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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

MPPL/IM/ASCCP/2006/0

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

Troubleshooting

8-1

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.
headoffice@pun.matherplatt.co.in
WILO AG,
NortkirchenstraBe 100, 44263 Dortmund,
Germany
+49 231 4102-0
+49 231 4102-363
info@wilo.de

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
headoffice@pun.matherplatt.co.in
WILO AG,
NortkirchenstraBe 100, 44263 Dortmund,
Germany
+49 231 4102-0
+49 231 4102-363
info@wilo.de

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

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: headoffice@pun.matherplatt.co.in

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

1-1

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&Ps 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

2-1

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
users 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

2-2

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

2-3

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&Ps 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

2-4

Mather + Platt
2.11

General Safety Information

Prime mover selection

When prime mover is in M&Ps 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&Ps 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

2-5

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 manufacturers 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

2-6

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

3-1

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

3-2

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.

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Mather + Platt

Handling, Transport & storage

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

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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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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 contractors 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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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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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 engineers 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 manufacturers 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.
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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

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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.
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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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Mather + Platt

Installation

Examples of good & bad suction layout

Fig. 13

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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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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 manufacturers 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 its 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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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.

MPPL/IM/ASCCP/2006/0

6-4

Mather + Platt

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 30C -35C 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.

MPPL/IM/ASCCP/2006/0

7-2

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.

MPPL/IM/ASCCP/2006/0

7-3

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.

MPPL/IM/ASCCP/2006/0

7-4

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:

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.

MPPL/IM/ASCCP/2006/0

7-5

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.

MPPL/IM/ASCCP/2006/0

7-6

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.

MPPL/IM/ASCCP/2006/0

7-7

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 % 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

MPPL/IM/ASCCP/2006/0

7-8

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.

MPPL/IM/ASCCP/2006/0

7-9

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

Pump not primed

Ensure that casing is fully filled and water comes out


from air-cock.

Pump or suction pipe not completely filled with


liquid

Check leaking foot valve in case of negative suction

Suction lift too high.

Reduce by lowering pump elevation or increase

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.

Excessive amount of air in liquid.

Check the reasons and eliminate. Gas gets


entrapped in liquid. Air may be entering through
suction joints.

Air pocket in suction line.

Ensure pipe fully filled and there is no


bend for negative suction.

Air leaks into suction line

Tighten pipe joints with solution.

Air leaks into pump through stuffing boxes.

Ensure stuffing box sealing.

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

8-1

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.

MPPL/IM/ASCCP/2006/0

8-3

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.

Typ

KW

RPM

M3/hr

H (m)

P(max)
Bar

T( C )

Year
of mfg

10

Total
Set wt

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.

Typ

KW

RPM

M3/hr

H (m)

P(max)
Bar

T( C )

Year
of mfg

10

Pump
Wt

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

Alignment with and without piping

Flushing of pipe lines and ensure no


leakages

Availability of sufficient liquid in sump /


suction as per specifications.

Installation of all instruments


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

Operation of suction, delivery and inline


valves

Proper supports for piping and other


allied equipments.

Availability of flushing / sealing liquid for


stuffing box.

Availability of sufficient cooling liquid for


bearings as specified

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

Nature of complaint

Date of receipt of pump at


site & date of commissioning
Was erection/commissioning
in M & Ps scope
Pump details
Pump type:
P.D. No:
Flow:

4
5

Head:
RPM:
Efficiency:

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

Static head (Elevation difference


between pump centreline &
discharge point)

(Enclose drawings / Sketch / photographs)


:
:
:
:
: Flooded
/ Suction lift
Details:
:

Installation details

Base frame

Loose

Base frame levelling readings

No of packers below base frame

Alignment readings

-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

Liquid specification
(Chemical analysis report)

Specific gravity:
Temperature :
Solid contents :

pH value :
Viscosity :

Operation parameters

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

Delivery Pr.
Speed
Volts

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
135
166
109
240
135
109
166
240
166
109
135
240
192
147
96
260

1
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
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

