Bosch TKA 865. Betreibershandbuch

Definition of engine outputof engines for gensets8PowerTimePower limitContinuous power30%P1P32PP4P6P5Permissible mean poweroutput during 24 hourst1t4t

Calculation of engine outputof engines for gensets9Calculation of the power output of gensetsGenerator efficiencyThe generator does not run without lo

Measuring the engine outputof engines for gensets10Estimate of the engine output on a genset engineOn estimating the utilisation of an industrial or r

Measuring the engine outputof engines for gensets11Linking these formulas leads to the following relationship:PMotor+ PLüfter)U I 3Ǹ cos öhGenera

Load application and control conditionsfor genset engines12Load applicationFundamental relationships:The speed characteristics of a genset when load i

Load application and control conditionsfor genset engines13Load application as per DIN 6280The diagram below is taken from DIN 6280 / ISO 3046 and sho

Load application and control conditionsfor genset engines14Control conditionsThe control conditions for the engine comply with the ISO standard power

Engine output of enginesto drive pumps15Power output characteristics of the pump to be drivenThe engines are approved to drive rotary pumps where the

Access to the engine16When installing the engine, ensure that there issufficient space for regular maintenance work asdefined in the Operator’s Manual

Access to the engine17D Draining and filling coolant(description in the Operating Instructions)D Visual check and tightening of screwed, hoseand pipe

Engine room ventilation18Engine operation causes component surfaces to become hot, dissipating radiant heat which must be con-ducted away by means of

Engine room ventilation19The air requirement to conduct away radiation heat is calculated as follows:V +Q 3600cp Dt rKey to this formula:Q = Tota

Engine room ventilation20Total amount of air requiredThe total amount of air required is calculated from the sum of the air required to conduct away r

Engine mountings21Elastic mountsGeneral informationElastic mounts for limiting dynamic loads channelled into the foundation are to be preferred to rig

Engine mountings22Supercritical adjustmentEngines with variable speedIf elastic mounts are used, supercritical adjustmentnminnkritu 1is required to pr

Engine mountings23Connection linesTo cancel out vibration amplitudes in systems with elastic mounts, all pipes leading away from the enginemust be unc

Engine mountings24Rigid mountsSuitability of enginesOnly engines with no free mass forces or free mass moments are suitable for rigid mounts. The foll

Engine mountings25Calculating the supporting forcesThe entire weight G of the engine (including oil and coolant) acts at the centre of gravity S. Data

Power take-off26The flywheelDepending on the kind of engine operation, MANoffers several flywheel variants. Criteria for select-ing a flywheel are:D U

Power take-off27Â Flywheel with additional mass for improving theregulating characteristics of genset engines ofthe D 28 model range (I = 4.212 kgm2).

Foreword1Dear CustomerThe purpose of these installation instructions is to:D Provide assistance and advice during the installation of stationary MAN i

Power take-off28Axial clearance of crankshaftCaution:The design axial clearance of the engines’crankshafts must not in any event be re-duced by flange

Transmission of power by propshafts29Coupling for large deflection anglesThe use of integrated couplings reduces vibration stress on engine and drivel

Transmission of power by propshafts30Basic guidelines for installing cardan shaftsIf a simple cardan, universal or ball joint is uniformly rotated whi

Transmission of power by propshafts31Installing cardan shaftsWhen connecting the cardan shaft halves, make sure that the markings (arrows) on the spli

Air intake system32Combustion air requirementThe engine requires a sufficient amount of fresh air (as indicated in the data sheets) for fully combusti

Air intake system33Dry air filter for continuous operationÀ Air inletÁ Air outletCharacteristics of the dry air filter with exchange-able paper elemen

Exhaust system34Basic elements of the engineering designDanger:The exhaust system must be completely gastight to fully exclude the danger of asphyxiat

Exhaust system35Acid-resistant steel is to be used preferably as material for the exhaust system. The high temperature of the exhaust gases of several

Exhaust system36Connecting exhaust system to engineInstall between the engine and exhaust systemresilient connecting elements, which permit enginemove

Exhaust system37Configuration of the exhaust systemWe recommend that, if possible, the maximum permissible backpressure value (= pressure drop) should

Contents2PageForeword 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust system38Average backpressure (pressure drop) in hPa per 1 m of exhaust pipe, depending on the exhaustgas mass flow in kg/h and the clear diame

Exhaust system39Average backpressure (pressure drop) in hPa per 90_ manifold (R/d = 1.5), depending on the ex-haust gas mass flow in kg/h and the clea

Exhaust system40Measuring the exhaust backpressureThe exhaust backpressure must be measured dur-ing startup.The measuring point of the exhaust gas bac

Exhaust system41Exhaust gas heat utilisation in stationary systemsIn stationary diesel engines for co-generation, exhaust gas heat exchangers are freq

Exhaust system42Properties of exhaust gas water preheatersExhaust gas water preheaters are frequently subject to considerable wear resulting from corr

Exhaust system43The usable temperature drop in the exhaust gases nt = (t1 − t2) is calculated as follows:t1 = temperature of the exhaust gases at the

Exhaust system44Catalytic convertersThe emission of harmful substances can be considerably lowered by means of exhaust-gas cleaning sys-tems.Exhaustga

Cooling system45Basic information on the cooling systemIf the cooling system functions properly, the engine will operate with fewer faults and its ser

Cooling system46Fan coolingThe following diagram shows the basic components of a standard cooling system for the engine coolantthat are obligatory for

