MIRRLEES BLACKSTONE ESL12 MK2 User manual

1

BLACKSTONE
INSTRUCTION
MMNUAL
ESL12 .r - 16Mk2
INDUSTRIAL AND&URINEENGINES
Publication No- 71 October 1994
Mirrlees Blackstone Ltd. Hazel Grove, Stockport,
Cheshire
SK7 5AH. England
Telephone: [phone] Tclefax: 061-487-1465 Telex: 667314

MIRRLEES BLACKSTONELTD
ESL 12- 16 Mk2InstructionManual
Amendment Record
e
e
d

ESL 12 & 16 Mk2
Preface
e- MB INSTRUCTION MANUAL
- BUCXSTONE
This manual has been compiled to assist suitably qualified engineers to operate and
maintaintheMirrleesBlackstoneESL12and
16 cylinder Mark2engines. It mustbe used in
conjunction with themanuals forthespecificancillary
or driven machinery supplied in the
particular application.
It is important to read the manual before attempting to carry out any operation
or
maintenance task. There are threemethods of locating information:
A quick reference, chapterlocation list (page i).
1)
2)
3)
A detailed contents list (pages ii - ix).
A subject index, and glossary of terms at the back of thebook.
At the start of each maintenance task
is a list of
Special tools and equipment required
Theminimum spareparts required for maintenance planning.
*
1)
2)
3) Any major associatcd tasks.
4)
Main component weights - asa guide to lifting and general handling.
Thefollowing standard headings areused in thetext:
‘WARNING:’- indicates a particularhazard to personal safety.
‘CAUTION’- indicates a particular risk of damage to the engine or component.
‘NOTE:’- is for information only.
‘Replacement’ is used as a general term meaning removal and installation.
‘Renewal’refers to the removal of a componentandtheinstallation of a newcomponent in
its place.
CAUTI0N:FOLLOWING MOUNTING ON FINAL OPERATIONAL SEATINGS BUT
PRIOR TOINITIALSTARTINGEACHENGINESHOULDBEBARREDFOR
A MINIMUM
OF FOUR (4) REVOLUTIONS.
Thefollowing documents aresupplied asnecessary and may be referred toin themanual:
1) Parts list.
Last Issued 1/1/93 Mirrlees Blackstone Ltd

MIRRLEES =
ESL 12 & 16 Mk2
-
INSTRUCTION MANUAL
Preface
- BL4CKSTOhW
2) Engine test data.
3) Baseplate drawings.
4)
5)
Specificsystems and wiring diagrams for the particular installation.
Where applicable, technical instructions for:
Turbocharger
Heatexchangers (oil and water coolers, intercooler, radiator)
Engine governor
Air compressor
Lubricating oil priming pump
Fuel lift pump
Flexible couplings and anti-vibration mountings
Any additional non-standard equipment, e.g.
off -engine pumps, electric
starter,off-engine air filters
Any enquiries in connection with this manual arewelcome and should be addressed to:
Technical Publications Department
Mirrlees Blackstone Limited
Bramhall Moor Lane Telefax:
[phone]
Hazel Grove, Stockport Telex: 667314 MIRLES G
Cheshire SK7-5AH Telephone: [phone]
England
No responsibility can be accepted by the Company for the misunderstanding or
misinterpretation of information provided in the manual, nor for the engineeringmethods
used.
This manual,
or anypart of it, maynot be reproduced without thewritten permission of the
manufacturer.
Themanual conforms to British Standard
4884, Parts 1 and 2.
a
Last Inued llV93 Mirrlees Blachtonc Ltd