Bush: --

900

Ball: SKF 6319

900

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

Ball: SKF 6319

900

Bush: --

900

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

94

20

94

20

94

20

94

20

94

20

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

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

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

Ball SKF6316

1800

Bush:--

1800

Ball: SKF 6319

1800

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

100

20

40000

100

20

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

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

Bush: -Ball SKF 6313


Ball: SKF 6319

Oil
Oil
Grease

-40000
40000

79

20

94

20

Bush: -Ball: SKF 6315

Oil
Oil

-40000

94

20

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

Ball: SKF 6316

Ball: 6316

Oil

40000

79

20

1200

Bush: --

Ball: SKF 6319

-40000
40000

20

Oil
Oil
Grease

79

1800

Bush: -Ball: SKF 6313


Ball: SKF 6319

94

20

1800

Bush: --

Ball: SKF 6319

-40000
40000

20

Oil
Oil
Grease

94

720

Bush: -Ball: SKF 6315


Ball: SKF 6319

94

20

720

Bush: --

Ball: SKF 6405

-40000
40000

20

NA

Oil
Oil
Grease

94

1800

Bush:
Ball: SKF 6315
Ball: SKF 6405

34

10

1800

NA

Bush: --, bush: --

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: --

Ball: SKF 6208

-40000
40000

11

NA

Oil
Oil
Grease

40

1800

Bush: -Thrust Disc


Ball: SKF 6208

38

11

1800

NA

Bush: --

Bush: --

75

15

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

1200

NA

Bush: --

Ball: SKF 6414

-40000
40000

16

NA

Oil
Oil
Grease

75

1200

Bush: -Thrust Disc


Ball: SKF 6414

69

16

1200

NA

Bush: --

Ball: SKF 6319

-40000
40000

16

Oil
Oil
Grease

75

1200

Bush:
Thrust Disc
Ball: SKF 6319

94

20

1200

Bush: --

Ball: SKF 6316

-40000
40000

20

Oil
Oil
Grease

94

1200

Bush: -Ball: SKF 6315


Ball: SKF 6316

79

20

900

Ball: SIKF NU 324

Grease

40000

119

25

900

-40000
40000

25

Oil
Oil
Grease

125

900

125

25

900

Bush: --

125

25

Ball: SKF NU324

Oil
Oil
Grease

--

888

40000

125

25

888

Bush: --

125

25

40000

125

25

600

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

600

Bush: --

25

Ball: SKF NU 324

-40000
40000

125

720

Oil
OIL
Grease

119

25

720

Bush: --

Oil
Oil

-40000

125

25

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

Ball: SKF NU 324

720

Bush: --

720

Ball: NU 324

Ball: SKF 7324


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

720

Bush: --

Bush: 6318

708

6 SPL

Ball: SKF 7224

Ball: SKF 7224

720

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

Bush: --

142

48/48 DV LONO
BUSH BRG.)

600

Bush: --

143

48/54 DV LONO
BUSH BRG.)

516

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

Oil
Oil
Ball:
Grease
Bush:
Oil
Grease

40000

125

25

40000

119

25

40000

125

25

40000

94

18

Oil

-40000

140

20

Oil

-40000

140

20

Oil

-40000

140

20

Oil

-40000

140

20

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

50

11

Bush:: -Thrust disc

Oil
Oil

40,000

56

11

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 bolts 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)

Page 2 of 58

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. operators 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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Page 3 of 58

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.

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

Page 4 of 58

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
Dseries 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

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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

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

50
50
51

Installation Dos and Donts

52

List of Regional Offices

53

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

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

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

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

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
60 / 12
A1-B5-A5-B3-A3-B6
A6-B2-A2-B4-A4-B1
Anticlockwise looking at flywheel
1.92 dm (1.92 Ltr)
23 dm
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 (74-82C), 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

10 bef. TDC
29 after B.D. C
41 bef. B.D.C
7 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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Page 12 of 58

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

Fan radiator

Injector

V belt pulley

Control panel

Damper

Centrifuge

Oil sump

Fuel on solenoid

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Page 14 of 58

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

1490 2006 1645 1060


D2
1170

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

A2

D1

295

700

750

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.

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

Page 16 of 58

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.

The D series engine uses a positive displacement, gear type pump, which is
gear driven.
The system has a pressure relief valve, lube oil filter and lube oil cooler, which
are mounted on Crank case.
Providing oil through push rod lubricates the rocker assembly.
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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Page 17 of 58

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

Dseries 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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Page 19 of 58

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

INSTALLED INCLINATION (MAX.)

--

MAX. TOTAL INCLINATION


(MAX.2 hours)

15

22.5

DURING OPERATION (MAX.3


min.)