Cooling system47Stationary diesel engine for co-generationThe diagram shows a heat exchanger and a second thermostat as additional components.TPTXFanD

Safety regulations3GeneralImportant safety regulations are summarised in this quick−reference overview and arranged by topic to ef-fectively convey th

Cooling system48Properties of diesel engine for co-generationCombined generation (co-generation) of power and heat makes sense only if the system is i

Cooling system49Components of the cooling systemThe fanThe fan in stationary engines is driven rigidly.If it is not possible to drive the fan from the

Cooling system50The coolant linesThe clear widths of the coolant lines from the en-gine to the cooling system À and from the coolingsystem to the engi

Cooling system51To achieve more or less complete air separation, even at reduced coolant levels in the expansion tank, it isnecessary to limit the coo

Cooling system52 Dimensioning and designing the cooling systemIf the cooling system is not obtained from MAN, it must be configured by the manufacture

Cooling system53Assessing the coolant circuitIn the coolant circuit, a certain amount of heat that corresponds to the engine load must be conductedawa

Cooling system54The minimum coolant circulation quantities are to be large enough to ensure that at maximum (blocked)output there is a temperature dif

Cooling system55The cooling output of the fan radiatorTo assess the cooling output of a cooling system, the cooling constant (KK) has been found relia

Intercooling56IntercoolingIntercooling has the following functions:D As a result of the increase in combustion air density due to the reduced temperat

Intercooling57The following values are to be complied with in the intercooler design:D permissible charge-air temperature downstream of radiator: max.

Safety regulations4D When working on the electrical system, first disconnect the earth cable of the batteryand reconnect this last to prevent short ci

Intercooling58Intercooling with air / water intercoolerIf the engine and cooling system are installed separately or if the charge air is used for othe

Electrical preheating of coolant59Design and functionTo guarantee quick starts and the quick take-up of load (e.g. in standby power units), the engine

Electrical preheating of coolant6012Attachment of the coolant preheater to a D 28 V-type engineÀ Heater with electrical connection 230 VÁ Non-return v

Fuel system61Fuel circuitFuel is sucked from the tank by the supply pump and fed to the inlet chamber of the injection pump via thefuel filter.The fue

Fuel system62Arrangement of the tank systemThe tank should be located at roughly the height of the engine. If this is impossible, the following po

Fuel system63Fuel flow diagram for a specialpurpose vehicle with lowlying tank located below the engine1243À Injection pumpÁ Additional

Fuel system64Fuel linesProtect the fuel against heating up.The return line is to be routed back to the tank separately. Direct integration into the su

Fuel system65Fuel prefilter and water separatorWe recommend that a prefilter (mesh width 30µ  60µ) and a water separator be provided inthe fuel sup

Flame starting system66On request MAN engines can be equipped with a flame starting system (flame starter).The purpose of a flame starting systemThe f

Electronic speed control on D 08 engines67Digital speed governor GAC SDG865-01-01Note:All the information in this chapter is an excerpt from the Opera

Safety regulations53. Regulations designed to prevent pollutionEngine oil and filter cartridges and elements, fuel / fuel filtersD Old oil must be pas

Electronic speed control on D 08 engines68Installation and connectionEXTERNALINTERNALSTOPSpeedpreselection(OPTION)Speedtrim+/−50RPM5kOhm,1/4W

Electronic speed control on D 28 engines69Layout of the electronic speed controlThe electronic speed control system consists of three components:Rpm s

Electronic speed control on D 28 engines70Function of the electronic speed governor GACThe GAC ESD 5221 electronic speed governor is used as an exampl

Electronic speed control on D 28 engines71À LED display for electronic overspeed controlÁ Output contacts “Overspeed” LED display for overspeed Overs

Electronic speed control on D 28 engines72Overspeed protectionIf an electronic speed governor is used, an overspeed protection independent of the gove

Electrical system73Engine monitoring controlMonitoring the coolant levelFluid−monitoring probes may be used to monitor the coolant level in the coolan

Electrical system74GeneratorBosch generator 28 V, 80 AConnections at the generatorÀ W (speed signal)Á L (charge indication)Â terminal 15 via ignition

75Appendix

Coolant hoses77Requirements for coolant linesExcerpt from the MAN Works StandardsBasis for this summaryThis summary is based on the MAN Works Standard

Engine vicinity6The engine vicinity is gaining increasing importance for assessing the installation situations for modern die-sel engines.The followin

Coolant hoses78Excerpt from factory standard MAN 334Material property requirements for hoses and moulded partsFor new constructions, electrochemically

Coolant hoses79Excerpt from factory standard MAN 307Material types, note on useType Basic require-ments accordingBasic require-ments accordingArea of

Coolant hoses80Excerpt from factory standard MAN 305Material types, note on useType Basic require-ments accordingBasic require-ments accordingArea of

Coolant hoses81DimensionsDimensions and permitted deviationsRated diameter dmmWall thickness s1mmInner layers2 2)minSmallestpermittedbendingRateddimen

Recommended values for assignment:Starter, battery size and starter cable82Engine typesD 08 engines D 28 R engines D 28 V enginesStarter type Bosch Bo

Wiring diagram838444

Index85AAir filter 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Partial vacuum downstream of air filter 32 . . . . . Air int

Index86TTank (manufacture) 61 . . . . . . . . . . . . . . . . . . . . . . . . Tank capacity 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Index87STUW

Definition of engine outputof engines for gensets7Definitions of rated output for genset enginesThe performance definitions for genset engines are lai