Section
Index
ESL 12 & 16 Mk2
= MB' BUCKSTONE INSTRUCTION MANUAL
OUICK REFERENCE CHAPTER LOCATION LIST
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6
SECTION 7
SECTION 8
SECTION 9
SECTION IQ
SECTION 1 1
INTRODUCTION
TECHNICAL DATA
CRANKCASE
AND CRANKSHAFT
CYLINDER HEAD, PISTON, CONNECTING RODAND LINER
CAMSHAFT, DRIVETRAINAND TAPPET BLOCK
AIR INLETAND EXHAUST SYSTEMS
FUEL SYSTEM
LUBRICATING
OIL SYSTEM
COOLING SYSTEM
AIR STARTSYSTEM
SAFETY DEVICES, CONTROLSAND INSTRUMENTATION
SECTION
12 OPERATING INSTRUCTIONS, ROUTINE MAINTENANCE
AND FAULT FINDING
SECTION
1.3
GLOSSARY
HYDRAULIC PACK, ENGINE LIFTING AND INSTALLATION
GLOSSARY OFABBREVIATIONS
& WORDS
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Section
Index
ESL 12 & 16Mk2
INSTRUCTION MANUAL
Z BLACXSTONE
SECTION 1 JNTRODUCTION PAGE
1.1. DESCRIPTION OFENGINE ........................................
1.2. ENGINE MAINTENANCE AND OVERHAUL - GENERAL ...........
1.3. HEALTH ANDSAFETY ............................................
1.4. LEAD ACID AND ALKALINE BAmRIES ...........................
Main Hazards - Electrolyte ..........................................
Precautions .........................................................
Protect the eyes ......................................................
1.5. EMERGENCY ACTION ............................................
Skin Contact ........................................................
Eye Contact ........................................................
MixingAcid and Water (Lead Acid Batteries) ............................
1.6. ENGINE SERIAL.NO . - example ....................................
1
3
5
6
6
6
6
7
7
7
7
7
SECTION 2 TECHNICALDATA PAGE
2.1. ENGINE LAYOUT AND GENERALDIMENSIONS ....................
2.2. SPECIFICATION ...................................................
2.3. COMPONENT WEIGHTS (approximate) ..............................
2.4. STANDARD PRESSURES &TEMPERATURES .......................
Automatic Alarm & Shutdown Systems .................................
Lubricating Oil System ...............................................
Fresh Water System ..................................................
Exhaust System .....................................................
2.5. TORQUELOADS AND HYDRAULICTENSIONING DATA ............
2.6. TIGHTENING TORQUES ..........................................
2.7. FUEL & LUBRICATING OIL SPECIFICATIONS ......................
Fuel SpecificationLimits .............................................
Fuel Properly Class ..................................................
Approved Engine Lubricants ..........................................
SECTION 3 CRANKCASEAND CRANKSHAFT
3.1. DESCRIPTION ....................................................
3.2. CRANKSHAFT AND MAIN BEARINGS ..............................
CrankshaftEndfloatCheck ...........................................
Crankshaft toMain Bearing Clearance Check ............................
Crankshaft Deflection Check ..........................................
Main BearingReplacement ...........................................
Main BearingRemoval ...............................................
ThrustBearingReplacement ..........................................
Thrust BearingRemoval ..............................................
Thrust BearingInstallation ............................................
Main BearingInstallation .............................................
1
3
4
5
5
5
5
5
6
7
7
7
8
8
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Contents ii Mirrlees Blackstone Ltd

