VGT Series Break-in Procedures

When engines are new, they require certain break-in, or run-in, procedures before they are subjected to heavy use. The reason is that, though the engines are tested at the factory, seals and gaskets need both heat and time to form a good seal, and the engine needs time to properly lubricate. If proper break-in procedures are not followed, severe engine damage can result.

Below is the procedures for our VGT Series of engines.

The Marinediesel VGT series engines need break-in time before being operating to its full potential. This is due to the design characteristics of the base engine.

Follow the recommendations below:

0-5hrs: Use varied load and rpm but do not load the engine above 50% throttle and keep maximum rpm below 2500. Do not stay at one load and rpm configuration for more than 30 minutes at a time.

5-10hrs: Use varied load and rpm but do not load the engine above 60% throttle and keep maximum rpm below 2800. Do not stay at one load and rpm configuration for more than 30 minutes at a time. A few short WOT trials up to 3600 rpm is allowed for performance trials

Do an oil and filter change after the engine has run a total of 10hrs.

10-30hrs: Use varied load and rpm, the engine can be used up to 100% throttle and full rpm for shorter periods. Do not stay at one load and rpm configuration for more than 30 minutes at a time.

Do an oil and filter change after the engine has run a total of 50hrs.
Use oil and filter as specified in the engine technical manual.

If you have any questions regarding this break-in procedure please consult the technical department at Marinediesel in Sweden.

 

 

515 Kilograms

 

515 Kilograms. That weight is the equivalent of:

  • An average adult polar bear
  • 1.1 times the weight of a grand piano
  • 30% of the weight of an average sized sedan
  • About 10% of the weight of an adult Tyrannosaurus Rex
  • 12 times the weight of a toilet
  • The weight of MarineDiesel’s VGT Series of marine engines

MarineDiesel manufactures the lightest, most compact, most powerful marine engines in their class. No competitors even come close. Though the comparison above is somewhat lighthearted, vessel displacement is a highly critical factor in vessel performance, and MarineDiesel leads the way in high power at low weight.

 

 

 

 

 

 

MarineDiesel Services Profile: Engine Installation and Commissioning

 

Today’s article continues our series profiling MarineDiesel’s various services.

Engine Installation and Commissioning

MarineDiesel understands that when we sell an engine, we often need to be the ones who install and commission that engine. Most commercial shipyards are perfectly competent to install an engine, yet, particularly on new projects, factory installation is desirable. It is also important to note that all MarineDiesel distributors are fully trained in engine installation and can perform these services locally.

One of the most critical tasks related to the reliability of  the entire propulsion system is the installation of engine and drive system. This can be performed by the operator, boat builder or the local Marinediesel representative, but it can also be performed by Marinediesel factory engineers on site anywhere in the world.
MarineDiesel factory engineers provide first grade quality service,  as well as reducing  the risk of breakdowns and stoppages related to poor installation. It can also allow for time to train local technicians on installations, thus, for the future, enhancing the skill and know-how level of the operator’s or boat builder’s own staff.
A professional installation  not only assures smooth  operation, but it also reduces operational  costs. In this context, prolonging engine  life  and  maintaining  operational efficiency are key objectives that are addressed by this program.
Marinediesel  can also supply a full project management service, supported  by expert personnel  and by a global back-up service. All this is targeted at the goal of providing the operator with complete confidence that the engines will run efficiently with excellent long term service.
Quality based , cost effective service delivered by factory engineers
Opportunity for the transfer of technology and know how.
Operational costs minimized due to reduced risk of breakdowns and stoppages related to poor installation
Expert project management
Peace of mind with full OEM warranty

COMMISSIONING
The  quality workmanship of the propulsion system installation is verifìed and signed off during the commissioning. Our  fìeld  service  engineers  are  uniquely experienced   in commissioning engines,  and  will ensure  that  every aspect of their  performance is fully tested  and  optimized before handover. This includes auxiliary equipment such as transmissions  and drive systems in liaising with other suppliers when necessary to ensure that every part of the installation functions correctly. Commissioning can be performed by Marinediesel fìeld service  engineers  on  site  anywhere  in the world. The  commissioning sign-off is also required  for warranty to take effect.

