults. During first commissioning, the pumps may be run for 8 hours trial operation and all the parameters like delivery pressure, current, bearing temperature, etc. Be recorded periodically.

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Mather + Platt

Start-up 6.11

Running Checks

Once the pump is started and duty conditions are set, operator intervention is not required except running checks and unless pump is to be stopped. Make the following checks at regular intervals. It is recommended that they be made at every change of shift. 6.11.1.

Check the suction and discharge pressure gauge for normal operating pressure, if there is significant drop in the suction or discharge pressure the pump may have lost its supply. In the event of this fault occurring, the pump must be stopped immediately and the cause of liquid loss eliminated.

6.11.2.

Check the stuffing box assembly for overheating.

6.12

Normal Shutdown

6.12.1

Close the delivery valve to reduce the load on the driving unit.

6.12.2

Depress the appropriate STOP button on the control panel.

6.12.3

When the pump has come to rest, close the suction-isolating valve.

6.12.4

Isolate any ancillary supplies.

6.13

Emergency Shutdown

In the event of any malfunction of the equipment, trip the pump set. When the pump has come to rest, close the suction & discharge valves, isolate the driving unit power supply & rectify the fault.

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Start-up

Fig. 14 LE & ME Split casing pump Ref 4580 4250 4230 3250 3200 3032 3031 3020 3010 3002 3001 2884 2764 2761

Description Safety guard “O” ring Air cock Coupling key Impeller key Sleeve nut (R.H.) Sleeve nut (L.H.) Locking washer Lock Nut Cowl Nut (R.H.) Cowl Nut (L.H.) Thrust collar Bearing housing (N.D.E.) Bearing housing (D.E.)

Ref 2754 2751 2600 2410 2310 2300 2100 2070 1800 1500 1181 1002 1001

See Fig. 16 for different bearing alignment.

MPPL/IM/ASCCP/2006/0

6-5

Description Bearing end cover (N.D.E.) Bearing end cover (D.E.) Deep groove ball bearing Gland packing Gland Lantern ring Shafts Sleeve Water deflector Shaft Impeller Neck ring Casing-bottom half Casing-Top half

Mather + Platt

Start-up

Fig. 15

Alternate Stuffing Box Sealing arrangement

Fig. 16 MPPL/IM/ASCCP/2006/0

6-6

Mather + Platt

Start-up

Fig. 17 cross sectional drawing 3 /4 & 4 /5 two-stage Medivane pump Schedule of parts Ref Description 4580 Safety guard 4250 “O” ring 4230 Air cock 4090 Grease nipple 3250 Coupling key 3200 Impeller key 3032 Sleeve nut (R.H.) 3031 Sleeve nut (L.H.) 3020 Locking washer 3010 Lock Nut 2884 Thrust collar 2764 Bearing housing (N.D.E.) 2761 Bearing housing (D.E.) 2801 Intermediate bearing bush 2756 Bearing end cover (N.D.E.) Outer 2755 Bearing end cover (N.D.E.) Inner 2753 Bearing end cover (D.E) Outer

MPPL/IM/ASCCP/2006/0

6-7

Ref 2752 2602 2600 2410 2402 2310 2300 2111 2100 1953 1800 1504 1503 1181 1002 1001

Description Bearing end cover (D.E) Inner Cylindrical roller bearing Deep groove ball bearing Gland packing Stuffing box bush Gland Lantern ring Spacer sleeve Shafts Sleeve Water deflector Shaft Impeller 2nd stage Impeller 1st stage Neck ring Casing-bottom half Casing-Top half

Mather + Platt

Start-up

Fig. 18 cross sectional drawing 9 /11 two-stage Medivane pump Schedule of parts Ref Description 4580 4230 3250 3200 3032 3031 3021 3010 3002 3001 2910 2834 2820 2801 2791 2760/1 2760 2756 2700

Safety guard Air cock Coupling key Impeller key Sleeve nut (R.H.) Sleeve nut (L.H.) Locking washer Lock nut Cowl nut (R.H.) Cowl nut (L.H.) Bearing cap Intermediate bearing sleeve Oil ring Intermediate bearing bush Dust cover Bearing housing (ball) Bearing housing (bush) Bearing end cover (N.D.E.) outer Bearing bush

MPPL/IM/ASCCP/2006/0

6-8

Ref

Description

2652 2651 2601 2410 2315 2310 2300 2103 2102 2070 1800 1509 1506 1181/1 1181 1003 1002 1001

Ball race spacer Ball race carrier Angular contract ball bearing Gland packing Junk ring inner Gland Lantern ring Suction sleeve Delivery sleeve Water deflector Shaft Impeller delivery 2nd stage Impeller suction 1st stage Neck ring 2nd stage Neck ring 1st stage Cross over pipe Casing - bottom half Casing - Top half

Mather + Platt 7

Maintenance

Maintenance

See also “General Safety information”, Section 2.

7.1

Routine maintenance & frequency of inspection

Centrifugal pump requires very little routine maintenance beyond periodic replenishing of grease in the bearing assemblies. However, serious troubles can be often avoided by regular observation and analysis of various working parameters. Some of the routine maintenance checks for this purpose are as under:

7.1.1

To keep daily logbook records of working parameters like suction and discharge pressure, flow rate, current drawn, bearing temperature, etc. These parameters should be recorded twice a shift. Any sudden change should be a signal for investigation. Refer Section A.2 for Maintenance & Inspection log.

7.1.2

Bearings will normally run at a temperature of 30˚C -35˚C above ambient temp. The ideal running temperature of bearings is 40 ˚C to 60 ˚C for ball bearings and 40 ˚C to 55 ˚C for bush bearings. This ideal figure may be extended provided the temperature is steady and not rising, but on no occasion should the temperature exceed 82 ˚C for all bearings and 75 ˚C for bush bearings. Overheating of ball and roller bearings is frequently caused by over packing them with grease. An Increase in the running temperature after adding grease is normal, but the temperature should return to its previous level, as the grease is distributed.

7.1.3

Vibration & sound level readings should be taken once in a fortnight and values compared with that of previous records.

7.1.4

Check that there is sufficient leakage from the gland packing to ensure proper cooling and lubrication.

7.1.5

Pump bearings should be replenished with correct grade of grease after every 1000 Hrs. Grease should be changed completely after every 3000 hours or as required by site condition. Recommended type and grade of grease is indicated in section 7.4.

7.1.6

For any abnormality observed from the visual/manual inspection and through maintenance & inspection logs, stop the pump and investigate.

7.1.7

Fault Finding - Many of the common faults which occur on centrifugal pumps and which can be diagnosed by observations are given in the chart under section 8.

In case fault can not be diagnosed, please fill up the Issue/Feed back report no SR01-02 and send to service department at Mather & Platt headquarters at Pune / nearby regional office or the representative within EEA. After a long period of service, wear will occur in parts of the pump, necessitating the renewal of a few components. Parts, those are most likely to be affected are impeller/ wearing ring, bearing, neck rings, impeller distance sleeves and stuffing box bushes. Logbook records will indicate wear as gradual deterioration of performance is noticed. Once this is known, pumps should be taken for overhaul. It is recommended that yearly stripping & checking of wear & tear and clearances should be done and overhauling where required.

MPPL/IM/ASCCP/2006/0

7-1

Mather + Platt

Maintenance 7.2

Overhaul maintenance

7.2.1 General information It is inevitable after long service that certain components will become worn. Frequently it is more economical to renew the worn components completely, but where site machining and engineering facilities are available most components can be restored if wear is not too far advanced. It is impossible to be mandatory regarding the periods at which major overhauls should be undertaken as this will be dependent upon the fluid being pumped, the site operating conditions, and the length of operational availability required. The determination of when major overhaul should be carried out will depend upon the performance of the pump, i.e. its rate of deterioration by reference to instrumentation, during the current operational period. If the hydraulic or mechanical performance has deteriorated to such an extent that no further deterioration can be tolerated during the next operational period, wearable components should be renewed. If related pair of components show a marked degree of wear in relation to the rest of the unit, then it may be sufficient to renew only the heavily worn components. If the wear is uniform throughout the pump, then all wearable components may require renewal. Measurements should be taken and recorded of all wearable components at the first, and every subsequent overhaul period. Reference to these records will enable an accurate assessment of the rate of wear to be made, and a reasonably accurate forecast regarding when a particular component may require renewal can be made. Information regarding original design dimensions and clearances is furnished in data sheet. Any other information if needed can be obtained on application from Service Department, Mather & Platt Pumps Ltd., Chinchwad, Pune 19, India. Such request must quote nameplate number and type of the pump in question. The parts most likely to be affected are: 1. 2. 3. 4. 5. 6.

Impeller. Neck Rings. Bearings. Sleeves. Stuffing Box Bush. Coupling bushes.

Before commencing dismantling operations, ensure that the following tools and tackles are available. 1.

A crane / chain pulley block suitable for handling the weight of pumping unit.

2.

A selection of ring and open-ended spanners in British, American, and Metric sizes.

3.

Eyebolts in British and Metric sizes.

4.

Cotton rope, wire rope and slings.

5.

Hardwood and metal packing blocks.

6.

Miscellaneous tools including a set of Allen keys, drills, pin

7.

Extractor / puller for bearing and coupling.

drivers, files etc.

After a long service, wear will occur in parts of the pump necessitating the renewal of the parts. Those most likely to be affected are impeller, Wear rings, bearings, and sleeves.

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Mather + Platt

Maintenance

7.2.2 Dismantling the pump top casing a.

Isolate the pump motor electrically.

b.

Isolate the pump system by closing suction and delivery valve.

c.

Remove two dowel pins and the split flange nuts.

d.

Remove nuts of split gland from both ends and slide away the gland. Remove gland packing as well as logging ring.

e.

Remove all fasteners joining top & bottom casing. Connect suitable lifting tackles to the eve bolts provided on top half casing. Remove the casing joint gasket.

7.2.3 Dismantling The Rotating Element To completely dismantle the rotating element proceed as follows: Remove the coupling screws / nuts, for coupling dismantling procedure refers Appendix 1. Remove both the bearing housing top half after removing setscrews and dowel pins. Rotating element can now be lifted clear off the casing along with neck rings and ball bearing. Ensure that it is lifted off the casing evenly and does not twist; otherwise the neck ring may be damaged. Place and support the rotor on wooden cradle in horizontal position. Pump half coupling now is withdrawn from the spindle; if necessary by using proper tackle like coupling puller. The coupling has a parallel bore and with a transition fit. Remove the coupling key. After removing coupling proceed as follows: a.

Dismantle both the inner and outer bearing end covers.

b.

Remove lock nut, lock washer, inner and outer spacer rings from the free end and side (Non-driving end).

c.

Remove the bearings using some form of extractor or puller. This must act directly on the inner race of the bearing to be removed. Never try to the inner race of the bearing by applying force to the outer race.

Unnecessary removal of the bearings should be avoided because removal of the bearing can damage it and cause deterioration of the interference fit. Except where removal is necessary to give access to the other parts, bearing should be removed only if they need close inspection. Symptoms, which will indicate the state of bearing, are the condition of the lubricant, the bearing running temperature, noise level and vibration during operation. d.

Take off the casing rings & (bearing bush & bearing carrier where applicable).

e.

Remove the water deflector and thrower from spindle from both sides.

f.

Unscrew and remove the sleeve nuts on both side and slide off the impeller & distance sleeve. If difficulty is experienced in withdrawing the sleeves, they may be drawn off with the impeller. It may be even advisable to apply some heat for easy withdrawal.

g.

Remove the impeller. It may be necessary to apply heat to the impeller for the removal. Apply heat uniformly from the shrouds inwards towards the hub. Before removing the impeller put a reference mark on the shaft for ease of reassembly at correct center position.

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Mather + Platt

Maintenance

7.2.4 Examination Of Internal Components With the pump and rotating element dismantled, the internal components and clearances can be checked.

7.2.5 Casing neck ring Use an internal micrometer to measure the bore of casing ring, taking measurements at intervals around the circumference to check for uneven wear. A comparison between this dimension and that of the impeller neck will indicate the amount of diametrical clearance between the casing neck ring and the impeller neck. If this clearance is 150% or more than the original design clearance, or if the deterioration in hydraulic performances has been such that no further deterioration can be tolerated during the next operation period, The impeller-wearing ring to casing neck ring clearance must be restored to the original design value by fitting small- in-bore neck rings, bored out to suit the diameter of the impeller.

7.2.6 Shaft Sleeves The shaft sleeve should be examined to see if it is grooved or generally worn. The outside diameter of the sleeve should be measured and a comparison made with the bore of the stuffing box bush through which the sleeve passes. The amount of clearance between the two can thus be checked to determine whether or not it is within acceptable limits.

7.2.7 Impeller and wearing ring a.

Inspect the impeller as follows: i. Examine the impeller for damage. ii. For corrosive /erosion pitting. iii. Cavitations pitting. iv. Bent or cracked vanes, inlet and outlet vane end wear.

Any of the above may be repaired, or if damage is extensive, impeller may need replacement. Further information should be sought from M + P, Service Dept. Chinchwad, Pune before any decision on repair work is taken. b.

Around the eye, wearing rings protects the impeller. Examine around the eye at neck portion for grooving in alignment with spindle axis; slight grooving is acceptable but deep or profuse grooving must be remedied by machining the impeller by taking a polish cut on wearing ring. Spare wear rings are supplied with excess outside diameter to facilitate machining after fitting. The wear rings are shrink fitted on impeller neck and are screwed.

c.

To check wear, around the impeller neck, use precision instruments such as out side micrometer to accurately measure the outside diameter. Measurements should be taken at intervals around the circumference to check the uneven wear. Differences between the neck OD and the neck ring ID measured will give us the clearance between the two. Clearance thus obtained should not be more than 150% of maximum designed clearance.

7.2.8 Shaft & keys Shaft should be checked for the trueness, or any other mechanical damage and corrosion. If the shaft is not true within 0.1 mm TIR, it should be replaced / repaired. Examine the shaft keys and key ways. Remove damaged or worn out keys.

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Mather + Platt

Maintenance

7.2.9 Bearings a.

Clean all the components using clean white spirit. Do not use chlorinated solvents such as trichloroethylene and carbon tetrachloride because they introduce a corrosion risk when used on ferrous materials.

If these chemicals are present for any reason a' No Smoking' rule must be strictly enforced. (CHLORINATED SOLVENT FUMES + TOBACCO SMOKE = TOXIC GAS). b.

Visually inspect the bearing. The balls, the inner and outer tracks must all be free from chipping, cracks, abrasions or discoloration.

c.

Check that the parts of the cage are firmly fixed together.

d.

Visually inspect the bore for any sign of damage. Burrs or any scratches caused during bearing withdrawal should be carefully removed by hand application of a fine oil stone, the treatment being confined to the minimum possible area.

e.

Visually inspect the outside diameter for signs of fretting, any stains may be carefully polished off, but abrasion must be kept to the absolute minimum that is required, followed by cleaning.

f.

Check that bearing rotates freely and smoothly. If there is any doubt regarding the serviceability of the bearing it should be replaced.

g.

Inspect the Bearing Cage as follows:

i

Visually inspect the bore for any signs of fretting, any stains may be carefully polished off, but abrasion must be kept to the absolute minimum that is required, followed by cleaning.

ii

Where fretting has occurred, bearing and housing should be clean and dry, and trial assembled. It is a transitional fit and may be described as a sucking fit without any detectable clearance or play between the outer race and the housing bore. Any assembly, which achieves this, may be considered as being acceptable, provided the bearing is serviceable. Assemblies, which do not achieve this degree.

