Thornycroft 90 User manual

BS 5514/1.
MARINEENGINES
TheThornycroft90 and108enginesareboth4cylinder,4stroke naturally
aspirated high speed diesel units,bothengines having electrically operatedheater
plugstoaid cold starting.
The castiron crankcase withribbedsidewalls housesa forgedsteel, fully
counterbalanced crankshaftcarried in threeorfivebearingsrespectively.
Afull pressure wetsump lubrication system is employed with a full flow
detachable elementtype oilfilterandintegratedlubricating oil cooler.
Thecooling system isindirectandusually employsan engine mountedheat
exchanger with abeltdriven rawwaterpump.This system isknown asIFWC
(internalfresh water cooled).
An optional system isEFWC(externalfresh water cooled.)This systemutilizes the
enginefreshwaterpumpandusuallyemploys skin tanksattachedtothehulltoserveasheat
exchangers.
Thesinglebeltdrivenalternatorandfreshwaterpump drive includeamanual
belt tensioningarrangementforlowmaintenancecompletes thecomprehensive
engine package.
90108
4Cylinder naturallyaspirated 4Cylinder naturallyaspirated
Powerintermittent at3500rpm =36BHPPower intermittentat3500rpm= 47BHP
continuousat
3000rpm =30BHPcontinuous at 3000rpm =38BHP
Maximumtorqueat 2400rpm =731bf ft
Maximum torque
Idle speed at
2500rpm = 531bf ft
=570rpm Idlespeed=570rpm
Minimum full loadspeed = 1500rpm
ENGINERATINGS
Minimumfullloadspeed=1500rpm
The type 90Enginemay be settodevelopcontinuous outputs from13.5to 30 BHPaccordingto
requirements
The type108 Enginemay be setto developcontinuousoutputs from 21to 38BHP
according to requirements.
Forspecial applicationswherefull power willnotberequiredforperiodsin
excess of 1hourinany12 hoursconsecutiverunningtheenginecanbe suppliedatan
intermittent ratingas shown above.
NOTE:All horsepower ratings quotedare attheengine flywheel.Dueallowancemust
be madefor transmissionlosseswhichwilldependonthetypeofgearboxfitted.
Fortropicaluseit isnecessarytoderate theengine by2% foreach 5%°C(10°F)
above 30°C(85°F) airtemperature atsea level. Insome parts oftheworld
furtherderating for humidityis necessaryinaccordance with

INITIAL STARTINGOFENGINE
PAGE
_.Engine mountinganddipstick marking.Fillingengine withoil.
2. Lubricant specificationfor engineand gearbox. Fillinggearbox.
3.Coolant/Corrosioninhibitor specification. Filling coolingsystem.
4. Primingthe engine oilsystem.
5.Bleeding the fuel systemtype90engines.
6.Bleeding the fuel systemtype108 engines.
7. Initial start. Normal start. Running in.
8. Operating guidelines.
9.Operating guidelines.
MAINTENANCE
Maintenanceschedule.
Engine oil and filter change
Engineoil and filter change
Fuelfilter change.Cleaning
fuellift pump. Gearboxoil
change. Cleaning airfilter.
Alternatordrivebeltadjustment
andreplacement.Rawwaterpump
adjustmentand replacement.
Checkingandsettingvalve
clearances. Procedurefor
retorquing cylinderhead nuts.Removal/Refitting
fuelinjectors.
Changingcoolant.
Drainingrawwater system.
External fresh water cooled engines.
Electrical system.
Fault finding.
Fault finding.
Laying up the engine.
Re-commissioning.
Notes.
10.
11.
12.
13.
14.
15.
16.
17.
Type90engines.
Type108engines.
18.
19
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.

THORNYCROFT
Page 1
CHECKINGENGINEMOUNTING
The maximuminstalledangleof the engineis15°, engine types 90/2,108and108/2
(10° for engine type90).Thisallows fora further rise of4°whenthe craft is
moving.Checktheangleofinstallationusingthecentreline of themountingfeet
bolts asadatum.Measurevertically on thecentrelineoftheundersideofthe
front mountingfoot bolttofindthe angleofinstallation Fig. 1
Fig. 1
HorizontalLine
Type 90 Type90/2Type 108
A93mm = 10°A138mm =150A 136mm =15°
46mm =5° 93mm =10° 91mm=10°
46mm= 5°46mm=5°
MARKING DIPSTICK, FILLING WITH OIL
Your engineis despatchedfrom thefactory without engineor gearboxoiland withan
unmarked enginedipstick.Aftertheboatis launched,andisresting at
itsnormaltrimangle,removethe oil fillercap fromtherockerboxFig.2andpour3.9
litresfor type90, 4.5litresfor type 90/2 or4.8
litresfor type 108ofspecifiedlubricant through thefiller
hole. Allow5minutesfor .theoiltodraininto thesump,
withdraw thedipstickandmarkitformaximumoil levelFig.
3(Useacentre punchformarkingasfiling anotch can
causefatigueandeventualbreakagewhiletheengine is
running). Thenmarkdipstickusing thesamemethod12.7mm
(%")belowthe maximummarkandthiswillbe theminimum
level.
CHECKINGENGINEMOUNTING,
MARKING DIPSTICK, FILLINGENGINEWITH OIL