 

 

Maintenance Tip of the Week – Belts 04/27/2015

 

 

Maintenance Tip of the Week – Belts 04/27/2015

NEVER replace belts on a marine engine with automotive belts. Belts manufactured for land use cannot withstand the extreme marine environment, and are likely to prematurely fail. Always use OEM belts as recommended in your manual, tightened to the correct tension, for the longest and most reliable engine life cycle.

 

 

 

MarineDiesel Services Profile: Engineering

 

 

We at MarineDiesel often refer to ourself as an engineering company, rather than as a manufacturer. The reason we do so is that a substantial portion of our annual revenues come from engineering services, rather than engine sales.

As a diesel engine maker, we are required to invest in a substantial level of infrastructure that is highly specialized. This infrastructure is used to customize engines and design engines for specific purposes, which makes MarineDiesel ideally suited to offer complete engineering services to our customers, whether they use our engines or not. Indeed, we consider several of our competitors also to be customers, since we have completed many such projects for them. This is a primary selling point for MarineDiesel: We can usually accomplish things both quicker and cheaper than our much larger competition cannot.

These services include, but are not limited to:

  • Torsional vibration analysis
  • Flow simulation
  • Engine Testing
  • Emissions Testing
  • Compliance Testing (eg. NATO or Intrinsically Safe)

As long as our facilities allow it, in terms of size (We do not have the facilities to test two stroke, 2 mW engines, for example), we can offer customers complete turnkey engineering solutions. Our facilities are state-of-the-art, designed by GM. We have the latest test cells, software, and equipment.

MD ENGINEERING hosts three engine dynos in its test facility, with each test cell having its own unique measurement range and options. This provides us a great span in terms of engine size and application to better meet our client’s requirements and specifications. All cells are equipped with high frequency, multi-channel data logging.

MD Engineering has been involved in complete engine control systems in a multitude of areas, some areas where we have deep knowledge and long experience:

• Control safety systems
• Torque management and control
• Air system diagnostics (MAF, EGR, Swirl)
• EOBD and OBDII controls and diagnostics
• Engine thermal management control and diagnostics
• After treatment systems control and diagnostics
• Stop/start control
• Boost system control for a wide variety of hardware setups:
• Single wastgate turbo and by-pass turbo
• Two-stage turbocharging
• Supercharger
• Twin turbo
• VNT turbo

Our engineers and product analysis experts can take a wide client brief for comparative benchmark and cross product comparison. This includes all aspects of the process from virtual analysis, desktop studies, static and dynamic repeatable test scenarios to full product teardown, measurement reporting and recommendations.

MarineDiesel, through the normal course of business, maintains partnerships with numerous naval architects, engineering firms, automobile manufacturers, other engine manufacturers, and designers. In fact, we are often the ones providing the project management services on complex projects.

To illustrate, we recently were involved in a project where we provided the engines for a new boat, along with the design, and handled the entire contracting process with the shipyard.

MD Engineering is a division of MD Group that comprises of three divisions with fields ranging from engineering to powertrain supply and marine propulsion engines.

For your next engineering project, please contact us today with the project details for a complete proposal.

 

 

 

 

 

 

 

 

MarineDiesel Services Profile: Factory Express Service

 

 

Today’s article continues our series highlighting the services MarineDiesel offers its’ customers.

We offer Factory Express Service to all MarineDiesel customers.

Express service Worldwide

Marinediesel understands the costs of vessel downtime and has responded to this with the FES program. Not only do we provide a comprehensive range of services and technical support for all Marinediesel products worldwide on land or at sea but the FES adds the fast response requirement of some clients.