An incorrect fit can allow one or both of the bearing tracks to creep, which will affect the running accuracy and the assembly and dismantling of a pump. Creep is the slow rotation of one track relative to its seating, it is undesirable since the spindle and the bore of the bearing or the housing and the outside -diameter of the bearing may become worn. Creep is not due to friction within a bearing but is generally caused due to radial loads rotating or oscillating in respect to fixed point on the track. If creep has occurred the interference fit of the bearing must be restored, either by metal spraying or chromium plating and regrinding the seating to the correct diameter; interference fits must not be simulated by knurling, scoring or distortion of the seating on which creep has occurred because such practices are ineffective and creep will quickly reoccur. Even if the bearing is prevented from creeping it will usually be distorted by the seating, and failure will result caused by local overloading and high frequency vibration. h.

Examine the abutment. Abutment for ball bearings must be flat and square with the axis-of rotation. The radius at the root of an abutment must be smaller than the corner radius of the track located against the abutment. The edge of the abutment must be reduced or chamfered; a burred edge can tilt or distort a bearing track.

i.

If after inspection, the bearing is reusable, completely coat all parts with rust preventive oil, working it well into the internal parts of the bearing. Wrap in clean greaseproof paper and store until required for replacement or refit on to the spindle if needed. In case of immediate use, coating of rust preventive oil is not necessary.

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Mather + Platt

Maintenance 7.2.10 Journal Bearings

Under normal conditions the shaft journals of the rotating element are uniformly loaded and provided that an adequate supply of clean oil is maintained with the bearing housings, the bearing will usually operate until wear is approximately 150% the original design clearance without detriment to mechanical performance of the pump. The most positive indication of the loss in bearing efficiency will be given by an increase in level of vibration. This increase may be gradual and difficult to detect or sudden and prominent. But when an increase is detected the reason must be investigated because it is a symptom that the bearings may require renewal even if the allowable degree of wear previously indicated has not been reached. The white metal lined bearing bushes should be inspected for: a.

Excessive clearance by measuring clearance between shaft journal and bush bearing.

b.

Deep axial or radial grooving which can lead to interrupted oil supply.

c.

Chipping of white metal lining. If clearance has become excessive or if bearing is not usable the same must be renewed.

After renewing the bushes, blue matching must be achieved with the shaft to ensure check clearances and maintain the record.

uniform contact. Also

7.2.11 Stuffing box bush Check bore of stuffing box bush and compare with sleeve diameter. If "clearance is excessive, the bush should be renewed.

7.2.12 Reassembly of rotating element If rotating element has been completely dismantled, the correct position for the impeller must be established as marked on the shaft prior to dismantling. Then commence re-assembly as under. a.

Fit the impeller key in the keyway of the spindle.

b.

Fit the impeller on the spindle in correct position.

c.

Fit the impeller distance sleeve on both sides of impeller to engage; with impeller key and tighten the sleeve nuts.

d.

Slide the neck ring on the spindle on both sides.

e.

Slide the stuffing box bushes on both sides. Slide the water thrower I deflector and inner bearing housing end covers on the shaft, one at each end.

f.

Slide the thrust collar and fit the thrust ball bearing on the shaft at free end in the cage. Slide the inner and outer spacer rings. Warm the bearing for ease. of fitment.

g.

Fit lock nut and lock washer on free end and tighten it fully.

h.

Bend back the tab of locking washer onto locknut.

i.

Slide the bearing on the D.E. side & locate the same in position.

While assembling stainless steel component, molybdenum-disulphide paste should be applied to prevent galling / seizure and also to facilitate easy removal in future.

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Mather + Platt

Maintenance

7.2.13 Re-assembly of the pump a.

Ensure that casing is clean, dry and free from foreign matter. Clean casing neck ring and stuffing box bush seating thoroughly and ensure they have no burrs.

b.

Carefully lower the element into the bottom half casing.

c.

Ensure that casing neck rings enter their half grooves in the bottom half casing.

d.

Ensure that stuffing box bushes enter their half grooves in bottom half casing.

e.

Fit the dowel pins of the both bearing housing and ensure that the spindle rotates freely and then tighten all the bearing fixing setscrews.

If the shaft does not rotate freely, the cause must be investigated and the fault rectified. f.

Fix at the drive end and free end, water throwers, dust covers and outer end covers to bearing housing by their setscrews.

g.

Cut a gasket from 0.25 mm thick black joint paper or similar gasket material and locate on flange of bottom half casing.

h.

Lower the top half casing by crane or chain pulley block on the bottom half casing.

Fit the split flange studs. Align dowel holes and fit dowel pins before tightening the nuts. The nuts must be tightened evenly in the diagonally opposite sequence.

During the tightening up procedure a careful check must be made to ensure that the rotating element continues to rotate freely. Any sign of stiffness or bending must be investigated immediately and the cause eliminated. i. j.

Insert gland packing, logging ring in proper sequence. Fit studs and split gland on both sides. Reconnect sealing water lines to stuffing boxes.

7.2.14 Final assembly a. b.

7.3

Refit and reconnect pump half coupling. Prime the pump and return it to service.

Spares

We recommended the following spares for various periods normally desired by pump users. a. For two years operation: Gland packing and bearings. b. For three years operation: Gland packing, bearings, neck rings, sleeves-nuts, glands and logging rings. c. For five years operation: One rotating element. Split casing pumps are easier for maintenance then other type of pumps. To take full advantage of this, it is recommended that a spare rotating element be ordered with the pump. This will reduce shutdown period to negligible value, while existing rotating element is removed for repairs.

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Mather + Platt

Maintenance 7.4

Lubrication

RECOMMENDATIONS FOR CENTRIFUGAL PUMPS ARE GIVEN BELOW:

International Manufacturers Where pumps are fitted with stainless shafts, we recommend that a colloidal graphite lubricant, e.g. Oil Dag (Achesons) be added by an amount corresponding to 1 ½ % to 2% by volume of lubricating oil as shown in the schedule. MANUFACTURER

OIL

GREASE

GREASE

Ring oil Bush type Bearings

Ball & Roller Bearings

For use with Mechanical Grease pumps

Alexander Duckham Co. Ltd.

Duckhams H2

Duckhams LB 15

Duckhams, LB 10

Esso Petroleum Co. Ltd.

Thresso 47

T.S.D. 807, (U.K.)

Firmax 1

Esoo multi Purpose Grease H. (0verseas) Germ Lubricants Ltd

Normal shafts,

Germac Neo Astra

Germ Gun Grease

Crem Dyno bear MH Mobile Companies throughout the world

Mobil' DTE oil Medium

Mobil Grease No.3

Mobil Grease No 2

National Benzole Co. Ltd

TCC-2

MPG - 1

MO- 1

BP Energol TH 80HB /

BP Energrease LS3

Power Petroleum Co. Ltd

BP Energol TH 100 HB

BP Energrease PR 3 OR LS 3

Regent Oil Co. Ltd.

Caltex Regal OIL B (R&O)

Caltex Multifac 2

Caltex Multifac 2

Shell Companies throughout the world

Shell Tube, Oil 29 / or Vltrea 31

Shell Nerita Grease 3 / or Shell Alvania Grease 3

Shell Unedo Grease 1

Sternol Ltd

Deotoyl M

Stemoline LHT

Sternoline T

Valvoline Oil Co

Valvoline No 1 or No.2 Turbine Oil

Volvine No. G.LI. Ball & Roller Bearing grease

Valvoline F.V 18

Wakefield-Dick Industrial Oils Ltd

Perfecto Light

Spheerol A.P. 3

Spheerol A.P. 2 OR impervia T

Perfecto Special X Hyspin 70

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Mather + Platt

Maintenance

Indian Manufacturers MANUFACTURER

Ring oil/Bush type Bearings

Grease

Indian Oil Corporation

Servo System-46

Servogem-2/3

Hindustan Petroleum

Enclo-46

Lithon-2/3

Bharat Petroleum

Hydral-46

Multipurpose Grease-3

Grease Lubricated Bearing

For oil Lubrication: 1.

ISO Grade 46 oil.

2.

All above oils are compatible with each other when fresh.

3.

It is unsafe to mix oil of two or more grades for use in Bearings.

4.

Number 46 is Viscosity at 40 degree centigrade in centistokes.

For Grease Lubrication: 1.

Only lithium base Grease to be used.

2.

Numbers mentioned stands for consistency.

3.

Grease of two different grades should not be used.

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Mather + Platt 8

Trouble shooting

Trouble shooting Chart

Sl No

Symptoms

Possible cause of trouble and remedies (Each number is defined in the list below)

--

Pump does not deliver water.

1,2,3,4,6,11,14,16,17,22,23

--

Insufficient capacity delivered.

2,3,4,5,6,7,8,9,10.11.14.17,20,22,23.29,30,31

--

Insufficient pressure developed

5,14,16,17,20,22,29,30,31

--

Pump loses prime after starting.

2,3,5,6,7,8,11,12,13

--

Pump requires excessive power.

15,16,17,18,19,20,23,24.26,27,29,33,34,37

--

Stuffing box leaks excessively.

12,13,24,26,32,33,34,35,36,38.39,40

--

Pump vibrates or it is noisy.

2,3,4,9,10,11,21.23,24,25.26.27,28,30,35,41,42,43, 44, 45,46,47

--

Bearings have short life.

24,26,27,28,35,36,41,42,43,44,45,46,47

--

Pump overheats and seizes.

1,4,21,22,24.27,28,35,36,41

Suction troubles

Remedies

1

Pump not primed

Ensure that casing is fully filled and water comes out from air-cock.

2

Pump or suction pipe not completely filled with liquid

Check leaking foot valve in case of negative suction

3

Suction lift too high.

Reduce by lowering pump elevation or increase

I

Water level. 4

Insufficient margin between pressure and vapor pressure.

Check that NPSH available is at least 1 meter more 1 meter more than NPSH required.

5

Excessive amount of air in liquid.

Check the reasons and eliminate. Gas gets entrapped in liquid. Air may be entering through suction joints.

6

Air pocket in suction line.

Ensure pipe fully filled and there is no bend for negative suction.

7

Air leaks into suction line

Tighten pipe joints with solution.

8

Air leaks into pump through stuffing boxes.

Ensure stuffing box sealing.

9

Foot valve too small or leaking.

Replace I Attend.

10

Foot valve partially clogged.

Clean

11

Inlet of suction pipe insufficiently submerged.

Ensure adequate submergence such that foot valve is not exposed.

12

Water seal pipe clogged.

Clean or change.

13

Logging ring is improperly located

Position logging ring centrally under sealing holes of

in stuffing box, preventing sealing

stuffing box.

fluid from entering to form seal.

MPPL/IM/ASCCP/2006/0

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Mather + Platt

Trouble shooting Suction Troubles (contd.)

Remedies

14

Speed too low.

Check motor RPM, supply frequency, Motor nameplate speed should be as specified on pump nameplate.

15

Speed too high.

Check motor RPM and supply frequency.

16

Direction of rotating wrong.

Check correct direction of rotation for motor before coupling to motor.

17

Total head of system higher than design head of pump.

Check the causes and refer to M&P. Measure with pressure gauge.

18

Total head of system lower than pump design head.

Check the causes and refer to M&P. Measure with pressure gauge.

19

Specific gravity of liquid different from design.

Refer to M&P.

20

Viscosity of liquid different from design.

Refer to M&P

21

0peration at very low capacity.

Check the causes and refer to M&P, Operate pump at rated duty.

22

Parallel operation of pumps unsuitable for such operation.

Refer to M&P with characteristics curves of pump.

Mechanical troubles

Remedies

23

Foreign matter in impeller.

Open and clean.

24

Misalignment.

Check with Dial gauge should be within limits and without undue pipe stresses.

25

Foundations not rigid.

Check, vibration on Bedplate, check hollowness.

26

Shaft bent.

Dismantle and check, Replace shaft.

27

Rotating part rubbing on stationary part.

Incorrect assembly, correct the assembly.

28

Bearing worn.

Check lubrication, shaft run out, alignment, replace if required

29

Wearing rings worn.

Replace.

30

Impeller damaged.

Replace.

31

Casing gasket defective, permitting internal leakage.

Replace.

Shaft or shaft sleeves worn

Replace.

32

or scored at packing. 33

Packing improperly installed.

Use correct grade and size of packing

34

Type of packing incorrect for operating condition.

Use correct grade and size of packing.

35

Shaft running' out of center because of worn bearings or misalignment.

Rectify.

36

Rotor out of balance, causing vibration.

Balance the rotor.

MPPL/IM/ASCCP/2006/0

8-2

Mather + Platt

Trouble shooting

37

Gland too tight, resulting in no flow of liquid to lubricate packing

Adjust gland. Ensure sealing water flow

38

Cooling liquid not being provided to water-cooled stuffing boxes.

Provide.

39

Excessive clearance at bottom of stuffing box between shaft and casing, causing packing to be forced into the pump.

Check pumps assembly.

40

Dirt or grit in sealing, liquid leading to scoring of shaft or shaft sleeve.

Provide clean liquid for flushing.

41

Excessive thrust caused by mechanical failure inside pump or by failure of hydraulic balancing device, if any (in case of multistage pump etc.)

Check pump operation and assembly

42

Excessive grease or oil in antifriction bearing housing or lack of cooling, causing excessive bearing temperature.

Attend.

43

Lack of lubrication.

Provide proper lubrication.

44

Improper installation of antifriction bearings (damage, incorrect assembly of stacked bearings, use of unmatched bearings as a pair I etc.)

Rectify or replace bearing.

45

Dirt in bearings

Investigate the cause and clean bearing.

46

Rusting of bearings from water in housing

Arrest water ingress.

47

Excessive cooling of water- cooled bearing, resulting in condensation of atmospheric moisture in bearing housing.

Reduce cooling water flow.

For any occurrence of any abnormal symptoms stop the pump and investigate the cause for corrective action without delay. For trouble shooting of prime mover, electrical panels, mechanical seals refer the respective manufacturers instruction manual.

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Mather + Platt

Lists, Tables, Type Plates & Checklists

A Lists, Tables, Type plates & Checklists A.1

List of machine operators

All persons working on or with the product confirms with their signatures that they have received, read and understood this operating and maintenance manual. In addition they obligate themselves to conscientiously follow the instructions provided. Non-observation releases the manufacturer from any warranty obligations.

Name

Starting date

Table 1: List of machine operators.

MPPL/IM/ASCCP/2006/0

A-1

Signature

Lists, Tables, Type Plates & Checklists A.2 Sl. No.

Mather + Platt

Maintenance and inspection log Date

Equipment No

MPPL/IM/ASCCP/2006/0

Details

Signature Name

A-2

Remarks

Mather + Platt

Lists, Tables, Type Plates & Checklists

A.3

Type Plates

3.3.1

Type plate for unitized pump set

11

Sr. no.

1

Typ

2

KW

3

RPM

4

M3/hr

5

H (m)

6

P(max) Bar

7

T( º C )

9

Year of mfg

10

Total Set wt

8

1-Machine Serial Number 2-Machine type 3-Rated power 4-Rated speed 5-Rated discharge 6-Rated head 7- Maximum head 8- Total Set weight (Pump+Motor+Bedplate) 9- Operating temperature 10-Year of manufacture 11-CE mark

MATHER & PLATT PUMPS LTD CHINCHWAD, PUNE 411019, INDIA

3.3.2

Type plate for bare pump

11

Sr. no.

1

Typ

2

KW

3

RPM

4

M3/hr

5

H (m)

6

P(max) Bar

7

T( º C )

9

Year of mfg

10

Pump Wt

8

MATHER & PLATT PUMPS LTD CHINCHWAD, PUNE 411019, INDIA

MPPL/IM/ASCCP/2006/0

A-3

1-Machine Serial Number 2-Machine type 3-Rated power 4-Rated speed 5-Rated discharge 6-Rated head 7- Maximum head 8- Pump weight 9- Operating temperature 10-Year of manufacture 11-CE mark

Lists, Tables, Type Plates & Checklist A.4

Leveling Records

Required accuracy of level is 0.05 mm / 250 mm

Level achieved:

Level Bottle used: Straight Edge used:

Checked by:

Verified by:

MPPL/IM/ASCCP/2006/0

A-4

Mather + Platt

Mather + Platt A.5

Lists, Tables, Type Plates & Checklists

Alignment Protocol

PUMP & MOTOR/ ENGINE/ TURBINE ALIGNMENT READINGS. PUMP SR. NO:

PUMP TYPE :

DRIVER SR. NO:

MAKE:

A)

TYPE:

Before connecting Suction & Delivery Piping: RADIAL

AXIAL

Gap between coupling halves: B)

After connecting Suction & Delivery Piping: RADIAL

AXIAL

Gap between coupling halves: Required: Acceptable Limit:

Checked by: Verified by:

MPPL/IM/ASCCP/2006/0

A-5

Lists, Tables, Type Plates & Checklists A.6

Mather + Platt

Pre-Starting Checks for Pump set Checked on

Sl No

Activities

1

Alignment with and without piping

2

Flushing of pipe lines and ensure no leakages

3

Availability of sufficient liquid in sump / suction as per specifications.