Section
ESL 12 & 16 Mk2
.
Index INSTRUCTION MANUAL
. BLACBTONE
3.3.
3.4.
3.5.
3.6.
3.7.
PUMPDRIVE SYSTEM .............................................
Belt Removal .......................................................
Fitting andTensioning a New Belt ......................................
Re-fitting and Re-tensioning a Used Belt ..............................
Crankshaft PulleyReplacement ........................................
Crankshaft PulleyRemoval ...........................................
Crankshaft PulleyInstallation .........................................
PumplRnsioner PulleyReplacement ...................................
Pumpmnsioner PulleyRemoval .......................................
Pump/”knsionerPulley Installation .....................................
Drivebelt Tensioner .................................................
TORSIONALVIBRATION DAMPER ................................
Holset Damper Fluid Sampling ........................................
Damper Replacement ................................................
Part 1 - Damper Replacement - Engineswithout a FreeEnd
fitensionShaft
.....................................................
Removal ...........................................................
Installation .........................................................
Part 2 . - Dam erReplacement - Engineswith a Free End
Removal
...........................................................
Installation .........................................................
FLYWHEEL .......................................................
FlywheelRemoval ...................................................
FlywheelInstallation .................................................
CRANKCASEFI’ITINGS ............................................
CrankcaseExtractor Fan .............................................
CrankcaseEnd Covers ...............................................
Sump ..............................................................
TurbochargerMounting Bracket .......................................
CrankcaseWater Drain Valves .........................................
TECHNICAL DATA ................................................
Stud TensioningData ................................................
ExtensionSha P t .....................................................
Flywheel Replacement ...............................................
SECTION 4 CYLINDER HEAD . PISTON . CONNECTING ROD AND LINER
4.1. DESCRIPTION ....................................................
CylinderHead Assembly .............................................
Valve and Rocker Gear ...............................................
Pistons .............................................................
ConnectingRods ....................................................
Cylinder Liners .....................................................
4.2. CYLINDER HEADASSEMBLY ......................................
Valve Clearance Adjustment (’Igppet Adjustment) ........................
CylinderHead Assembly Replacement ..................................
CylinderHead Assembly Removal .....................................
CylinderHead AssemblyInstallation ...................................
17
18
19
20
21
21
21
22
22
22
23
24
24
27
28
28
29
30
30
31
32
32
33
34
34
34
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38
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MRRLEES=
Section
Index
ESL 12 & 16 Mk2
. INSTRUCTION MANUAL
Servicingthe Cylinder Head Assembly ..................................
CylinderHead Dismantling ...........................................
CylinderHead Re-Assembly .........................................
Valve and ValveSeat Insert Grinding ...................................
Valve Guide Renewal ................................................
Vake SeatInsert Renewal ............................................
CylinderHead Stud Renewal ..........................................
4.3.
PISTON AND CONNECTING RODASSEMBLY .......................
ConnectingRodLarge-End Endfloat Check ............................
Large End Bearing Block Replacement .................................
Large End Bearing Block Removal .....................................
Piston and ConnectingRod Shank AssemblyReplacement .................
Piston and ConnectingRod AssemblyRemoval ..........................
ServicingThePiston And Connecting Rod Assembly ......................
Piston and ConnectingRod ShankAssembly Installation ..................
Large End Bearing to Crankpin 'Vertical' Clearance Check ................
Large EndBearing Block Installations ..................................
ComponentWeights: ..................................................
SmallEnd Bearing (Bush) Renewal .....................................
4.4. CYLINDERLINER .................................................
Liner Deglazing .....................................................
LinerReplacement ..................................................
Liner Removal ......................................................
Liner Installation ....................................................
4.5. TECHNICAL DATA ................................................
Con-Rod, Piston &Liner ............................................
Valve & Rocker Gear ................................................
SECTION 5
CAMSHAFT . DRIVETRAIN AND TAPPET BLOCK
5.1. DESCRIPTION ....................................................
Camshaft ..........................................................
DriveTrain .........................................................
Tappets ............................................................
Pushrods ...........................................................
5.2. CAMSHAIT .......................................................
Camshaft TimingCheck ..............................................
Camshaft Removal ..................................................
Camshaft Installation ................................................
5.3. CAMSHAITDRIVETRAIN ........................................
Camshaft Drive Train Replacement ....................................
Camshaft GearTrain Removal..........................................
Inspection of theCamshaft GearRain ..................................
Camshaft GearTrain Installation ......................................
Camshaft Replacement ................................ : ..............
Gear Shaft Bush Renewal (Compound and Idler Gears) ...................
.
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17
17
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22
22
23
24
24
21
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35
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39
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