FES field engineers can be mobilised to sites anywhere in the world within a very short timeframe. FES engineers can perform the task independently or act as supervisors for local staff where required. Capabilities within the FES-team is vast including capability to perform torsional analysis in vessel, logging equipment for mechanical and electronic engines, power tests in vessel to mention a very few. Marinediesel is unique in supplying this service for the particular power range.

Key benefits:

» Skilled engineers available Worldwide
» Cost effective compared to cost of downtime
» On-site supervision of local staff reduces cost
» Express Service
» Full OEM technical backup

Contact your local MarineDiesel dealer or distributor today for complete details.

 

 

MarineDiesel Services Profile: FACT Customer Training

Today’s article continues our series highlighting MarineDiesel’s services.

Training is one of the most important aspects of engine manufacturing that exists. If customers are not adequately trained in the maintenance and operation of our products, then they will not experience the full advantages and benefits MarineDiesel engines offer to them. We are the marine engine experts, and we view training as sharing our knowledge.

All MarineDiesel distributors are capable of providing FACT training on a local basis.

TRANSFER OF KNOW HOW
Skilled and trained local technicians and engineers are essential for any operations long term targets related to cost and performance. Marinediesels training service provide the means to improve skill and productivity of local employees while enhancing the performance of the engines by making them run longer, more efficiently and more reliably.

FACT training stands for Fuel, Air, Compression and Timing which once theoretically understood are the bases for all diesel engines performance as well as an essential tool for diagnostics. Marinediesel offers a wide range of training courses that can be tailored to specific customer requirements. There are several options available but the most commonly requested courses are the FACT level 1 and FACT level 2.

FACT Level 1 is a one week course targeted for technicians, engineers or operators who want to gain a better insight into diesel engine design and operation as well as service and maintenance. The course is divided 50/50 into theory based and hands-on work.

FACT Level 2 is a two week course targeted for technicians, engineers or operators wanting more detailed hands on instruction and practical participation. The course covers theory and practice for major maintenance work, overhaul procedures and trouble shooting techniques.

KEY BENEFITS
» Quality-based, cost effective training and know-how transfer
» In depth understanding of engine theory minimize problems and aid trouble-shooting
» Theory as well as hands on instructions
» Training at Marinediesel’s training centre in Sweden or at location anywhere in the world.
» Courses can be tailored to meet client specific requirements
» Reduced downtime through more skillful operation and maintenance.

Courses can include:
» Theory of the 4-stroke diesel engine
» Engine construction and overall design
» Specialty tools
» Identification and location of components
» Safety instructions
» Preventive maintenance
» Scheduled maintenance
» Engine overhaul
» Tolerances and clearances
» Mechanical diagnostics
» Electronic diagnostics
» General trouble shooting
» CAN based diagnostics software
» Fuel systems
» Cooling systems
» Boost systems

Contact your local MarineDiesel distributor today for complete details.

 

 

 

MarineDiesel Services Profile – Factory Replacement Program

 

Today’s article starts a short series of articles highlighting the various services that MarineDiesel offers to its’ customers.

Over 80% of MarineDiesel customers are commercial or government users. Customers whose engines typically operate every single day, under the harshest of environmental and operational conditions. These types of applications cost customers serious money when engines break down or otherwise experience mechanical problems.

That is why MarineDiesel developed its’ Factory Replacement Program, or FRP.

FACTORY BASED OVERHAULS

Marinediesel as a company has always looked at ways to assist clients and operators in meeting their long term targets. In this progress Marinediesel has developed the FRP or factory Replacement Program which allows
the operator to get first grade quality service as well as reducing and scheduling operational costs. In this context, prolonging engine life and maintaining operational efficiency are key objectives which are addressed by the program.
Marinediesel, as the OEM manufacturer of the engine, has the in-depth knowledge and experience required for quality overhauls. Every aspect of our service is based on rigorous quality standards and supported by top-level
technical expertise at Marinediesels modern facilities. The FRP allows the operator to have a fixed cost per hour that includes replacement engine at TBO-time. Please contact Marinediesel direct or your local representative for further information. The FRP is available for all Marinediesel products.
As a part of the program we work closely with our operators to ensure that maintenance tasks are scheduled to minimize downtime and optimize engine running hours.