4

Installation of all instruments a. Suction and delivery pressure gauges b. Pressure switches c. Temperature gauges d. Any other as supplied / specified.

5

Operation of suction, delivery and inline valves

6

Proper supports for piping and other allied equipments.

7

Availability of flushing / sealing liquid for stuffing box.

8

Availability of sufficient cooling liquid for bearings as specified

9

Free rotation of pump and drive shafts

10

Lubrication of bearings

11

Checking of insulation resistance of motor

12

Proper cable termination

13

Motor protection relay settings

14

Check all interlocks as specified / provided

15

No a. b. c.

16

Coupling of pump and drive and free rotation of shafts in coupled condition

17

Suction valve is fully opened

18

Pump is fully primed and all air is vented

19

Delivery valve is closed (if required)

20

Emergency shut down is possible.

load trial operation of drive Direction of rotation is ok Noise and vibration within limits Bearing temperatures and winding temperatures are within limits d. Overall operation is satisfactory

MPPL/IM/ASCCP/2006/0

A-6

Remarks

Mather + Platt A.7

Lists, Tables, Type Plates & Checklists

Pump commissioning report

SR02-04

Date: Pump Details a. Pump Sr.No. b. Type of pump c. Head d. Capacity e. Rpm f. Construction

Details of Motor a. Motor make b. Sr. no. c. Motor frame size d. KW / HP e. RPM f. Voltage

Details of System a. Application b. Liquid c. pH Value d. Suction

Piping Details a. Suction pipe size b. Delivery pipe size c. Valves d. Expansion joints

Flooded/Lift

Pump operating parameters a. Suction pressure b. Discharge pressure c. RPM d. DE bearing temperature e. NDE bearing temperature f. Duration of trial run

Motor operating parameters a. Current b. Voltage c. RPM d. DE bearing temperature e. NDE bearing temperature f. Winding temperature (maximum)

Observations & Remarks:

Checked by: Verified by: MPPL/IM/ASCCP/2006/0

A-7

Lists, Tables, Type Plates & Checklists A.8

Mather + Platt

Issue / Feedback report

SR01-O2 Page 1

Date: To Mather and Platt Pumps Ltd. P.O. Box No. 7, Chinchwad, Mumbai-Pune Road, Pune-411019, India. 1 Client / Site

:

2

Nature of complaint

:

3

Date of receipt of pump at site & date of commissioning Was erection/commissioning in M & P’s scope Pump details Pump type: P.D. No: Flow:

:

4 5

:

Head: RPM: Efficiency:

6

Prime mover details Make: Sr. No.: Frame size / Type: KW/HP rating:

Motor / Engine RPM: Volts: Full load current: Insulating class:

7 a b c d e

Site layout Suction pipe details, valves Discharge pipe details, valves Expansion joints, strainer etc. Suction sump details Suction conditions

f

Static head (Elevation difference between pump centreline & discharge point)

(Enclose drawings / Sketch / photographs) : : : : : Flooded / Suction lift Details: :

8

Installation details

a

Base frame

Loose

b

Base frame levelling readings

:

c

No of packers below base frame

:

d

Alignment readings

e

-With pipe connection

:

-Without pipe connection

:

Coupling type & gap between couplings halves

:

MPPL/IM/ASCCP/2006/0

A-8

/ Turbine

/Anchored with foundation bolts

Mather + Platt

Lists, Tables, Type Plates & Checklists SR01-O2 Page 2

9 a b

Operation details Application of pump Solo / parallel / series operation

c

Liquid specification (Chemical analysis report)

Specific gravity: Temperature : Solid contents :

pH value : Viscosity :

d

Operation parameters

Suction Pr. : Discharge : Motor current : Frequency : VibrationsOverall readings: Bearing temp. : Suction pr. : Motor current :

Delivery Pr. Speed Volts

e

Parameters at close valve / minimum flow condition

: :

Filtered readings: Discharge Pr. Volts

Minimum flow : 10

Routine or major overhauls carried out if any (Give details)

:

11

Any other details or observation

:

12

Investigation engineers report

:

13

Spare requirement

:

14

Course of action finalized

:

15

Service Charges

:

Any other observation:

Prepared by: MPPL/IM/ASCCP/2006/0

Checked by: A-9

: : :

: :

Mather + Platt B

Machine data sheet

Pump Technical data

B.1 Performance Mather & Platt pumps are furnished for a particular duty and service conditions advised on your order / data sheet. Changes in hydraulic system will affect the pumps performance. See Safety, Sec 2, duty condition.clause 2.3

B.2 Pressure limits The operating pressure has been selected to meet your specific requirements. See Safety, Sec 2, duty condition -clause 2.3.

B.3 Temperature limitation Refer the order specification/Data sheet

B.4 Flange loads Loads, which can be exerted on the pump flanges by the connecting, pipe flanges.

EACH NOZZLE

EACH END NOZZLE

EACH SIDE NOZZLE

EACH TOP NOZZLE

Nominal size of the Nozzle Plate (INCHES) FX FY FZ FR FX FY FZ FR FX FY FZ FR FX FY FZ FR

1’’ 117 145 95 210 117 95 145 210 145 95 117 210 163 124 81 220

1 ¼ ‘’ 135 166 109 240 135 109 166 240 166 109 135 240 192 147 96 260

1 ½ ‘’ 142 176 116 255 142 116 176 255 176 116 142 255 247 189 124 335

2’’ 160 200 130 290 160 130 200 290 200 130 160 290 340 260 170 460

2 ½ ‘’ 200 255 160 370 200 160 255 370 255 160 200 370 510 390 325 720

3’’ 4’’ 240 320 300 400 200 280 430 570 240 320 200 280 300 400 430 570 300 400 200 280 240 320 430 570 700 980 530 740 350 500 950 1330

5’’ 440 560 360 800 440 360 560 800 560 360 440 800 1300 1000 750 1800

(Ref API 610) 6’’ 560 700 460 1010 560 460 700 1010 700 460 560 1010 1700 1300 870 2310

7’’ 700 900 580 1300 700 580 900 1300 900 580 700 1300 2100 1600 1070 2850

8’’ 850 1100 700 1560 850 700 1100 1560 1100 700 850 1560 2600 1900 1300 3500

9" 1000 1300 850 1900 1000 850 1300 1900 1300 850 1000 1900 3100 2400 1500 4000

10’’ 1200 1500 1000 2200 1200 1000 1500 2200 1500 1000 1200 2200 3700 2800 1800 5000

11’’ 1350 1650 1100 2400 1350 1100 1650 2400 1650 1100 1350 2400 4050 3100 2050 5550

12’’ 1500 1800 1200 2600 1500 1200 1800 2600 1800 1200 1500 2600 4500 3400 2200 6100

14’’ 1600 2000 1300 2900 1600 1300 2000 2900 2000 1300 1600 2900 4700 3500 2300 6300

Forces – LB Moments – lb ft Each Top Side Nozzle Each Nozzle

2.2 = Kg

7.22 = Kg m

HSC PUMPS: LE, ME, ST, LONO ETC. MPPL/IM/ASCCP/2006/0

B-1

15’’ 1800 2200 1400 3100 1800 1400 2200 3100 2200 1400 1800 3100 5200 3900 2600 7000

16’’ 1900 2300 1500 3300 1900 1500 2300 3300 2300 1500 1900 3300 5400 4000 2700 7200

Mather + Platt

Machine data sheet

Loads, which can be exerted on the pump flanges by the connecting, pipe flanges.

EACH TOP NOZZLE

FX FY FZ FR

EACH NOZZLE

EACH END NOZZLE

FX FY FZ FR

EACH SIDE NOZZLE

Nominal size of the Nozzle Plate (INCHES)

FX FY FZ FR FX FY FZ FR

18" 2100 2500 1650 3650 2100 1650 2500 3650 2500 1650 2100 3650 5700 4250 2900 7600

20" 2250 2750 1775 3970 2250 1775 1750 3970 2750 1775 2250 3970 5900 4500 3100 8000

22" 2425 2950 1850 4250 2425 1850 2950 4250 2950 1850 2425 4250 6050 4650 3175 8250

24" 2550 3100 2025 4500 2550 2025 3100 4500 3100 2025 2550 4500 6200 4750 3250 8450

26" 2675 3300 2125 4750 2675 2125 3300 4750 3300 2125 2675 4750 6400 4900 3400 8750

28" 2775 3400 2200 4900 2775 2200 3400 4900 3400 2200 2775 4900 6600 5000 3550 9000

30" 2825 3500 2775 5000 2825 2275 3500 5000 3500 2275 2825 5000 6800 5125 3600 9200

(Ref API 610)

32" 2875 3600 2300 5150 2875 2300 3600 5150 3600 2300 2875 5150 7000 5150 3650 9400

33" 2900 3625 2325 5250 2900 2375 3625 5200 3625 2325 2900 5200 7200 5175 3675 9600

36" 2950 3675 2400 5300 2950 2400 3675 5300 3675 2400 2950 5300 7400 5400 3800 9900

38" 3000 3740 2470 5400 3000 2480 3740 5400 3740 2480 3000 5400 7620 5570 3930 --

40" 3055 3810 2545 5515 3055 2560 3810 5515 3810 2560 3055 5515 7845 5745 4065 --

42" 3110 3875 2525 5630 3110 2645 3875 5630 3875 2645 3110 5630 8075 5925 4200 --

44" 3170 3945 2700 5755 3170 2735 3945 5755 3945 2735 3170 5755 8315 6115 4345 --

46" 3225 4015 2780 5875 3225 2825 4015 5875 4015 2825 3225 5875 8560 6305 4490 --

48" 3285 4090 2865 6000 3285 2915 4090 6000 4090 2915 3285 6000 8810 6505 4645 --

Forces – lb Moments – lb ft Each Top Side Nozzle Each Nozzle

2.2 = Kg

7.22 = Kg m

HSC PUMPS: LE, ME, ST, LONO ETC.

MPPL/IM/ASCCP/2006/0

B-2

50" 3340 4165 2950 6130 3340 3010 4165 6130 4165 3010 3340 6130 9070 6710 4800 --

52" 3400 4240 3040 6260 3400 3110 4240 6260 4240 3110 3400 6260 9340 6920 4965 --

Mather + Platt B.5

Machine data sheet

Bearings, Lubrication, Gland packing

HSC pumps SL NO

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55

PUMP MODEL

SINGLE STAGE PUMPS 50/65 ASN-H 50/80 ASN-H 50/80 BSN 65/80 CST 80/100 ASN 80/100 ASN-H 80/100 AST 80/100 BSN 80/100 CSN 100/125 ASN 100/125 CSN 100/125 AST 100/125 BST 125/150 AST 125/150 AST-H 125/150 BST 125/150 CST 150/200 BST 150/200 CST 150/200 DST 150/200 DST-A 200/250 AST MK 1 200/300 BST 200/250 CST 200/250 DST 200/250 EST 250/250 AST 250/250 AST-L 250/300 BST 300/350 AST 300/400 BST 350/450 AST 350/450 BST 350/450 CST 400/450 CST 400/500 AST 400/500 BST 400/500 DST 500/600 AST 500/600 BST 500/600 CST 8/8 ALE 8/10 ALE 10/12 ALE MK I 10/12 ALE 12/14 ALE 12/14 ALE MK I 14/16 ALE MK 1 14/16 ALE MK 2 20/20 ALE (BUSH BRG.) 24/24 ALE (BALL BRG.) 24/24 ALE (BUSH BRG.) 24/24 ALE MK I (Ball BRG.) 24/24 ALE MK I (BUSH BRG.) 30/30 ALE (BALL BRG.)

MPPL/IM/ASCCP/2006/0

MAX RPM

ELEMENT

3000 3000 1800 1800 1800 3000 3000 1800 1800 1800 1800 1800 1800 1800 3000 1800 1500 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1200 1200 1800 1200 1800 1200 1800 1200 1200 1200 1800 1800 1800 1800 1800 1800 1200 1800

00 SPL 0 SPL 00 0 SPL 0 0 SPL 0 0 0 0 0 0 0 1 1 1 1 2 2 3 3 1 2 3 4 4 2 1 3 3 3 4 SPL. 4 SPL. 4 5 4 5 6 5 6 6 2 2 3 3 3 3 4 4

1200

5

Bush: --

900

6

Ball: SKF 6319

900

6

Bush: --

BRG. DE

Ball: SKF 6204 ZZ Ball: SKF 6304 ZZ Ball: SKF 6304 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 ZZ Ball: SKF 6305 ZZ Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6306 Ball: SKF 6306 Ball: SKF 6306 Ball: SKF 6306 Ball: SKF 6308 Ball: SKF 6308 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6306 Ball: SKF 6308 Ball: SKF 6311 Ball: SKF 6314 Ball: SKF 6314 Ball: SKF 6308 Ball: SKF 6306 ZZ Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6314 Ball: SKF 6314 ZZ Ball: SKF 6314 Ball: SKF 6316 Ball: SKF 6314 Ball: SKF 6316 Ball: SKF 6319 Ball: SKF 6319 Ball: SKF 6319 Ball: SKF 6319 Ball: SKF 6308 Ball: SKF 6308 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6314 Ball SKF 6314

900

6

Ball: SKF 6319

900

6

Bush: --

900

6

Ball: SKF 6319

B-3

BRG. NDE

Ball: SKF 6303 ZZ Ball: SKF 6304 ZZ Ball: SKF 6304 Ball: SKF 6305 Ball: SKF 305 Ball: SKF 6305 ZZ Ball: SKF 6305 ZZ Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6306 Ball: SKF 6306 Ball: SKF 6306 Ball: SKF 6306 Ball: SKF 6308 Ball: SKF 6308 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6306 Ball: SKF 6308 Ball: SKF 6311 Ball: SKF 6314 Ball: SKF 6314 Ball: SKF 6308 Ball: SKF 6306 ZZ Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6314 Ball: SKF 6314 ZZ Ball; SKF 6314 Ball: SKF 6316 Ball: SKF 6314 Ball: SKF 6316 Ball: SKF 6319 Ball: SKF 6319 Ball: SKF 6319 Ball: SKF 6319 Ball: SKF 6308 Ball: SKF 6308 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6314 Ball: SKF 6314 Bush: -Ball: SKF 6313 Ball: SKF 6319 Bush: – Ball: SKF 6315 Ball: SKF 6319 Bush: -Ball: SKF 6315 Ball: SKF 6319

BRG LUB

BRG LIFE HRS

Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Oil. Grease. Grease Oil Oil Grease Oil Oil Grease

40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 -40000 40000 -40000 40000 -40000 40000

SHAFT GLAND ST BOX DIA AT PACK NO OF CPLG ING RINGS MM SIZE

19.5 19.5 19 24 24 24 24 24 24 24 24 24 24 29 29 29 29 39 39 54 54 29 39 54 69 69 39 29 54 54 54 69 69 69 79 69 79 94 79 94 94 39 39 54 54 54 54 69 69

6 10 10 8 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 16 16 10 10 16 17 17 10 10 16 16 16 17 17 17 20 17 20 20 20 20 20 10 10 16 16 16 16 17 17

8 4 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

79

20

5

94

20

5

94

20

5

94

20

5

94

20

5

94

20

5

Mather + Platt

Machine data sheet SL NO

PUMP MODEL

MAX RPM

56

30/30 ALE (BUSH BRG.) 30/30 ALE T (DV) (BUSH BRG.) 30/30 ALE T (DV) (BUSH BRG.) 6/8 BLE 6/8 BLE 8/10 BLE 10/12 BLE 10/12 BLE MK I 12/14 BLE 6/8 CME 6/8 CME MK 1 6/8 CME MK 2 8/10 CME-TA 8/10 CME-TB 10/12 CME 12/14 CME 14/16 CME (BALL BRG.( 14/16 CME (BUSH BRG.) 14/18 CME (BALL BRG.) 16/18 CME (BUSH BRG.) 18/20 CME MK 2 (BALL BRG.) 18/20 CME MK 2 (BUSH BRG.) 20/24 DV CME (Ball BRG.) 20/24 DV CME (BUSH BRG.) 24/24 CME (Ball BRG.) 24/24 CME (BUSH BRG.) 24/28 CME 8/8 DME TA 8/8 DME TB 8/10 DME 10/12 DME 12/14 DME 16/18 DME D.V. 18/20 DME (BALL BRG.) 18/20 DME (BUSH BRG.) 10/12 EME (BALL BRG.) 10/12 EME (BUSH BRG.) 14/16 EME (BALL BRG.) 14/16 EME (BUSH BRG.) 14/16 EME MK1 (BALL BRG.) 14/16 EME MK1 (BUSH BRG.) 14/18 EME (BALL BRG.) 14/18 EME (BUSH BRG.) 14/18 EME H (BALL BRG.) 14/18 EME H (BUSH BRG.)