LUBRICANTENGINEAND GEARBOX
`Page2
ENGINE OIL
RUNNING INOILS
Do NOT use specialrunning-in lubricatingoilsforneworrebuiltengines. Use the
lubricatingoilsspecifiedfornormalengineoperation.
ENGINE OILVISCOSITY RECOMMENDATIONS
The useof amulti-graded lubricatingoilhas beenfound toimprove oil
consumptionand improveenginecranking in coldtemperatureswhilemaintaining
lubricationat highoperating temperatures.Amulti-grade oil conformingto
MIL-L-20104B is.recommendedwith theviscositygrades showninFig.4.The useof
single grade lubricatingoilisnotrecommended exceptforsyntheticoilsused
in arctic conditions.
AtmosphericTemperatureViscosity
Above-10°C 20W50
-20°C to10°C 1OW30 or 1OW40
Below -10°C5W30 or 5W40
Fig. 4.
GEARBOXOIL
Borg Warner AutomaticTransmission Fluid (Type A)
Hurth AutomaticTrnamsission Fluid(Type A)
Newage PRMSAE 20EngineOilMinus18°Cto 0°C
SAE 30engineOilAbove0°C
FILLINGTHEGEARBOX
Remove theoil fillerplugcombined dipstick from thetop of thegearbox. This is
inapproximatelythe same position on Hurth, NewagePRM andBorg Warner. Using
aplasticbottleorfunnel, fillthegearboxup to the maximummarkon the
dipstick.Thereisonelevelmarkonthe Hurthdipstick, theothershavehigh
and low marks.
THORNYCRO
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Fig. 5.

MFig.8
COOLING SYSTEM
Page3
COOLANT
Useanti-freezeduring allseasonsto protect theenginecooling system from
corrosionas wellasfreeze damage.Using thefollowinganti-freezesolution%.
25%33% 50%
Solution Solution Solution
Complete protectionlO°F(-12C)3°F(-16C)-4°F(-20°C)
Safe protection1°F(-17C) -8°F(-22C)-18°F(-28°C)
Intropicalclimates whereanti-freeze availabilitymaybe limited, corrosion
inhibitorto protecttheenginecoolingsystem.
NOTE: Corrosion inhibitor is NOT an anti-freeze. COOLANT QUANTITIES
Complete systemincludingengine(IFWC) types 90and 108 engines.
5.1Litres
Forexternalfreshwatercooledengines (EFWC)See Page23. FILLINGTHE COOLING
SYSTEM
Remove thefiller capfrom the heat exchangerFig. 6 and fill thesystem
withcoolant.This willtakeapproximately5minutesas the system self
bleeds. Fillto 5mmbelow the filler necklevel mark.Refit filler cap.
THORNYCROFT
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MFig.9
405i
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Page4
PRIMING THE ENGINEOILSYSTEM(TYPE90/2R ENGINESONLY)
Asonlyaresidual amountof oilis present in the oilpump,filterandoil
galleries of theengine,itis therefore necessary to primethe systembefore the
engineis run.Connecttheenginestarterbatteriesdisconnect power tothe
fuel solenoid valveon theinjectionpumpFig. 7and cranktheengineover using
thekeystarter switch until pressureregisters ontheoil pressuregauge.
Stopcrankingand check theengineand gearboxfor oilorwaterleaks.Replace
power connector.
Fig.7
PRIMINGTHE ENGINEOILSYSTEM (TYPE90 AND/108ENGINES)
As onlyaresidualamount ofoil is presentintheoil pumpfilterand oil
galleriesofthe engine itistherefore necessaryto prime thesystem beforethe
engine is run. Connect the enginestarter batteries,operatethekeystarter
switch withthe stop control out,crankthe engineoveruntilpressure registers
ontheoil pressure gauge.Stop crankingandcheck theengineand gearboxfor
oil or water leaks.
PRIMINGTHEENGINEOIL SYSTEM THOMYCWFT