18

22.5

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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

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

3.2.3 Water specifications:


pH value

68

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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 10C, 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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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

Lube oil temperature

85-100

Water temperature

78-90

4
5

Suction depression (new air


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

550

Exhaust back pressure

Steady state rpm variation

RPM

Max fuel suction lift

Meter

Typical fuel temperature

35 - 39

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mm Hg

150

25

340 mm of water

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Operation and Maintenance Manual D Series TBD4IV12 Engine

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
Check all electrical, fuel, exhaust and other connections and ensure tightness.
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.
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 FF 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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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-

1.5 Bar

Steady state lube oil temp

90-110C

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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 80F (27C) At climates between 80F and
At climates over 100F (38C)
specific gravity corrected to 100OF (27C-38C) specific gravity specific gravity corrected to
(60F) (16C)
corrected to (60F) (16C)
(60F) (16C)
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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Operation and Maintenance Manual D Series TBD4IV12 Engine

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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Operation and Maintenance Manual D Series TBD4IV12 Engine

5.11

Maintenance Schedule

**

Check Fuel level


in tank

**

Check water level


in radiator

**

Check Battery
condition

**

Clean coarse fuel


filter

Change air filter


element

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

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

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

Page 45 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

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

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

**

**

**
**

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

Page 46 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

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

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

**
**

**

**

**

**

**

Every 500

Page 47 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

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

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

Page 48 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

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.

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

Page 49 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

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

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

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

Page 50 of 58

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.

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

Page 51 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

7.0

Installation Dos and Donts

7.1

Dos

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

Donts

Never install the engine on inclined surface.


Remember that a good installation reduces running cost, maintenance cost, provides reliable
and safe service.

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

Page 52 of 58

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
kmj@greavesmail.com

Mr. R.P.Chaudhary
Vice President

Tel. 020-27473407(O)
Mob-9922433770
Fax-020 27474567.
rpc@greavesmail.com

Mr. A.K.Adwani
General Manager- Marketing

Tel. 020-27473405(O)
Mob-9830776659
Fax-020 27474567.
aka@greavesmail.com

Mr.V.D.SIVKUMAR
General Manager Marketing

Tel.020-27472127(O)
Fax-020 27474567.
Mob-9922923977
vdsivkumar@greavesmail.com

Mr. Mahesh Manwani


Divisional ManagerMarketing

Tel. 020-27471079(O)
Tel. 020-25905083
Fax- 020-27474567
Mob-9881152393
mmanwani@greavesmail.com

Mr. A.V.Naik
Divisional Manager Service

Tel. 020-27450274(O)
Tel.020- 32540909
Mob- 9822477359
avn@greavesmail.com

Mr. P.S.Chitale
Sr. Manager Training

Tel. 020-27475425(O)
Tel.020- 27492114
psc@greavesmail.com

Mr. Sanjay Govaikar


Dy. Manager Marketing contracts

Tel.020 27488490 (O)


Tel.020 25280083
Mob.9850828325
sgowaikar@greavesmail.com

Mr. S.G.Ranade
Manager Marketing-Spares

Tel. 020-27471079(O)
Tel. 020-32662917
Mob- 9822477354
sgr@greavesmail.com
Tel. 020-67308211(O)
Tel.020-27484982
Mob-9823041131
rrtupe@greavesmail.com

Mr. R.R.Tupe
Sr.Engineer Service

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

Page 53 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

PUNE

Mr. Yogesh D.Kshirsagar


Engineer Service

Tel .020-67308211 (O)


Mob- 9922965241
ydk@greavesmail.com

Mr. M.N.Patankar
Engineer Service

Tel .020-27475425 (O)