900

6

900

6 SPL.

900

6 SPL.

1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1800 1200

2 2 3 3 3 3 2 2 2 3 3 4 4 5

1200

5

Bush: --

1200 1200

5 5

Ball: SKF6313 Bush: --

1200 1200

5 5

Ball: SKF 6316 Bush --

1200 1200

6 6

Ball SKF 6319 Bush: --

1200 1200

6 6

Ball: SKF 6319 Bush: --

1200 1800 1800 1800 1800 1800 1200 1200 1200

6 3 3 4 4 4 6 6 6

Ball: SKF 22319C Ball: SK F6311 Ball: SK F6311 Ball: SK F6314 Ball: SK F6314 Ball: SK F6314 Ball: SKF 6319 Ball: SKF 6319 Bush: --

1800 1800

5 5

Ball: SKF 6316 Bush: --

1800 1800

5 5

Ball: SKF 6316 Bush: --

1800 1800

5 5

Ball: SKF 6316 Bush --

1800

5

Ball SKF6316

1800

5

Bush:--

1800

6

Ball: SKF 6319

1800

6

Bush: --

57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100

MPPL/IM/ASCCP/2006/0

ELEMENT

SHAFT GLAND ST BOX DIA AT PACK NO OF CPLG RINGS ING MM SIZE

BRG. DE

BRG. NDE

BRG LUB

BRG LIFE HRS

Bush: --

Bush: -Ball: SKF 6315 -Ball: SKF 6315 Ball: SKF 6315

-40000 40000

94

20

5

100

20

5

40000

100

20

5

Ball: SKF6308 Ball: SKF6308 Ball: SKF6311 Ball: SKF6311 Ball: SKF6311 Ball: SKF6311 Ball: SKF6308 Ball: SKF6308 Ball: SKF6308 Ball: SKF6311 Ball: SKF6311 Ball: SKF 6314 ZZ Ball: SKF6314 Ball: SKF6316

Oil Oil Oil Grease Bush: Oil Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease

40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000

79 39 54 54 54 54 39 39 39 54 54 69 69 79

20 10 15 16 16 16 10 10 10 16 16 16 17 20

5 5 5 5 5 5 5 5 5 5 5 5 5 5

Bush: -Ball: SKF 6313 Ball: SKF 6316 Bush: – Ball: SKF 6313 Ball: SKF 6316 Bush Ball SKF 6313 Ball SKF 6319 Bush: -Ball SKF 6315 Ball: SKF 6319 Bush: -Ball: SKF 6315 Ball: SKF 7319 Ball: SKF 6311 Ball: SKF 6311 Ball: SKF 6314 Ball: SKF 6314 Ball: SKF 6314 Ball: SKF 6319 Ball: SKF 6319 Bush: -Ball: SKF 6315 Ball: SKF 6316 Bush: -Ball: SKF 6313 Ball: SKF 6316 Bush: -Ball: SKF 6313 Ball: SKF 6316 Bush -Ball SKF 6313 Ball SKF 6316

Oil Oil Grease Oil Oil Grease Oil Oil Grease Oil Oil Grease Oil Oil Oil Grease Grease Grease Grease Grease Grease Grease Oil Oil Oil Oil OIL Oil Oil Oil Oil Oil Oil Oil

-40000 40000 -40000 40000 -40000 40000 -40000 40000 -40000 40000 40000 40000 40000 40000 40000 40000 40000 -40000 40000 -40000 40000 -40000 40000 -40000 40000

79

20

5

79 79

20 20

5 5

79 79

20 20

5 5

94 94

20 20

5 5

94 94

20 20

5 5

94 54 54 69 69 69 94 94 94

20 16 16 16 17 17 20 20 20

5 5 5 5 5 5 5 5 5

79 79

20 20

5 5

79 79

20 20

5 5

79 79

20 20

5 5

79

20

5

Bush: -Ball SKF 6313 Ball: SKF 6319

Oil Oil Grease

-40000 40000

79

20

5

94

20

5

Bush: -Ball: SKF 6315

Oil Oil

-40000

94

20

5

Bush: LG2 with WML Bush: LG2 with WML Ball: SKF6308 Ball: SKF6308 Ball: SKF6311 Ball: SKF6311 Ball: SKF6311 Ball: SKF6311 Ball: SKF6308 Ball: SKF6308 Ball: SKF6308 Ball: SKF6311 Ball: SKF6311 Ball: SKF 6314 ZZ Ball: SKF6314 Ball: SKF6314

B-4

Mather + Platt SL NO

PUMP MODEL

MAX RPM

101

16/20 EME (BALL BRG.) 16/20 EME (BUSH BRG.) 500/600 EME (BALL BRG.) 500/600 EME (BUSH BRG.) 33/36 LSL (BALL BRG.) 33/36 LSL (BUSH BRG.) 5/6 MEDI (BALL BRG.) 5/6 MEDI (BUSH BRG. BRG. ) 4/5 LONO 5/6 LONO 8/10 LONO (BALL BRG.) 8/10 LONO (BUSH BRG.) 8/10 LONO MK1 (Ball BRG.) 8/10 LONO MK1 (BUSH BRG.) 16/20 LONO T-60 MK 1 (BUSH BRG.) 16/20 LONO T-30 MK 1 (BALL BRG.) 16/20 LONO T-30 MK 1 (BUSH BRG.) 16/20 LONO T-30 MK 2 (BALL BRG.) 16/20 LONO T-30 MK 2 (BUSH BRG.) 20/24 DV MEDI (BALL BRG.) 20/24 DV MEDI (BUSH BRG.) 20/24 MEDI. T1 (Ball BRG.0 28/28 LONO

1200

102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 133 134

28/28 LONO (BUSH BRG.) 24/30 DV LONO (BALL BRG.) 24/30 DV LONO (BUSH BRG.) 24/30 DV LONO TB MK-I (BALL BRG.) 24/30 DV LONO TB MK-I (BUSH BRG.) 30/36 DV LONO (BALL BRG.) 36/36 DV LONO (BMC) (BALL BRG.) 36/36 DV LONO (BMC) (BUSH BRG.) 36/36 DV LONO MK-I (RCF) (BALL BRG.) 36/36 DV LONO MK-I (RCF) (BUSH BRG.)

MPPL/IM/ASCCP/2006/0

ELEMENT

Machine data sheet SHAFT GLAND ST BOX DIA AT PACK NO OF CPLG RINGS ING MM SIZE

BRG. DE

BRG. NDE

BRG LUB

BRG LIFE HRS

5

Ball: SKF 6316

Ball: 6316

Oil

40000

79

20

5

1200

5

Bush: --

5

Ball: SKF 6319

-40000 40000

20

6

Oil Oil Grease

79

1800

Bush: -Ball: SKF 6313 Ball: SKF 6319

94

20

5

1800

6

Bush: --

5

Ball: SKF 6319

-40000 40000

20

6

Oil Oil Grease

94

720

Bush: -Ball: SKF 6315 Ball: SKF 6319

94

20

5

720

6

Bush: --

5

Ball: SKF 6405

-40000 40000

20

NA

Oil Oil Grease

94

1800

Bush: Ball: SKF 6315 Ball: SKF 6405

34

10

5

1800

NA

Bush: --, bush: --

5

Roller: SKF N206 Roller: SKF N 206 Ball: SKF 6208

-40000 40000 40000 40000

10

NA NA NA

Oil Oil Grease Grease Grease

28

3600 1800 1800

Bush: -Thrust Disc Ball: SKF 6305 Ball: SKF 6305 Ball: SKF 6208

28 28 38

10 10 11

5 5 5

1800

NA

Bush: --

5

Ball: SKF 6208

-40000 40000

11

NA

Oil Oil Grease

40

1800

Bush: -Thrust Disc Ball: SKF 6208

38

11

5

1800

NA

Bush: --

5

Bush: --

75

15

5

1200

NA

Ball: SKF 6414

-40000 -40000 40000

11

NA

Oil Oil Oil Oil Grease

40

1200

Bush: -Thrust Disc -Ball: SKF 6313 Ball: SKF 6414

69

16

5

1200

NA

Bush: --

5

Ball: SKF 6414

-40000 40000

16

NA

Oil Oil Grease

75

1200

Bush: -Thrust Disc Ball: SKF 6414

69

16

5

1200

NA

Bush: --

5

Ball: SKF 6319

-40000 40000

16

6

Oil Oil Grease

75

1200

Bush: Thrust Disc Ball: SKF 6319

94

20

5

1200

6

Bush: --

5

Ball: SKF 6316

-40000 40000

20

5

Oil Oil Grease

94

1200

Bush: -Ball: SKF 6315 Ball: SKF 6316

79

20

5

900

7

Ball: SIKF NU 324

Grease

40000

119

25

5

900

7

-40000 40000

25

5

7

Oil Oil Grease

125

900

125

25

5

900

7

Bush: --

125

25

5

7

Ball: SKF NU324

Oil Oil Grease

--

888

40000

125

25

5

888

7

Bush: --

125

25

5

7

40000

125

25

5

600

7

Ball: SKF 7224 BCB Ball: SKF NU 324

Oil Oil Grease

40000

900

Ball: SKF 7324 BCB Bush: -Ball: SKF 6318 Ball: SKF 7224 BCB Bush: -Ball: SKF 6318 Ball: SKF 7224 BCB Bush ; -Ball: SKF 6318 Ball: SKF 6318

Grease

40000

119

25

5

600

7

Bush: --

25

5

7

Ball: SKF NU 324

-40000 40000

125

720

Oil OIL Grease

119

25

5

720

7

Bush: --

Oil Oil

-40000

125

25

5

Bush: -Ball: SKF NU 324

B-5

Ball: SKF 7324 BCB Bush: -Ball: SKF 6318 Ball: 7324 SKF BCB Bush: -Ball SKF 6318

Mather + Platt

Machine data sheet 135 136 137 138 139 140

36/36 DV LONO MK 2 (VSP) (BALL BRG.) 36/36 DV LONO MK 2 (VSP) (BUSH BRG.) 36/36 DV LONO MK 3 (BALL BRG.) 36/36 DV LONO MK 3 (BUSH BRG.) 36/36 DV MK4 (99/1802& 3) (BALL BRG.) 36/42 DV LONO (BUSH BRG.)

720

7

Ball: SKF NU 324

720

7

Bush: --

720

7

Ball: NU 324

Ball: SKF 7324 BCB Bush: -Ball: SKF 6318 Ball: 7324 BCB

720

7

Bush: --

Bush: 6318

708

6 SPL

Ball: SKF 7224

Ball: SKF 7224

720

8

Bush: --

Bush: -Ball: SKF 6318 or 22318 Bush: -Ball: SKF 6318 or 22318 Bush: -Ball: SKF 6318 or 22318 Bush: -Ball: SKF 6318 or 22318 D.G. Ball: Ball: SKF 6304 Ball: SKF 6305 Ball: SKF 6305 Ball : SKF 6405

141

42/42 DV LONO (BUSH BRG.)

600

8

Bush: --

142

48/48 DV LONO BUSH BRG.)

600

8

Bush: --

143

48/54 DV LONO BUSH BRG.)

516

8

Bush: --

144 144 145 146 147

2/3 MEDIVANE 3/4 MEDIVANE 4/5 MEDI MK1 4/5 MEDI MK1 5/6 MEDI (BALL BRG.) 5/6 MEDI (BUSH BRG.) 9/11 MEDI (BALL BRG.) 9/11 MEDI (BUSH BRG.) TWO STAGE PUMPS 80/100GST 80/100 GSN 100/125 GST 100/125 GSN 100/150 GST 100/150 IGME, MK I 125/150 GST 125/150 GSN 150/200 GST 150/200 GSN 250/300 GST 2/3- 2 STG. MEDIVANE 3/4-2 STG. MEDIVANE 4/5-2STG. MEDI MK 4/5-2STG. MEDI MK1 4/6 IGME 6/8 GME 6/8 – 2 STG. MEDI 6/80 GME 9/11 –2 STG. MEDI TU 9/11 2 STG. MEDI MK 1

3000 1800 1800 1800 1800

NA NA NA NA NA

Roller: SKF N205 Roller: SKF N205 Roller: SKF N206 Roller: SKF N206 Ball: SKF 6405

1800

NA

Bush: --

1800

NA

Ball: SKF 6310

1800

NA

Bush: --

1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 1500 3000 3000 3000 2650 1500 1800 1800 1500 1800 1800

NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA

148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171

Grease

40000

119

25

5

Oil Oil Ball: Grease Bush: Oil Grease

40000

125

25

5

40000

119

25

5

40000

125

25

5

40000

94

18

5

Oil

-40000

140

20

5

Oil

-40000

140

20

5

Oil

-40000

140

20

5

Oil

-40000

140

20

5

Grease Grease Grease Grease Grease

40000 40000 40000 40000 40000

24 24 28 28 34

8 10 10 10 10

5 5 5 5 5

Bush: -Thrust disc Ball: SKF 6310

Oil Oil Grease

-40000 40000

28

10

5

50

11

5

Bush:: -Thrust disc

Oil Oil

40,000

56

11

5

Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease Grease

40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000

29 29 29 34 39 39 39 44 54 54 79 24 28 34 34 39 69 44 69 75/74 75/74

9.5 10 9.5 9.5 9.5 9.5 9.5 9.5 15 11.5 20 8 8 8 8 8 16 10.5 16 12.5 12.5

5 4 5 12 5 5 5 12 5 13 5 5 5 5 5 5 5 5 5 5 5

Ball: SKF6306 Ball: SKF6306 Ball: SKF6306 Ball: SKF6306 Ball: SKF6306 Ball: SKF6306 Ball: SKF6307 ZZ Ball: SKF6307 ZZ Ball: SKF6308 Ball: SKF6308 Ball: SKF6306 Ball: SKF6306 Ball: SKF6308 Ball: SKF6308 Ball: SKF6309 ZZ Ball: SKF6309 ZZ Ball: SKF6310 Ball: SKF6310 Ball: SKF6311 ZZ Ball: SKF6311 ZZ Ball: SKF6316 Ball: SKF6316 Ball: SKF6305 Ball: SKF6305 Roller: SKF N206 Ball: SKF6305 Roller: SKF N307 Ball: SKF6405 Roller: SKF N307 Ball: SKF6405 Ball: SKF 6308 Ball: SKF6308 Ball: SKF 6314 Ball: SKF6314 Ball SKF 6409 Ball SKF6409 Ball: SKF 6314 Ball: SKF7314 Ball: SKF NU1015 Ball: SKF3315 Ball: SKF NU1015 Ball: SKF3315

Bearing numbers sufficed with ZZ are shielded and pre lubricated bearings.