KEY BENEFITS
» Quality-based, cost effective service delivered to highest OEM standards
» Technical support and problem solving advice from highly experienced engineers
» Operations maintained at optimum levels with efficient turn-around
» Engine performance thoroughly tested thus avoiding any delays in operation
» Flexible, customer-focused programs

OVERHAULS

Ängelholm is the world headquarters for Marinediesel and the entire MD Group, and it is here that engines
are overhauled under the FRP program. These facilities include:
» Large workshop for teardown, cleaning, inspection and assembly
» 3 top of the line test cells dedicated for the program
» 2 hot test cells
» In-house environmentally controlled paint shop providing highest quality finishing
» Commissioning and on-site service support packages
» In-house R&D and engineering-lab department for any QA or material inspections required
» Full torsional vibration analysis equipment
» Dedicated sub-assembly areas to ensure cleanliness and highest quality assembly
» Full inventory of all parts

PRODUCTS SUPPORTED
» MD200
» MD250SC
» MD300SC
» MD-VGT350
» MD-VGT400
» MD-VGT450
» MD-VGT500

Contact your local MarineDiesel dealer today for complete details on our FRP program and how it can help you minimize downtime.

 

 

 

 

Maintenance Tip of the Week – Sludge 04/20/2015

 

Maintenance Tip of the Week – Sludge

When changing oil filters, inspect the old filter for excessive sludge, metallic bits, or rubbish. This is a leading indicator of serious mechanical wear in the cylinders, pistons, and other engine components.

 

Adulterated Diesel Fuel

 

 

One of the biggest mechanical issues MarineDiesel encounters with our engines is poor fuel quality. Sometimes, this is unavoidable, and you simply receive a bad batch of fuel that has become contaminated, or has been sitting in a tank for too long.

However, a much more serious problem comes from adulterated fuel. This is often hard to detect, and vessel owners often have a difficult time proving where the fuel was adulterated.

Why do people tamper with fuel?

Three primary reasons:

  1. To cover up theft (replacing diesel that is stolen with other fluids).
  2. To circumvent emissions regulations. (Less-refined fuels are cheaper than diesel).
  3. To save money. (Fuel is an enormous portion of operating expenses. Though not wise, some operators still do this practice.)

Adulterated fuel does not burn cleanly. It also has a different caloric output than pure diesel. So, engine performance, at its’ most base level, will always suffer with adulterated fuel. The engine ECU is calibrated to use good quality fuel, and the engine compression is set to burn quality fuel.

The primary additive to diesel fuel that we encounter is Kerosene. Kerosene is petroleum-based, and your engines will burn it (this will void the warranty), however, if the percentage of Kerosene in a tank of fuel starts getting too high, serious damage to the injectors can result, translating into a very expensive repair. Why do people use Kerosene? It is much less refined than Ultra Low Sulfur Diesel, and therefore much cheaper. It also is usually taxed at a far lower rate than diesel, making it attractive for unscrupulous bunkers to add into fuel stocks. Unfortunately, in some countries this practice is extremely common, with percentages sometimes exceeding 60% Kerosene. Needless to say, any emissions compliance goes straight out of the door when these situations occur.

What else is often added?

One of the biggest messes is paraffin. Again, your engines will burn it, but as the fuel cools, paraffin solidifies, and has a tendency to clog the entire fuel system, resulting in a messy, and expensive, repair. We have also seen other liquids, including seawater, added to fuel tanks.

So, what can you do? Unfortunately, not much. Use bunkers who are trusted. Periodically have fuel samples checked for quality. Have crews monitor exhaust temperatures and check consumption rates versus fuel receipts. Keep fuel filters clean and change the elements when clogged, even if it is before scheduled service periods. Never tamper with fuel. Always check your engine manual to see a list of approved fuels.