Tel.020-26933413.
Mob- 9765275160
mnp@greavesmail.com

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
rk@greavesmail.com

Mr. M.C.Upadhyaya
Manager Service

Tel.-011-23318037(O)
Tel - 011- 22621450 (R)
Mob- 9810898093
mcu@greavesmail.com

Mr.Kapil Sharma
Commercial Executive

Tel.-011-23730554
ksharma@greavesmail.com

Mr.Pankaj Vishwakarma
Sales Executive

Tel. 011-23730554
Mob- 9810092540
pvk@greavesmail.com

Mr.Rajesh Mishra
Service Executive

Mob. 9718199670
rmishra@greavesmail.com

P S Guleria
BG-1 Service

Tel.011-2370554(o)
011-25645435(R)
Mob. 9871816336
psg@greavesmail.com

Mr.Kapil Saini
Service Engineer

Tel.011-23730554
Mob. 9891442407
ksaini@greavesmail.com

Mr.Satpal Dabas
Service Engineer

Tel-01123730554
sdabas@greavesmail.com

KANPUR
LOCATI
ON

Mr.Praveen Dubey
Area sales executive

Tel-0512-3040730
Mob-9935546733
fax-0512-3014212
pdubey@greavesmail.com

JAIPUR
LOCATI
ON

Mr. Manish Kumar Trivedi


BG-1 Service

Mob. 9314254422

DELHI

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

Page 54 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

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
sray@greavesmail.com

Mr.Debesh Chakborthy
Sr. Service Execuitive

Tel-033- 22421459(O)
033-24817661
Mob- 9836886517
dcy@greavesmail.com

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
kad@greavesmail.com

Mr. Mishra
Service Engineer

Mob- 9835156387
akmishra@greavesmail.com

Mr.Barpujari
Service Engineer

Mob- 9864155225
sbarpujari@greavesmail.com

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
ave@greavesmail.com

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
sjain@greavesmail.com

Mr. M B Kulkarni
Sr. Service Manager

Chembur Office.

Tel - 022-25264711(O)
Tel - 022-28406702
Fax-022-25262622.
Mob - 9820605381
mbk@greavesmail.com

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

Page 55 of 58

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
sekarps@greavesmail.com

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
sbarmanray@greavesmail.com

Mr.Piush Patel
Sales Executive

Tel-079-26581861(O)
Tel-079-27531161(R)
Mob - 9924373900
prpatel@greavesmail.com

Mr.Rathod Nikul
Sales Executive

Tel-079-26581861(O)
Tel-079-65420632 (R)
Mob - 9909919147
nmr@greavesmail.com

Mr.Sameer Delwadi
Executive Engineer-Service

Tel-079-26581861(O)
Fax-079-26587783
Tel-0265-2394233.(R)
Mob -9879604668
sddalwadi@greavesmail.com

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
rlk@greavesmail.com

Sandeep Singh,

KATARE POWER INDUSTRY


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

Telefax-07314090021,Mobile9425059587
Email ubsharma.indore@gmail.com
katare_umesh@rediffmail.com
srsingh@greavesmail.com

SOUTHERN REGION
CHENNAI

Diesel Engines Unit

Wavoo Mansion, 6th floor


48 (old no.39) Rajaji Salai
Chennai- 600001

Mr.DARSHAN DESAI
Regional Manager

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

Tel- 91-44-25255200(O),25224571
Fax-91-44-25224557
Tel-044-25224571(O)
Tel-044- 24464955
dkd@greavesmail.com

Page 56 of 58

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
kkv@greavesmail.com

Mr.K I SAHAYARAJ
Area Sales Manager-Parts

Tel- 044-25251351(O)
Tel - 044 - 26281674
Mob-09444211306
kis@greavesmail.com

Mr.N Govindrajan
Service Executive

Mob-9442550218
ngovindrajan@greavesmail.com

Mr. Chandrashekhar
Sales Executive
Mob-9952230892

Mr. G.V. Subramanyam


Service Executive
Tel- 91-44-25255200(O)
Mob - 9445360010
gvsn@greavesmail.com,

Diesel Engines Unit

16/3 Ali Asker road


Bangalore 560052

Tel- 044-25240358(O)
Mob - 9845130928
bellarygururaj@greavesmail.com,

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
nhanmanthu@greavesmail.com

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
knmajnu@greavesmail.com

KOCH
OFFICE

Mr. P R Radhakrishnan
Service Executive

Mob-9447579062
pradhakrishnan@greavesmail.com

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
avj@greavesmail.com

Sukhdeep S. Grover
Dy. General Manager
Exports

Ph.No 022 - 24397640


Cell no 98190 02035
gss@greavesmail.com

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

Page 57 of 58

Operation and Maintenance Manual D Series TBD4IV12 Engine

Manish Kumar
Divisional Manager

Phone No 022 - 24397642


Cell no 9833742768
manishk@greavesmail.com

Sandip Unni
Area Sales Manager

Phone No 022-24397643
cell no 9819776961
su@greavesmail.com

P.P.Doctor
Dy.Manager Exports

phone no 022-24397644
cell no 9820403311
ppd@greavesmail.com

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

Page 58 of 58