MPPL/IM/ASCCP/2006/0

B-6

Mather + Platt

Machine data sheet

B.6 Recommended bolting & screw torques Failure of threaded fasteners due to over-tightening can occur by bolt shank fracture or by stripping of the nut and / or bolt’s thread. a bolt or screw assembled with a nut of appropriate class is intended to provide an assembly capable of being tightened to the bolt proof load without thread stripping occurring. The torque value to be set for a particular size of screw is dependent upon: 1. 2. 3. 4. 5.

Material of screw. Parent metal. Whether the screw is untreated or plated. Whether the screw is dry or lubricated. The depth of the thread.

Tightening Torques – Untreated Screw (Black finish) Friction of coefficient 0.14 Property Class 5.6 8.8 10.9 12.9

Torque Nm Ft. lb Nm Ft. lb Nm Ft. lb Nm Ft. lb

M6

M8

M10

M12

4.6 3.3 10.5 7.7 15 11 18 13

11 8.1 26 19 36 26 43 31

22 16 51 37 72 53 87 64

39 28 89 65 125 92 150 110

Nominal diameter – Coarse thread M16 M20 M24 M27 M30 95 70 215 158 305 224 365 269

184 135 420 309 590 435 710 523

315 232 725 534 1020 752 1220 899

470 346 1070 789 1510 1113 1810 1334

636 468 1450 1069 2050 1511 2450 1805

M33

M36

M39

865 637 1970 1452 2770 2042 3330 2455

1111 819 2530 1865 3680 2625 4260 3156

1440 1062 3290 2426 4520 3407 5550 4093

Tightening Torques – Electrically Zink plated Friction of coefficient 0.125 Property Class

Torque

5.6

Nm Ft. lb Nm Ft. lb Nm Ft. lb Nm Ft. lb

8.8 10.9 12.9

MPPL/IM/ASCCP/2006/0

M6

M8

M10

M12

4.3 3.1 9.9 7.3 14 10.3 16.5 12.1

10.5 7.7 24 17.7 34 25 40 29

21 15 48 35 67 49 81 59

36 25 83 61 117 86.2 140 103

Nominal diameter – Coarse thread M16 M20 M24 M27 M30 88 64 200 147 285 210 340 260

B-7

171 126 390 297 550 405 650 485

295 217 675 497 960 708 1140 84o

435 320 995 733 1400 1032 1660 1239

560 435 1350 995 1900 1401 2280 1681

M33

M36

M39

800 590 1830 1349 2580 1902 3090 2276

1030 768 2360 1740 3310 2441 3880 2535

1340 988 3050 2249 4290 3163 5150 3798

OPERATION & MAINTENANCE MANUAL

D SERIES – TBD4I - V12 ENGINE

GREAVES COTTON LTD. AUXILIARY POWER DIV. Chinchwad, Pune 411019, India, Tel: (91) – 20 – 27473564/67308200 Fax:(91) – 20 - 27472276.

Document number. 1 234 0 006 033 4 (00)

Page 1 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

Foreword `We thank you for choosing Greaves D series engine for your application. D series engines are water-cooled, four-stroke, multi-cylinder, direct injection compression ignition engines. The engines are designed using modern concepts. The engines are suitable for various off-road applications. In addition to the performance parameters the engine designers have paid special attention to ease of maintenance, ease of assembly and dis-assembly, reliability and standardization. The engines are compatible with existing emission norms and are capable of achieving the future emission norms. The rigid construction of engine has reduced the noise and vibration to a very low level. This manual describes the operating instruction and maintenance schedules of the engine. It is necessary that manual needs to be read carefully before putting the engine into operation. Good installation, clean water, air, lube oil, fuel and timely maintenance will enhance the life of your engine, reduce your running cost and reduce the down time. We would like to emphasize the use of only genuine spare parts for the engine. Use the services of only authorized service dealer for maintenance. Use only listed lube oils, water additives. Training facility is also available with Greaves where technicians can be trained. Continuous improvement may cause changes in this manual. In case the change is important, we make it a point to inform the owners of the engine. This manual is regularly updated to include these changes. In case of any queries, problems do not hesitate to contact our service dealer, regional office. Greaves Cotton Ltd. AUXILIARY POWER DIV. Service and Spares Department Chinchwad, Pune 411019 (INDIA) Ph: +91 (020) 27473564 /67308200 Fax: +91 (020) 27472276

Document number. 1 234 0 006 033 4 (00)

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

Warranty Policy (Diesel engines) Greaves Cotton Ltd. warranty for the machinery is limited to its faulty design, defective materials/ components and/or workman-ship and is valid until a period of 15 months from the date of dispatch of machinery from its Works/Warehouse or one year from the date of commissioning or completion of 3500 hours of operation, whichever event shall occur first. OR Greaves Cotton Ltd. warranty for the machinery is limited to its faulty design, defective materials/ components and/or workman-ship and is valid until a period of 24 months from the date of dispatch of machinery from its Works/Warehouse or 18 months from the date of commissioning or completion of 5000 hours of operation, whichever event shall occur first provided the user of the machinery uses recommended genuine spare parts including “Greaves Maxtherm “ Lube Oil & Coolant wherever applicable and use of genuine Air Filter element and Lube Oil Filter element purchased only from Authorized Dealers of Greaves Cotton Ltd. The foregoing warranty is not applicable in the event, interalia, if • • • • • • • • • • • •

The machinery has been stored improperly and not protected from adverse weather conditions of any nature. Assembly of the Genset is not carried out as per the recommendation. Canopy manufactured and supplied along with the DG Set is not as per the ARAI approved drawings provided by DEU. If OEM has his own approved design through authorized agencies and is adversely affecting performance of engine. If the DG set is installed and is in use without approved acoustic enclosure (canopy). The machinery has not been installed strictly as per the recommendations of Greaves Cotton Ltd. and operated in accordance with the instructions contained in the Greaves Cotton Ltd. operational manual. The defective / improper fuel, lubricants, coolants and any of their associated systems are utilized Unauthorized person carries out repairs and alterations. The maintenance of the machinery is not strictly done as per the procedure detailed in Greaves Cotton Ltd. operator’s handbook/instruction manual. Improper tools and equipments are utilized at any stage during erection, commissioning and maintenance. During operation, the engine is improperly shut down or happened to over speeding or is subjected to misuse, negligence or accident. Failure in any way results from use of components / parts not manufactured or not authorized by us for use on our engine.

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

TERMS OF WARRANTY •

The components having shelf life like rubber components, belts, hoses and replacement filters / consumables which are normally maintenance spares are not covered within the scope of this warranty.

•

In cases of complaints which are proprietary bought out items, our warranty is limited to the extent of warranty of the manufacturer to us.

•

If the engine is improperly stored beyond period of six months without recommended long storage treatment and used without recommended depreservation.

•

All goods are supplied on the condition that under no circumstances we undertake liability for the indirect or consequential loss or damage of any nature.

•

The warranty shall not apply to fair wear and tear of the individual components or damages due to the negligence or improper handling by the purchaser or his employees or agents or due to damage by any cause beyond our control.

•

The warranty does not apply to detect arising due to fault in periodic preventive maintenance and lapse in the use of recommended genuine spare parts including “Greaves Maxtherm” Lube Oil & Coolant wherever applicable and use of genuine Air Filter element and Lube Oil Filter element and also subject to adequate quantity of lubricating oil / coolant in respective circuits.

•

In case of DG set manufactured and supplied by Greaves Cotton Ltd.,, warranty in respect of following items will be restricted to 1000 hours of operation or 3 months, whichever shall occur first.

Main alternator Meters, battery charging alternator components & indicating instruments Protection relays and control fuses MCCB, ACB, contactors and accessories of the engine and the power control panel. Indication lamps and batteries •

Claim under warranty shall be summarily rejected if the defects are not notified within warranty period specified above and lodged within 3 days of the expiry of the warranty period.

•

The new or repaired part of parts will be delivered free of cost Ex-works Chinchwad Pune. Any additional delivery cost to be borne by the purchaser.

•

In respect of any warranty claim accepted by us, we shall arrange to replace or repair relevant and respective parts free of cost to the customer. If parts are replaced, the defective part shall be property of Greaves Cotton Ltd.. In any case, wherever the parts are supplied with free charges, Greaves Cotton Ltd. shall not be liable for any fitment and / or other charges.

•

Greaves Cotton Ltd. shall not be responsible for replacement of the complete unit under any circumstances. In case of any warranty claim, the responsibility of Greaves Cotton Ltd. shall be limited to the extent of replacement or supply of defective parts.

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

Modifications summary Modification No. 00

Document Number / Date 1 234 0 006 033 4 / 10.06.09

Document number. 1 234 0 006 033 4 (00)

Details of Modifications New Release

Page No ---

Page 5 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

Contents Sr. no -------------

Chapter name Foreword Warranty statements Modification summary Contents

Page number 2 3 5 6

1.1 1.2 1.3

General Safety Operation Guidelines Maintenance Guidelines

8 8 8 8

2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.7.1 2.7.2 2.7.3 2.7.4

Engine Description Engine Orientation Engine Nameplate Location of Name Plate Cylinder Nomenclature Engine nomenclature system Technical data Engine Illustrations Radiator side Cross section view Engine Dimensions and Weight Engine Lifting Instructions

9 9 9 9 10 10 11 13 13 14 15 16

3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 3.4.3

Systems Lubrication System TBD 4I V12 –Engines lubrication system D–series lubrication system D – Series lubrication system Permissible engine inclination Cooling Systems D – Series Engine Cooling System D – Series Cooling System Data Water Specification Coolant Additives Filling Up Coolant On A New Installation Topping Up Coolant In An Already Installed Engine Draining The System Thermostat Element Replacement Water Pump Cleaning Radiator Fuel System D – Series Engine Fuel System Trapped Air Removal From The System Electrical System Starter/Alternator Electrical Control Panel Battery

17 17 18 18 19 20 21 22 23 24 24 24 25 25 26 26 27 28 28 29 30 30 30 30

4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5

Engine Operation Standard And Typical Operating Conditions Starting The Engine Safety Instructions First time start after installation In case of Key start In case of push button start AMF operation start up

31 31 32 32 32 33 33 33

1

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

Sr. no 4.3 4.4 4.5

Chapter name Stopping the engine Safety stop Running in

Page number 34 34 34

5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1

Service and Maintenance Maintenance of Lube oil system General Changing Lube Oil Checking Oil Level Changing Oil Filter Maintenance Of Fuel System Fuel Filter

35 35 35 35 36 37 38 38

5.2.3 5.2.4 5.2.5 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11

Fuel Injection Pump Injector NOP Adjustment Dry Type Air Cleaner Inspection and Checking of V Belt Tension Checking and Adjustment of Valve Clearance Flywheel Run out Timing Gear Maintenance Of Cooling System Battery Checking Instructions Electronic Governor and Actuator Fitment Turbo charging Maintenance Schedule

38 39 39 40 41 41 42 42 43 44 44 45

6

Engine Preservation Engine preservation during prolonged period of non-usage Putting a preserved engine back into operation.

50 50 51

7

Installation Do’s and Don’ts

52

8

List of Regional Offices

53

9

Contact addresses

66

6.1 6.2

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Page 7 of 58

Operation and Maintenance Manual D Series – TBD4V12 Engine

1.0 General 1.1 Safety Safety of your personnel, property and equipment should be the first priority during installation, operation, maintenance of your engine and equipment. The engine can cause harm in the following ways against which your personnel have to guard. Sr. No 1 2

Hazard Rotating parts High temperature Hot or hazardous sprays Electrical shocks/sparks Loose objects Poison

3 4 5. 6

• • • • •

Example Flywheel, pulleys, radiator fan Exhaust related parts, exhaust gases, water, oil Fuel, lube oil, water, exhaust leaks or hose/pipe bursts Alternators, starters, control panels, battery wirings Loose parts flying out (likelihood especially after maintenance) Additives, diesel, lube oil, exhaust gases can cause damage if consumed or inhaled

Never get near the engine while it is running wearing loose items like tie, long chains, scarf, long loose clothes, tags with mobile phones etc. Display safety instruction clearly in the operating area. Make the operating persons aware of the safety related issues. Provide necessary safety equipment to the operating persons. Follow all applicable safety related regulations and laws.

1.2 Operation Guidelines It is assumed that the reader and the user of these operating instruction is familiar with the basic mode of operation of four stroke combustion engine and is able to follow technical issues reasonably well. The text has been kept therefore as short as possible for clarity and is backed by photographs and sketches. Read the instructions carefully before installation of the engine or equipment. In case of any doubt or difficulty, seek help from authorized service dealers. Your engine needs clean air, clean fuel, clean lube oil and clean coolant. Giving attention to these factors improves the life of your equipment, reduces the running costs, and also increases the mean time between failures. Maintenance Guidelines • • • • • • •

Please read the maintenance instructions. Seek services of authorized service dealers if needed. Follow maintenance schedules. Plan your maintenance. Always use genuine spare parts, listed lube oil, listed additives and unadulterated fuel from reputed agency. Always use correct tools. Always carry out maintenance in a clean area. Follow good engineering practices during maintenance

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Page 8 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

2.0

Engine Description 2.1

Engine Orientation

Figure 2.1.1 Engine Orientation 2.2.1

Engine Nameplate

Figure 2.2.1 Engine Name Plate 2.3

Location of Nameplate

Nameplate

Figure 2.3.1 Location Of Nameplate

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Page 9 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

Cylinder nomenclature Flywheel side

Figure 2.4.1 Cylinder Nomenclature

2.5

Engine nomenclature system

Figure 2.5.1 Engine nomenclature Example – TBD 4I V12 – Turbocharged after cooled diesel engine D4 series V - Type 12 cylinders

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Page 10 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

2.6

Technical Data TBD 4I V12- Engine Specifications for DG set application Sr. No. Parameter A) General A1 Type A2 Bore(mm) A3 Stroke(mm) A4 Pos. of cylinder / No of cylinder A5 Firing order A6 Direction of rotation A7 Swept volume per cylinder(cc) A8 Total swept volume(ltr) A9 Aspiration A10 Cooling A11 Compression ratio A12 Starting B) Power B1 Rated power(kW Gross) B2 Overload (1 hour in 12 hours - ISO 3046)(kW Gross) B3 RPM B4 Governing C) Drives C1 Water pump C2 Lube oil pump C3 Radiator fan C4 Alternator D) Systems D1 Cooling D2

Lubrication

D3

Fuel Injection

E) Filtrations E1 Air Filter E2 Lube oil Filter E3 Fuel Filter F) Service Data F1 Inlet valve tappet clearance cold F2 Exhaust valve tappet clearance cold F3 Bumping clearance F4 Crankshaft axial play F5 Connecting-rod axial play F6 Flywheel housing face run out w.r.t. crank shaft axis F7 Flywheel housing bore run out w. r. t crank shaft axis

Document number. 1 234 0 006 033 4 (00)

TBD4IV12 4 stroke, direct injection, compression ignition 132 140 60º / 12 A1-B5-A5-B3-A3-B6 A6-B2-A2-B4-A4-B1 Anticlockwise looking at flywheel 1.92 dm³ (1.92 Ltr) 23 dm³ Turbocharged after cooled Water cooled 1 : 15 Electric start (24 VDC) Refer engine name plate 10% 1500 Class A1- IS 10000, less than 4.5 % Centrifugal, belt driven G-rotor, gear driven Belt driven, separate fan drive Belt drive Pressurized (7PSI) water cooled with radiator, with thermostat (74-82ºC), pusher fan for genset application. Pressurized (4-5 bar) Sump capacity 41 liters Oil temperature in sump 120 °C max Inline fuel pump BOSCH (MICO) P type injector Dry type Spin on type Twin bowl 0.3 mm 0.5 mm 1.2 mm 0.4 mm max 1.2 mm Max. 0.25 mm Max. 0.10 mm Max.

Page 11 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

G) Valve / Fuel injection timing G1 Inlet valve opens G2 Inlet valve closes G3 Exhaust valve opens G4 Exhaust valve closes G5 Fuel Injection timing G6

Firing order

10º bef. TDC 29º after B.D. C 41º bef. B.D.C 7º after. T.D.C 15°+/-1° BTDC Fuel injection timing need to be correctly set in order to get good performance of the engine. A1-B5-A5-B3-A3-B6 A6-B2-A2-B4-A4-B1

H) Bolt Torque tightening data H1 M B Cap bolts H2 Cylinder head bolts H3 Inlet, exhaust manifold H4 Turbocharger bolt H5 Connecting rod H6 Flywheel bolts H7 Flywheel housing bolts H8 Injector nut H9 Oil Sump H10 Idler Gear H11 Pulley H12 M 12 (10.9CL) H13 M 10 (8.8CL) H14 M 8 (8.8CL)

28 -29 da Nm (mkp) 30 - 32 da Nm (mkp) 6 kgm 8 kgm 5-9-13Kgm (Torque in step) 26 – 27 da Nm (mkp) 25 – 26 da Nm (mkp) 5 kgm 6 kgm 6 kgm 17Kgm 13Kgm 7Kgm 2.5Kgm

J) Bolt Torque tightening data J1 Normal speed J2 Firing speed J3 Lowest idling speed

1500 RPM 115 RPM 650 RPM

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

2.7.1

2.7 Engine Illustrations Engine genset view

Figure 2.7.1.1 Radiator side

1 2 3 4 5 6 7

Radiator Thermostats Crankcase breather Fuel filter Cylinder head Oil bath air filter Turbocharger

Document number. 1 234 0 006 033 4 (00)

8 9 10 11 12 13 14

Starter Exhaust pipe Oil filler neck with dipstick Name plate Engine foot Charging alternator Alternator

Page 13 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

TBD4 V12 Base engine

Figure 2.7.2.1 – base engine side

1

Fan radiator

5

Injector

2

V belt pulley

6

Control panel

3

Damper

7

Centrifuge

4

Oil sump

8

Fuel on solenoid

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

2.7.3

Dimensions and weight -

For overall dimensions see the layout drawing at the end of this manual. Engine weight - 2550 kg Flywheel HOUSING flange – SAE 1 /SAE 0

Fig 2.7.3.1 Overall Engine Dimensions

ENGINE TYPE

ENGINE ADDITIONAL WEIGHT WEIGHT FOR SEAWORTHY PACKING IN Kg.

TBD4IV12 1400 Kg.

275

DIMENTION IN MM A

A3

B

1490 2006 1645 1060 D2 1170

Document number. 1 234 0 006 033 4 (00)

A2

C

D

D1

295

700

750

E

F

H

J

350

200

42.5

1141

Page 15 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

2.7.4

Engine Lifting Instructions

Figure 2.7.4.1 Lifting Hook Take all safety precautions while lifting and moving the engine. Only trained personnel should handle the engine. You can consult Greaves service dealers, if necessary. Remove water and oil from the engine before lifting. Use wooden blocks under engine feet. Avoid jerks or abrupt resting of engine. The engine should never be rested, stored or lifted in any other than upright. The engine should never be rolled on the ground. Use only the eyebolts provided on the engine crankcase for lifting purpose. The eyebolts are to be used for lifting engine only. Do not lift engine coupled with alternator or entire DG set using these bolts. Ensure that, these I bolts are completely engaged before engine is lifted. While lifting the engine, use correct size of tackles, ropes, chains, cranes, hoists or any other lifting or transportation device. While lifting or transportation, the ropes or tackles should be positioned in such a way that they do not damage engine components like rocker cover, fuel pumps, pipes, etc. The engine should be balanced while lifting and moving. Do not keep the engine hanging on lifting tackles.

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

3.0

Systems 3.1

3.1.1

Lubrication System

TBD 4V12 Engine lubrication system D series engines use positive pressurized lubrication system. The main functions of the lubrication system are as follows: • • • •

Lubrication of friction related parts. To carry away the heat generated by friction To avoid corrosion To wash away debris created by friction wear.

¾ The D series engine uses a positive displacement, gear type pump, which is gear driven. ¾ The system has a pressure relief valve, lube oil filter and lube oil cooler, which are mounted on Crank case. ¾ Providing oil through push rod lubricates the rocker assembly. ¾ The fuel pump and turbo chargers are positively lubricated. The lube oil system is adequately designed to provide sufficient lubrication, oil change period, filter element life and minimize lube oil consumption and running cost.

Return via pocket in cylinder head and push rod pocket in crankcase

Figure 3.1.1.1 Lubrication System Recommended Oil for Dseries engines Company Oil brand name Greaves Cotton Ltd Greaves Maxtherm (API CF -4- 15 W 40)

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

3.1.2

D –series lubrication system

Figure 3.1.2.1 D - Series Lubrication System

1 2 3 4 5 6 7 8 9 10

Oil pan Lub. oil pump Cooling oil pump Suction pipe Oil cooler Bypass pipe for cooler Lub. oil change filter Bypass valve for lub. oil change filter Gallery Crankshaft bearing

Document number. 1 234 0 006 033 4 (00)

11 12 13 14 15 16 17 18 19 20

Big end bearing Camshaft bearing Injection nozzle for piston cooling Piston Mushroom tappet Pushrod Rocker arm Exhaust turbocharger Pipe to injection pump Return to oil pan

Page 18 of 58

Operation and Maintenance Manual D Series – TBD4IV12 Engine

3.1.3

D–series lubrication system

Figure 3.1.3.1 D – Series Lubrication System

1. 2. 3.

Engine oil pump Three-gear suction pump Suction spaces

4. 5. 7.

Oil pan Return piping Suction piping

Lube oil pump is rotor type pump. Lube oil Pressure at various working conditions is as below Speed

Pressure bar

Low idle speed

1.5 to 2 bar

High idle speed Under full load operating conditions

5 to 6 bar 3 to 5 bar

If at any operating condition the lube oil pressure drops below 1.75 bar, then change lube oil filter element. If the problem persists then contact authorized service agent or dealer.

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

3.1.4

Permissible engine inclination Permissible Engine Inclination is given bellow for standard sump. However for continuous or intermittent operation at higher inclinations, contact our technical team for approval.

Figure 3.1.4.1 Engine Inclination

ENGINE INCLINATION

LONGITUDINAL

TRANSVERSAL

1

INSTALLED INCLINATION (MAX.)

6º

--

2

MAX. TOTAL INCLINATION (MAX.2 hours)

15º

22.5º

3

DURING OPERATION (MAX.3 min.)

18º

22.5º

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

3.2 3.2.1

Engine Cooling Systems: D series engines cooling system with air to air after cooling system: D series engines are water-cooled engines. The water pump is belt driven. The water is cooled by a radiator-fan system. The fan is driven by a fan drive. The water also cools lube oil in the lube oil cooler. Thermostats (74C start opening and full open @82C) controls the water temperature. The radiator has a pressure cap, which maintains a pressure @ 0.5 bar (7 psi). A drain plug is provided on bottom header of radiator to drain the cooling system. The cooling system provides adequate cooling in a simple and efficient manner to satisfy the cooling needs of Canopized genset application.

Figure 3.2.1.1 Cooling System 1 3 4 5

Thermostats Cooling water supply for cylinder Bank-B Oil cooler Cooling water pumps

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6 7 8 9 10

Cooling water supply for cylinder Bank-A Radiator for engine circuit Air to Air after cooler Fan By-pass line

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

Figure 3.2.1.2 D – Series Cooling System (Twin circuit cooling) with air to water after cooler

1.

Water pump for engine cooling

5.

Thermostat

2.

Water pump for after cooler

6.

Bypass pipe

3.

Air to water after cooler

7.

Return pipe to radiator

4.

Radiator with secondary core

8.

Fan

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

Figure 3.2.1.3 D series Cooling System for std NA / T engines

3.2.2

1. 2.

Water manifold pipe Water outlet at the cylinder heads

3. 4.

Water outlet from crankcase to cylinder head Cooling water pipe to cylinder Bank B

5.

Water jacket in crankcase

6.

Oil cooler

7 8

By pass pipe from thermostat to pump Water pump

9

Thermostat

10

Radiator

11

Cooling water pipe to cylinder bank A

Cooling system data

Pump

Centrifugal

Drive

Belt driven

PRV in radiator cap

7 psi

Typical steady state water temp

88 – 92 ° C nominal

Max allowable water temp

96 ±2° C

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3.2.3 Water specifications: pH value

6–8

Calcium/magnesium hardness

180-ppm max

Chlorides

Less than 40 ppm

Sulfates

Less than 100 ppm

TDS (Total Dissolved Solids)

Less than 400 ppm

3.2.4 Coolant additive specification Fill requisite quantity of cooling water duly mixed with Greaves maxtherm speciality summer coolant / anti-freeze compounds about 20% by volume or cooling conditioner with anti-freeze , if required. 3.2.5

Filling up coolant on a new installation

The engine can be supplied with the coolant additive, which has to be added to water after installation. For this refer procedure below: • • • • • • • • • •

Open the de-aeration plug. Open the radiator cap. Ensure all hoses are in place and tighten the hose clips. Prepare coolant in the specified proportion. Pour coolant through the spout. Coolant takes some time to fill up the system through the radiator tubes. Wait for 20 seconds before restarting the pouring. Coolant will first start coming out of the de-aeration opening. Wait for the air to escape and close the plug. Keep on pouring till the water is filled up in the radiator top tank. Close the cap firmly.

Figure 3.2.5.1 Radiator Cap

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Figure 3.2.5.2 De-aeration Plug

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3.2.6 a) b) c) d) e)

Topping up coolant in an already installed engine

Never open the radiator cap of an engine that has just stopped. Wait for at least 15 minutes after stopping the engine. For normal top ups, it is not necessary to de-aerate the system. Fill up coolant & wait till the coolant level settles. Confirm that the level is correct. Put the radiator cap back.

Fig. 3.2.6.1 Topping up Coolant

Draining the system: Note: Coolant mixture is poisonous. Store it safely. The drain plug on oil cooler is for draining the coolant below water pump level on bank B-side. The drain plug on the radiator is for draining the remaining system. Drain the coolant in a tray. Dispose off the coolant safely in an environmentally friendly way.

Figure 3.2.7.1 Drain Plug on Radiator

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Figure 3.2.7.2 Drain Plug On Oil Cooler

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3.2.8

Thermostat element replacement: Thermostat is provided in the cooling circuit to attain the stable coolant temperature as quickly as possible at any ambient conditions. Running engine for long hours on cold coolant increases the wear and tear of the liners and piston rings. For this reason, it is wrong to run an engine without a thermostat. However, for tropical climatic conditions where the ambient temperatures are above 10ºC, thermostats open very quickly and close the bypass line. Normally the thermostat does not require any regular maintenance. However, if sudden coolant temperature variation is observed, inspect the thermostat. If the element is not resting properly on its seat or if there is any other defect in the thermostat, it is advisable to replace thermostat.

Figure 3.2.8.1 thermostat on engine 3.2.9

Water pump

Figure 3.2.9.1 Water Pump D series engine have belt driven water pump. the fresh water (coolant) is circulated by a centrifugal pump ( water pump) The cooling circuit can be seen from the Figure 3.2.1.2 D – Series Cooling System

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3.2.10 Cleaning the radiator : Radiator has to be cleaned every 500 hours. This frequency can vary depending on the dust condition in the area of installation. Blowing compressed air in the direction opposite to the normal fan airflow direction cleans radiator. Do not use water or chemicals. These can harden the deposits into very hard cake-like formations, which are very difficult to dislodge.

Figure 3.2.10.1 Cleaning the radiator CAC

Radiator

Thermosta

Bypass PIPE

Radiator Fan

` Figure 3.2.10.2 Radiator charge air cooler

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3.3

Fuel System:

3.3.1

D Series engine fuel system Engine must be operated with good quality diesel. Preferred quality specifications are (IS: 1460 - 2005) – cetane no 51, Sulfur 0.015% max, density 0.835 gm/cc D series engine uses inline high pressure fuel injection pump, with multi-hole mechanical injectors. It is provided with a feed pump and double element fuel filter. The system is calibrated to deliver performance and meet emission norms. Since the high pressure injection system is used on this engine, gravity flow of fuel from fuel tank to fuel injection pump (FIP) is recommended. The fuel tank height can be up to three meters (to be recommended by installation / service engineer), it can also be below FIP provided suction head is up to one meter.

Figure 3.3.1.1 Fuel System 1. 2. 3. 4. 5.

Tank Overflow pipe Leak-off line Injection pressure line Fuel filter

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6. 7. 8. 9. 10.

Injection pump Overflow valve Feed pump Injection valve Fuel pre-filter

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3.3.1.2 Fuel system FIP and injectors are supplied by BOSCH and warranty is covered. Servicing these is a highly skilled work. This has to be done by authorized service agency or shop. 3.3.2

Trapped Air Removal from System Bleeding of FIP needs to be performed • • •

Before engine operates first time. After long period of inactivity. If FIP or HPP loosened and there is air in the line.

Fig 3.3.2.1Removing air from fuel line Bleeding Process; • Unscrew Hand priming pump knob. • Loosen fuel inlet banjo. • Pump manually, till fuel comes through the screw free of air Knob may be relocked.

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3.4

Electrical system 3.4.1

Starter / Alternator Electrical system is provided with the engine including a 24 Volts starter and a 28V alternator.

Figure 3.4.1.1 Starter 3.4.2

Figure 3.4.1.2 Alternator

Electrical Control Panel Engine instrument panel has operating controls and gauges. Engine can be stopped and monitoring of engine parameters during operation of the engine.

Figure 3.4.2.1 Control Panel 3.4.3

Battery

Fig. 3.4.3.1 Battery 2 x 12 Volt, 180 Ah capacity batteries are recommended

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4

Engine Operation 4.1

Standard and Typical Operating Conditions

Sr. no 1 2 3 4 5 6 7 8 9

Standard Operating Conditions Parameters Unit Value Remark Ambient temperature °C 25 (ISO 3046) Relative humidity % 60 (ISO 3046) Altitude (ISO 3046) m 100 Ambient temperature at Only for turbocharged and turbo after which deration will be °C 35 cooled engines applicable Relative humidity at which Not for turbocharged and turbo after % 85 deration will be applicable cooled engines Altitude at which deration will Only for turbocharged and turbo after m 1000 cooled engines be applicable Minimum temp at which °C 0 engine can be started without starting aid At 1.5 m above ground in normal Air cleanliness for standard mg/m3 25 industrial area or agricultural land on dry air cleaner a wind less conditions Less than Inclination in both directions For genset application 1 deg

Typical steady state operating parameters 1

Lube oil pressure

bar

4-5

2

Lube oil temperature

°C

85-100

3

Water temperature

°C

78-90

4 5

Suction depression (new air mm WC Max cleaner element) Suction depression (clogged mm WC Max air cleaner element)

550

6

Exhaust back pressure

7

Steady state rpm variation

±RPM

5

8

Max fuel suction lift

Meter

1

9

Typical fuel temperature

°C

35 - 39

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mm Hg

150

25

340 mm of water

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4.2

Starting the Engine 4.2.1

Safety Instructions – • The legal regulation for safety must generally be observed • The engine may only be operated or maintained by trained staff • Ensure cleanliness in the engine canopy/compartment. • Cleaning maintenance and repair should be done when engine is stopped and secured. First time start after installation ¾ Check all electrical, fuel, exhaust and other connections and ensure tightness. ¾ Check that all critical fasteners/hose clips are tightened (Flywheel coupling, foot mounting, AVM bolts, crank pulley bolts, etc). Check engine alignment (for open coupling) and mounting on foundation. ¾ Engine is filled with Lube oil through the filler neck. Oil to be filled at desired level to be checked with dipstick. Confirm that engine has adequate coolant and oil.

Oil filler neck

•

Fig 4.2.2.1 Lube Oil Filler Neck Confirm that air bubbles have been removed from fuel and coolant circuit.

•

Check belt tension and make adjustments, if required.

• • • •

Confirm the battery condition. Confirm that all necessary safety guards are in place. Confirm if all safety precautions have been taken. Confirm that the electrical breaker is in OFF position.

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Note: Sudden loading of the engine from 0 to 100% of rated load is to be avoided for turbocharged and turbo after cooled engine. In turbo after cooled engines, sudden loading is limited to 45 to 50 % of the rated power as per ISO 8528. Never try to start the engine on load. • Start the engine and run on no load for 5 to 10 minutes. • Observe abnormalities like noise, vibration, rattling brackets, leakages, etc. and take corrective action. • Check oil pressure. Confirm that all the meters are working. • Confirm that every thing is OK and then slowly load the engine. • The engine is provided with a battery-charging alternator. • During the normal running of the engine, the charging lamp should be OFF. If the battery-charging lamp turns ON during engine running, it is an indication that the battery is not getting charged. Check the circuit and take corrective actions. 4.2.3

In case of Key start: • For starting the engine turn the key from “ÓFF” to “ON” This will light up the battery voltage gauge and the pilot lamp will light up. • Turn the key further. Engine will rotate, when the engine picks up speed, release the key.

CONTROL PANEL

Figure 4.2.3.1 Control Panel Note: • Wait for 20 to 30 seconds between 2 startup attempts. • Do not turn the key when the engine is running. 4.2.4

In case of push button start • Press the push button. Release immediately when the engine picks up speed. Note: • Do not push the button when the engine is running. • Wait for 20 to30 seconds between 2 startup attempts.

4.2.5

AMF operation start up • • • •

In case of Auto Mains Failure (AMF) mode operation of genset application, the engine starts automatically when the grid power fails. It is extremely important to inform everybody that genset is in AMF mode. Access to area nearby genset should be avoided as the engine can start automatically without notice. In case of maintenance, it is necessary to put the engine in non-AMF mode (manual mode) and remove battery cables before starting maintenance.

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4.3

Stopping the engine • • • •

Remove the load from the engine. Run for 2 minutes to stabilize the temperatures. Recommended for turbocharged and turbo after cooled engines. Push the stop button to stop the engine. The engine can also be stopped manually by turning the stop lever on the fuel pump (Photo STOP lever on fuel pump).

Stop leaver

Fig. 4.3.1 Fuel Stop Valve. Turn the key to “Off” mode so that battery does not get depleted / discharged. 4.4

Safety stop The engine will automatically stop in case of certain safety conditions like • High water temperature • Low lube oil pressure Check the reason for this event before trying to restart. Do not restart till the event is completely examined and corrective action is taken. Never bypass safeties or try to change their operating limits.

4.5

Running-in Running-in of the engine is extremely important for the engine (means what). A good running on will ensure good, long life for the engine. During the first 60 hours of running, do not load the engine suddenly and restrict the load to ≤80 %. After 60 hours, the engine can be loaded suddenly (Typically a sudden load of 45 % of the rated load is allowed as per ISO 8528) and then full load can be applied. After 60 hours carry out the following actions: • Change oil, • Change lube oil filter cartridge, • Change fuel filter elements, • Change fuel filter on feed pump (Button filter or sediment bowl), • Check belt tension and correct it, if required, • Check tappet clearance and correct it, if required, • Check engine for leakages and tighten the fasteners, if required Take corrective action if abnormal noise, vibrations are observed. Now the engine is ready for its long life.

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5.1.1

5.0

Service and Maintenance

5.1

Maintenance of Lube oil system

General Oil change periods depend on the engine usage, application, site conditions, installation and quality of fuel and lube oil. It is necessary that oil should be changed at least once in six months, if the engine use is less than specified, oil change period varies. For genset applications, it is necessary that the engine be installed on level horizontal plane area (Angle 1 deg max). For trolley mounted genset transitional angle of 12 deg is acceptable. However, genset should never be run in an inclined position on continuous basis. TBD4V12 Sump capacities

68 Liters

Sump high mark

52Liters

Oil change period Oil filter change period

First oil change after 60hr.,next oil change ref. page no. 45, sr. no. 11 Refer page no. 45, sr. no. 9

Steady state lube oil pressure

4 – 5 bar

Lub. oil pressure at n = 750 min-¹

1.5 Bar

Steady state lube oil temp

90-110°C

Lube oil viscosity grade recommendation

5.1.2

Ambient temp (Deg C)

Grade of oil

-20 to + 20

SAE 10 W 30

-10 to +55

SAE 15 W 40

-5 to +45

SAE 20 W 40

Changing Lube Oil

Figure 5.1.2.1 Drain Plug

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After the specified oil change period, oil should be changed irrespective of the oil condition. In this period, the chemical properties of the oil are depleted. This is not visible to naked eye or cannot be judged by experience or feel. Start the engine and run it till it gets warmed up. When the oil temperature reaches 70 to 80 °C, stop the engine. Place a tray under the sump drain plug and open the drain plug. Please note that the oil is hot. Drain completely. (Approximately 20 minutes). Refit the drain plug. Remove the oil filter and drain it. Fill up the oil filter with fresh specified oil from sealed pack and refit the oil filter. (Refer figure 5.1.4.1) Open the oil-filling cap. Take required quantity of specified oil from a sealed package. Pour in the filler through a funnel, after a specified quantity is if filled up, confirm oil level by dipstick. (Refer figure 5.1.3.1) and fit the oil filler cap

Figure 5.1.2.2. Oil Filling Dispose off the used oil in a proper environmentally friendly way. 5.1.3

Checking oil level

Figure 5.1.3.1. Checking oil level

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The above preferably is done before starting the engine. If the engine is running, then stop it and wait for 30 minutes (for an accurate measure of oil level). Routine checking can be done in a few minutes after stopping the engine. Lube oil sump capacity is 52 liters at dipstick marking. Fill the oil till upper level mark without exceeding it. Do not operate engine with oil level below lower mark. Remove dipstick and wipe it. Re-insert the dipstick till it rests on the collar. Remove the dipstick and observe the oil level. If the level is between low mark and high mark, oil level is ok. If level is below low oil level mark, fill up oil at least to between low and high oil marks. If the oil level is above high-level mark, then drain the oil and bring the level back to high level. More oil in the sump than required is not only a waste; in extreme cases it is injurious for the engine.

5.1.4

Changing oil filter

Lub. Oil filter

Figure 5.1.4.1 Changing oil filter • • • • • • •

This operation is done preferably a few hours after the oil is changed. D series engines use spin-on type oil filters Clean up the lube oil filter area on the engine. Remove the oil filter cartridge. A commercially available strap type tool can be used to remove the oil filter cartridge. The cartridge has oil in it and has to be stored carefully to avoid spillage. Take a new genuine oil filter cartridge. Fill up fresh specified oil from sealed package into the oil filter cartridge. Fit it only by hand tightening. Check for leakage from the collar of the oil filter cartridge after starting the engine.

Note: Never try to clean up a cartridge and re-use. This causes severe injury to the engine.

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5.2

Maintenance of Fuel System Use only clean fuel, without water or particulate suspension, impurities etc. Maintain the fuel level in fuel tank to full level, for reducing the possibility of air lock and condensation entering the system. Bleeding of air must be done if • Engine operates first time, • If it is idle for long time, • If High Pressure Pipe lines are loosened, • If air is trapped in the system between fuel tank and feeds pump by means of flexible pipe.

5.2.1

Fuel filter To protect the FIP and Injectors, fuel filter is provided before FIP. If the filter element is contaminated then it need to be replaced. For changing fuel filter cartridge • • • • •

Close the fuel cock (for a positive head fuel tank system) Loosen the filter bowl. Coat the seal of the new filter element with fuel. Fit the filter element in filter bowl, then re-fit the assembly to filter head. Bleed the fuel filter as explained earlier in 3.3.2

Figure 5.2.1.1 Fuel Filter Similarly you can change filter element if required from fuel filter.

5.2.2

Fuel Injection Pump It is recommended that Fuel Injection pump servicing is done by BOSCH authorized service agent / personnel at authorized service center preferably through Greaves service personnel.

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5.2.4

Injector NOP (nozzle opening pressure) adjustment Injector servicing needs to be done by authorized service personnel. Hence this needs to be brought to the authorized service station for servicing and setting.

Figure 5.2.4.1 Nozzle Testing (Description of nozzle testing)

5.2.5

Dry Type Air Cleaner The outer element in the air cleaner needs to be replaced or serviced, when maximum allowable restriction has been reached. Check with vacuum indicator. Remove the outer element gently so that no dust is fallen inside the housing. Clean the filter housing with a dry cloth, after blanking the outlet pipe of air filter housing. It is recommended to replace the filter element once used. But, only in exceptional cases, the filter element is cleaned by means of a blower, and the air is to be blown from inside to outside, in longitudinal direction. Reassemble the element after careful inspection and confirmation for reuse. In case of twin element air filter, same procedure is to be followed as above for outer element. However, do not clean or remove the inner element ever till the outer element is replaced two times i.e change the inner element every third time replacement of outer element. For heavy dusty conditions, construction sites, it is recommended to use air pre-cleaner (with auto dust ejection).

Figure 5.2.5.1 Air Filter

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Figure 5.2.5.2 Air Filter Element

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5.3

Inspection and checking of ‘V’ belt tension Ensure that the belt tension is correct by pressing it, at middle of the belt, by finger or thumb as shown. Deflection needs to be 5 to 8 mm. It can be adjusted at the tension roller adjustor as shown below. Operate the engine with new belt for five to ten minutes and then re-adjust the belt tension.

Tension adjustment

Figure 5.3.1 Inspection and Checking of V Belt Tension

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Checking and Adjustment of Valve clearance

Adjust the valve clearance when engine is in cold condition. Adjust the clearance with piston at TDC and ensure that both valves are closed. Clearance is 0.3 mm. inlet and 0.5 mm for exhaust valves.

Figure 5.4.1 Checking and adjustment of Valve Clearance

5.5 Flywheel Run out Flywheel run out on face to be maintained as 0.2 mm. Flywheel coupling mounting bore run out wrt. Crank shaft axis 0.10 mm max

Figure 5.5.1 Flywheel Run-outs

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5.6

Timing Gear Except oil pump gear, all other gears in the gear train have timing markings, which need to be aligned to get correct fuel injection and valve timing.

FIP Gear

Cam gear

Crank shaft gear

Figure 5.6.1 Timing Gear 5.7

Maintenance of cooling system

The engine cooling system contains belt driven water pump, cooling passages on the engine and cylinder head, water manifold, thermostat, radiator and lube oil cooler (which is cooled by engine water) The coolant used should be clean, free from dirt or dust, floating matter, colorless, without smell. Add Greaves supplied coolant additive, in correct proportion, for efficient cooling of the system. Bad water can cause severe corrosion and scalling. These corrosion products can block cooling system and severely damage the engine. Hard water can completely chock up the cooling system with scale formation of salts, sulfates and other compounds. This can cause engine seizure. Never use concentrated acidic compounds or soda lime to clean up the cooling system.

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5.8

Battery Checking Instructions

The battery is of lead acid type. After 150 hours of running it should receive the attention as follows: Brush the dirt from the battery. Remove the vent plugs. Check the level of Acid. •

• •

The acid in each cell should be kept in level with the top of the separators. Top up, if necessary, with distilled water. Do not allow distilled water to come in contact with metal, use only the glass or plastic or earthenware container and funnel. Do not bring a naked light bulb near when plugs are removed or when the battery is on charge as the gas given off by the acid is highly inflammable. The charge of the battery can be checked with hydrometer which shows specific gravity of the electrolyte. This varies with the state of the charge. Check the specific gravity of the acid with a hydrometer. When charged the specific gravity should be as follows:

A B C At climates below 80ºF (27ºC) At climates between 80ºF and At climates over 100ºF (38ºC) specific gravity corrected to 100OF (27ºC-38ºC) specific gravity specific gravity corrected to (60ºF) (16ºC) corrected to (60ºF) (16ºC) (60ºF) (16ºC) 1.28-1.30 1.25-1.27 1.22-1.24 When the hydrometer shows as low as 1.25 for “A”, “1.20” for B and “1.18” for “C” the battery must be charged as soon as possible, either by the engine or from an external source. • •

Clean the vent plugs and free their air passages. Ensure that the terminals are free from corrosion. If corrosion has taken place, the terminal should be disconnected from the battery and the corrosion scraped off. Wipe with a rag moistened with weak ammonia or bicarbonate of soda solution. The terminal should be bolted tightly on the terminal posts and coated with petroleum jelly (no grease).

Please note that while engine is supplied charged on low amperage or slow charge from authorized battery maintenance / repair shop. Time required for initial battery charging is approximately 48 Hrs. Always use battery fully charged while commissioning of engine. Some assorted maintenance jobs • • • •

Starter brushes to be replaced, if worn out sufficiently. To clean exhaust, silencer and piping for soot. Fuel tank to be drained to remove sediments or cleaned at regular intervals. Check and tighten fasteners, if required at regular intervals.

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5.9

Electronic Governor and actuator fitment

Engine speed is sensed by magnetic pickup sensor. This signal is used by electronic control unit to give signal to rotary actuator to control stop lever of fuel injection pump to control the speed of engine at 1500 rpm.

Sensor wire control unit Lever on actuator connecting stop lever of FIP Actuator

Fig 5.9.1 Actuator

5.10

Turbo charging – The purpose of turbo charging the engine is to boost the inlet pressure of the air, there by increasing the mass flow of air in to the combustion chamber to deliver higher power from the same engine. Further increase in power of the engine, the compressed air from the compressor of the turbocharger is cooled by means of after cooling.

Turbocharger

Fig 5.10.1 - Turbocharger

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5.11

Maintenance Schedule

**

3

Check Fuel level in tank

**

4

Check water level in radiator

**

5

Check Battery condition

**

6

Clean coarse fuel filter

7

Change air filter element

9

Change oil filter cartridge

10

Change fuel filter cartridge

11 Changing oil

12

**

**

**

Every 500 Hrs

**

**

**

**

**

**

Every 500 Hrs

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

**

Cleaning up radiator fins

Checking up valve 13 clearance and set if necessary

**

Tightening up external fasteners

**

**

Clean injector, nozzles and spray 15 Change if necessary

**

**

**

**

14

16

3500 hours

**

3000 hours

**

1500 hours

**

1000 hours

Others

Check oil level in Sump Check Belt 2 tension 1

500 hours

Particulars

Daily

Sr. no

10000 hours

Maintenance Schedule

Cleaning up fuel tank

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Typical change periods are maximum periods. Depending on the local conditions, these may have to be shortened. Set up your own maintenance frequency with experience, Based on site conditions First re-set valve clearance after 60hours of running. Check regularly

Or at least once in a year

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17

Cleaning up exhaust silencer

Checking exhaust bellows and 18 change if necessary Checking valve and insert 19 condition, change if necessary

Others

10000 hours

3500 hours

3000 hours

1500 hours

1000 hours

Particulars

500 hours

Sr. no

Daily

Maintenance Schedule

**

Or at least once in a year

**

After 3500 Hrs

**

Calibrating fuel 20 pump

**

To be done by Bosch authorized dealer

Changing valve 21 stem seals if leakage observed

**

If leakage is observed

Changing gear 22 end and flywheel end oil seals

**

Whenever the oil leakage is observed

Changing 23 thermostat element

**

24

Changing cylinder head gaskets

**

Changing air / 25 exhaust / water manifold gaskets Checking sensors and change if 26 necessary

**

**

Overhauling 27 starter and alternator Checking and change AV 28 mountings if necessary Checking and 29 changing AV mounts if required Replace radiator 31 cap with rubber ring 32

All hoses and hose clips

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**

**

** **

Major overhaul should be carried out at 10000 hours or ** 7 years whichever is

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Changing water pump if required

Changing valves, valve guides and 37 valve seat inserts if required 38

**

Changing high pressure pipes

**

Changing 39 injectors if required 40

41

Others

earlier. Carry ** out all activities of top overhaul also. Except rubber ** parts and gaskets, if metal parts can be ** reusable, then these are not needed to be ** replaced based on condition of the parts.

Changing main 33 bearings if required Changing conrod big end and small 34 end bearings if required Changing set of 35 gaskets and O rings 36

10000 hours

3500 hours

3000 hours

1500 hours

1000 hours

Particulars

500 hours

Sr. no

Daily

Maintenance Schedule

**

Changing liners if required

**

Changing piston assembly if required

**

Checking and changing con rod 42 small end bush if required

**

Changing fuel 43 pump elements if required

**

To be procured from Bosch authorized dealer

Changing AV mountings

**

If required

Checking all critical fasteners 45 and replace if necessary

**

44

46

Checking fan drive assembly

47

Add coolant additive

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** **

**

**

**

**

**

Every 500

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Others

10000 hours

3500 hours

3000 hours

1500 hours

1000 hours

Particulars

500 hours

Sr. no

Daily

Maintenance Schedule

hrs 48

Replace cooling water and additive

** **

49 Change belt

50

Check engine protection system

**

**

**

Note :This schedule is applicable only when Greaves Maxtherm oil and coolant are used

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Notes Never re-use following items • Cylinder head gasket, • Copper washers, • O-rings, • Valve stem seals, • Oil seals, Top and major overhaul depends on the type of loading, quality of installation, quality and regularity of maintenance, etc., the above mentioned intervals are typical periods. Users should keep a close watch on their engine installation to see the signs of service requirement. It is also advisable to get the engine overhauled in lean operation period or ahead of a heavy season of running.

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6.0

Engine Preservation

6.1

Engine preservation during prolonged period of non-usage

If the period between engine dispatch from Greaves and the installation is more than six months or if a engine is to be non operational for more than twelve months, the engine has to be preserved to avoid damage due to corrosion, dust, and other factors. Preferably a preserved engine should be covered in plastic sheet and stored in cool dry, shaded place. Following instructions are to be followed for engine preservation: Run the engine with clean fuel at rated speed at no load for about 10 minutes. This warms up the engine and the lube oil is circulated all over inside the engine. Stop the engine and immediately drain the oil. Fill up the engine with one of the preservative oils to the low level mark on dipstick. Choose preservative oil from the list given below. Run the engine at rated speed with no load for 5 minutes. Make a clean solution of preservative oil and diesel (1: 5 ratio) and connect the mixture to the fuel pump inlet by gravity feed. Drain the coolant from cooling system. Rinse the system thoroughly with clean water. Fill the cooling system with mixture of water and any of the coolant additives listed - in the requisite ratio. Crank the engine and run it at rated speed with no load for half a minute. Stop the engine. Remove air cleaner, fuel filter and lube oil filter, pack them separately. Drain preservative oil from sump and refit the drain plug. Drain water-preservative mixture from cooling circuit. Treat all unpainted open surfaces with rust preventive coats. Seal all openings with caps, plastic sheets or waterproof paper. Seal the dipstick with the tape. After this point do not rotate the engine. Remove belts and store separately. The battery should be disconnected. Ensure electrolyte level. Charge the battery at regular intervals. Put a mark on the engine indicating date of preservation. Periodically inspect the engine for corrosion, effects of humidity and dirt. The above procedure has to be repeated after every 12 months. Recommended preservatives Manufacturer

Rust preventive

Bharat Petroleum

Bharat Rustol 152

Indian Oil Corporation

Servo RP 125

Hindustan Petroleum

Rustop 274

Veedol

Veedol Rustop IT

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Cooling system Bharat Sherol B emulsion with water (1: 20 ratio) Servo Cut S 20% Emulsion with water Koolkit 40.5% emulsion with water Veedol Amulkut 4 Emulsion with water 1:15

Lube oil and fuel circuit Bharat Preserve oil 30 Servo preserves 30. Servo Run-N oil 30 Auto run T 120 Veedol 30/40

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

6.2

Putting a preserved engine back into operation.(check numbering) • • • • • • • • •

Remove all seals. Clean up the engine. Remove rust preventive coat. Fit air cleaner, fuel filter, Lube oil filter, and belts. Use new filter elements. Apply correct tension to the belts. If rubber components (Hoses, belts, etc) are cracked or brittle, replace them. Fill up correct grade oil up to the high level mark on dipstick. Fill up coolant. Remove trapped air. Connect supply of clean fuel. Remove trapped air. Fit a charged battery. Check the electrical connections. Run the engine at rated speed at no load for 5 minutes. Observe and look for any irregular noise, vibration, etc. If some irregular behavior is observed take corrective actions or call authorized service dealer. Start the engine and put it into service.

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

7.0

Installation Do’s and Don’ts

7.1

Do’s

Install the engine on horizontal, hard area. This area should be properly ventilated. It should have access to maintenance areas. All the mounting structure should properly rest on the ground. Check with civil engineers and architects before mounting the engine on slabs, beams, raised structures, above ground floor, etc. Check fire hazard possibility near fuel, oil storage. Plan release direction of the exhaust. Judge engine size properly. Seek help from Greaves service dealers or area offices for this purpose. Provide adequate safety measures around installation area. 7.2

Don’ts

Never install the engine on inclined surface. Remember that a good installation reduces running cost, maintenance cost, provides reliable and safe service.

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

8.0

GCL regional office and Dealer Addresses

Location Name

Address

Tele. / Fax & e mail

HEAD OFFICE MARKETING PUNE

AUXILIARY POWER DIV.

Mumbai-Pune Road Chinchwad, Pune- 411019

K.M.Joshi Exe.Vice President

Tel. 91-20-27473564(O) /67308200 Fax- . 91-20-27472276 / 27474567 After Office Hours91-20-27472601(O) www.greavescotton.com Tel-091-020-27462230(O) Fax-91-20-27472276 [email protected]

Mr. R.P.Chaudhary Vice President

Tel. 020-27473407(O) Mob-9922433770 Fax-020 27474567. [email protected]

Mr. A.K.Adwani General Manager- Marketing

Tel. 020-27473405(O) Mob-9830776659 Fax-020 27474567. [email protected]

Mr.V.D.SIVKUMAR General Manager Marketing

Tel.020-27472127(O) Fax-020 27474567. Mob-9922923977 [email protected]

Mr. Mahesh Manwani Divisional ManagerMarketing

Tel. 020-27471079(O) Tel. 020-25905083® Fax- 020-27474567 Mob-9881152393 [email protected]

Mr. A.V.Naik Divisional Manager Service

Tel. 020-27450274(O) Tel.020- 32540909 ® Mob- 9822477359 [email protected]

Mr. P.S.Chitale Sr. Manager Training

Tel. 020-27475425(O) Tel.020- 27492114 ® [email protected]

Mr. Sanjay Govaikar Dy. Manager Marketing contracts

Tel.020 27488490 (O) Tel.020 25280083 ® Mob.9850828325 [email protected]

Mr. S.G.Ranade Manager Marketing-Spares

Tel. 020-27471079(O) Tel. 020-32662917 ® Mob- 9822477354 [email protected] Tel. 020-67308211(O) Tel.020-27484982® Mob-9823041131 [email protected]

Mr. R.R.Tupe Sr.Engineer Service

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

PUNE

Mr. Yogesh D.Kshirsagar Engineer Service

Tel .020-67308211 (O) Mob- 9922965241 [email protected]

Mr. M.N.Patankar Engineer Service

Tel .020-27475425 (O) Tel.020-26933413.® Mob- 9765275160 [email protected]

NORTHERN REGION DELHI

Diesel engine unit

Express Building Annexe 9-10. Bahadur Shah Zafar Marg, P.B.no- 7024, New Delhi110002

Tel. 91-11-23730554 (O) Tel. 91-11-23317039(O) Fax- 91-11-23359782 91-11-23357739

Rajiv Kulshreshta Regional Manager

Tel. 01123359783 Mobile-9810898096 [email protected]

Mr. M.C.Upadhyaya Manager Service

Tel.-011-23318037(O) Tel - 011- 22621450 (R) Mob- 9810898093 [email protected]

Mr.Kapil Sharma Commercial Executive

Tel.-011-23730554 [email protected]

Mr.Pankaj Vishwakarma Sales Executive

Tel. 011-23730554 Mob- 9810092540 [email protected]

Mr.Rajesh Mishra Service Executive

Mob. 9718199670 [email protected]

P S Guleria BG-1 Service

Tel.011-2370554(o) 011-25645435(R) Mob. 9871816336 [email protected]

Mr.Kapil Saini Service Engineer

Tel.011-23730554 Mob. 9891442407 [email protected]

Mr.Satpal Dabas Service Engineer

Tel-01123730554 [email protected]

KANPUR LOCATI ON

Mr.Praveen Dubey Area sales executive

Tel-0512-3040730 Mob-9935546733 fax-0512-3014212 [email protected]

JAIPUR LOCATI ON

Mr. Manish Kumar Trivedi BG-1 Service

Mob. 9314254422

DELHI

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EASTERN REGION KOLKAT TA REGION AL OFFICE

Ranchi BRANCH OFFICE

Guwahati BRANCH OFFICE

Greaves cotton ltd. Regional office

Thaper House 25, Brabourne Road, Kolkatta- 700001

Tel- 91-33-2421459(O), 22424321/20/16/17

Fax- 91-33-22424325

Mr. S.Ray Area Sales Manager

Tel-033- 22421459(O) 033-24817661 ® Mob- 9831116820 [email protected]

Mr.Debesh Chakborthy Sr. Service Execuitive

Tel-033- 22421459(O) 033-24817661 ® Mob- 9836886517 [email protected]

Diesel Engines Unit

Opp.Arya hotel H.B Road ,Second floor . LALUR,Ranchi - 834 001

Tel- 91-651-2530900/2530981 Fax 91-651-2530981

Mr. A.K.Das Sr.Branch Manager

Tel- 91-651-2530900/2530981 Fax 91-651-2530998 Tel-0651-2202407 Mob- 9835158912 [email protected]

Mr. Mishra Service Engineer

Mob- 9835156387 [email protected]

Mr.Barpujari Service Engineer

Mob- 9864155225 [email protected]

WEASTERN REGION MUMBAI BRANCH OFFICE

Diesel Engines Unit

corporate park II, 4th Floor Sion Trombay Road Chembur , Mumbai 400071

Tel - 91-22-25264646(O) Fax No. 91-22-25262622, 2526480

H.P.Mandan Regional Manager

Western Region Chembur Office.

Tel - 022-25262676(O) Tel - 022-28058115 ® Mob - 9820605379 [email protected]

Mr. Sanjay Jain Divisional Manager Marketing

corporate park II,Sion Trombay Road Chembur.Mumbai-71.

Tel - 022-25264710(O) Tel - 022 - 26052367 ® Fax-022-25262622. Mob - 9819852440 [email protected]

Mr. M B Kulkarni Sr. Service Manager

Chembur Office.

Tel - 022-25264711(O) Tel - 022-28406702 ® Fax-022-25262622. Mob - 9820605381 [email protected]

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

MUMBAI BRANCH OFFICE

Mr.P S Sekar Senior Executive(Spares)

Chembur Office.

Tel - 022-25264713(O) Tel- 022-24038457® Fax-022-25262622. Mob- 9892406616 [email protected]

AHMED ABAD

Diesel Engines Unit

Jaldarshan' opp.natraj cinema,Ashram Road, Navrangpura Ahmedabad 380009

Tel - 91-79-26581856 Fax - 91-79-26587783

Ahmeda bad office

Mr.S Barman Ray Branch Manager

Tel - 079 - 26585709(O) Tel - 079 - 65411073 ® Mob - 9825147873 Fax-079-26587783 [email protected]

Mr.Piush Patel Sales Executive

Tel-079-26581861(O) Tel-079-27531161(R) Mob - 9924373900 [email protected]

Mr.Rathod Nikul Sales Executive

Tel-079-26581861(O) Tel-079-65420632 (R) Mob - 9909919147 [email protected]

Mr.Sameer Delwadi Executive Engineer-Service

Tel-079-26581861(O) Fax-079-26587783 Tel-0265-2394233.(R) Mob -9879604668 [email protected]

Goa office

INDORE

GOA- RESIDENT OFFICE

C/o UPA engineering Sales & Services Vasco-da-Gama

Tel- 0832-2514512, 2513685(O)

Mr. R.L.Kanitkar Resident Service Engineer

A2, Amerkar Residency, Near Saibaba Temple, New Wadem Vasco-da-Gama, Goa- 403802

Tel- 0832-2512424 ® Mob- 9890931892 [email protected]

Sandeep Singh,

KATARE POWER INDUSTRY 114, Dayes Tower, 19/2 Manoramagunj Palasia Point, Indore - 452001

Telefax-07314090021,Mobile9425059587 Email [email protected] [email protected] [email protected]

SOUTHERN REGION CHENNAI

Diesel Engines Unit

Wavoo Mansion, 6th floor 48 (old no.39) Rajaji Salai Chennai- 600001

Mr.DARSHAN DESAI Regional Manager

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Tel- 91-44-25255200(O),25224571 Fax-91-44-25224557 Tel-044-25224571(O) Tel-044- 24464955 ® [email protected]

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

BANGAL ORE

Mr. K.K.Vishwanathan Divisional Manager Marketing

Tel-044-25240141(O) Tel - 044 - 24806927 ® Mob-9840291041 [email protected]

Mr.K I SAHAYARAJ Area Sales Manager-Parts

Tel- 044-25251351(O) Tel - 044 - 26281674 Mob-09444211306 [email protected]

Mr.N Govindrajan Service Executive

Mob-9442550218 [email protected]

Mr. Chandrashekhar Sales Executive Mob-9952230892

Mr. G.V. Subramanyam Service Executive Tel- 91-44-25255200(O) Mob - 9445360010 [email protected],

Diesel Engines Unit

16/3 Ali Asker road Bangalore 560052

Tel- 044-25240358(O) Mob - 9845130928 [email protected],

Mr. Gururaj Bellary AREA Service Managere Hyderabad 6-2-47 A.C.Guards P.o.Box No-9 Hyderabad-500004

HYDERA BAD

Tel- 040-23314025(O) Tel- 040-23316446(O) Tel- 040-23390544(O) Tel- 040-23318557(O) Mobile :9440089850 [email protected]

Mr. N Hanmanthu Area Service Executive Mr. K.S. Thampan Branch Manager

Tel- 080-22262062(O) Tel- 080-22253472(O)

6-2-47 A.C.Guards

Tel- 0484-2359272(O) Tel- 0484-2359661(O) Fax-0484-2359589

KOCH OFFICE

Mr. K N Majnu Service Executive

Mob-9447705855 [email protected]

KOCH OFFICE

Mr. P R Radhakrishnan Service Executive

Mob-9447579062 [email protected]

INTERNATIONAL OPERATIONAL Industry Manor

Appasahabe Marathe Marg Prahabadevi Mumbai 400 025

Phone No 022 - 24381147 , 24397614 Fax - 022 - 24377730 , 24379555

A.V.Jondhale General Manager

022 - 24381147 , 24397614 Cell no 98206 05379 [email protected]

Sukhdeep S. Grover Dy. General Manager Exports

Ph.No – 022 - 24397640 Cell no 98190 02035 [email protected]

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Operation and Maintenance Manual D Series – TBD4IV12 Engine

Manish Kumar Divisional Manager

Phone No 022 - 24397642 Cell no 9833742768 [email protected]

Sandip Unni Area Sales Manager

Phone No 022-24397643 cell no 9819776961 [email protected]

P.P.Doctor Dy.Manager Exports

phone no 022-24397644 cell no 9820403311 [email protected]

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