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e MB

1BLACKSTONE
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
0
Section 1

INTRODUCTION

M L121 MA ZEN I M
E

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Figure 1 General View Of Engine
1.1. DESCRIPTION 0F ENGINE
The ESL 12and 16 cylinder Mark2 engines have been designed to give a high fuel efficiency
and a long service life with the lowest possible maintenance and operating costs.
Turbochargers, intercooler and four-valve cylinder heads are fitted as standard to increase
the fuel economy and the available power. The engine can be supplied in either distillate
fuel (refined diesel oil) burning or heavy fuel (unrefined oil) burning versions.
The crankshaftkonnecting rod assembly is mass-balanced to minimise vibration and
torsional stresses. The rotatingmassesof the engine and driven equipment are ’tuned’by an
individually selected flywheel and a damper for the same reason and to avoid harmful
resonant stresses over the engine’s speed range.
A flat drive belt transmits power from the crankshaft to the engine driven pumps.

A two stage, automatic engine protection system, normally consisting of an alarm circuit
and an engine shutdown circuit operating via the governor, is triggered if sensors detect
operating conditions outside safe limits, e.g. low lubricating oil pressure. Engine overspeed
protection is provided by an independent, mechanically operated system, which shuts off
the engine’s charge air supply when operated.

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LastIssued 1/1/93 1-1 Mirrlees Blacktone Ltd
Section 1 ESL 12 & 16 Mk2
INSTRUCTION MANUAL MB
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- BUCKSTONE
Hydraulic stud-tensioning is used in place of torque loading on the most highly stressed
engine studs.
No changes should be made to the engine which could affect its operation without the prior
agreement of Mirrlees Blackstone Limited.

The engine conforms to the International Standards Organisation (1.50) notation in that:
1. The free-end of the engine is opposite to the flywheel end.
2. The standard direction of crankshaft rotation is clockwise, looking onto the flywheel end.
3. The cylinders are numbered, beginning number 1 at the flywheel end.
4. 'A'cylinder bank is on the left 'B'cylinder bank is on the right, looking on to the flywheel and
irrespective of direction of rotation.

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Last Issued 1/1/93 1-2 Mirrlces Blackstone Ltd
e MB
= BLACKSTOhE
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 1

However, for design reasons, B1 cylinder is nearer to the flywheel than A1 which is not to
I S 0 notation.

Every engine is built with care and skill and is thoroughly tested before leaving the factory.
Proper installation, regular maintenance and careful operation will help to ensure a long
and trouble-free life. To ensure the minimum of delay in engine maintenance, a basic or a
comprehensive spares list and lists of gasket and seal sets for various tasks are supplied in
the parts manual.

Addresses for enquiries:


Spare Parts should be obtained from the local Agent or from:-
Mirrlees Blackstone Limited
Uffington Road Telefax: (0780) 56694
STAMFORD Telex: 32234 MBSTAM G
Lincs. PE9 2GB Telephone: (0780) 64641
England Telegrams: Mirrlees, Stamford
Telefax: (0780) 65850
Service Enauiries: should be addressed to local agents or to :
Service Department
Mirrlees Blackstone Limited
Bramhall Moor Lane Telefax: (061) 487 1465
Hazel Grove, Stockport Telex: 667314 MIRLES G
Cheshire SK7-5AH Telephone: (061) 483 1000
England
THIS MANUAL DESCRIBES A BASIC ENGINE WITH THE FOLLOWING FEATURES AS
STANDARD:

1) Direction of rotation - clockwise, looking on to the flywheel end.


2) Direct, into cylinder compressed air starting.

3) One turbocharger and one intercooler, situated at the free end.

4) Controls and instruments situated at the flywheel end of the engine.

5) Electronic governor and instrumentation.

6) Both raw (through-flow) and fresh (circulating) cooling water systems.

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LastIssued 1/1/93 1-3 Mirrlecs Blackstonc Ltd
Section 1 ESL 12 & 16 Mk2
INSTRUCTION MANUAL
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- BLACKSTOh!E
Distillate oil fuelled.

ENGI N E MAINTENANCEANDOVERHAUL - GENERAI,


The manual is written to enable maintenance checks to be carried out with the minimum
possible dismantling and removal of components. This avoids disturbing bedded-in
components and removes the subsequent risk of mis-assembly. If the results of these
checks are within the limits specified in ‘Technical Data’, the components are best left well
alone.
Certain operations such as cleaning heat exchangers and oil coolers on marine installations
should only be carried out on shore.
Before using a torquewrench, the setting must be checked and, if necessary, adjusted. Also,
if using a geared adaptor, the appropriate (reduced) torque MUST be used, to give the
correct torque on the nutbolt itself. Failure to do this can result in serious component
over- stressing. For safety reasons the torque wrench must be grasped at the hand grip and
not part way down the handle.
Inspect all screw-threads before fitting and renew if damaged. Lubricate all threads with
clean engine lubricating oil before fitting, unless otherwise specified.
Studs can be damaged by tightening the nut whilst the stud itself is not fully engaged. Check
that studs are properly fitted, before tightening nuts.
When fitting or removing nuts or bolts arranged radially (except for hydraulically tensioned
studs), follow the sequence given in Figure 3.
Do not allow grease or fluids to enter blind, tapped-holes - hydraulic action when fitting
the bolt/stud could fracture the component.
Marking components for alignment - this should be done using a pencil or a felt
marker-pen if no permanent mark is wanted. A scribed line may be used as a permanent
mark but on highly stressed or bearing surfaces.
Ensure that any chemicals used, e.g. solvents or additives are suitable for the use to which
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they are put follow the manufacturers’ instructions when using.
Ensure that any wood used within the engine during maintenance is good quality hardwood
and that it is free from dirt and loose splinters.
Before barring the engine over, loosen the pressure release plug in each cylinder head two
turns (Figure 4) and observe the safety precautions listed below, under ’Moving Parts’.
Tighten the pressure release plugs after completion of barringkewicing operations to avoid
the ingress of dirt and moisture into the cylinders.

Last Isrued 1/1/93 1-4 Mirrleer; Blackstone Ltd


MB
a -- BLACXSTOhE
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 1

Figure 3 -Tightening order for Figure 4 -Barring the flywheel round


radial nutsbolts 1. Crankcase cavity water drain
2. Pressure release plug

13. HEALTH AND SAFETY - (General Hazards And Precautions To Be Takenl;


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Moving Parts the engine should not be run with guards and covers removed, unless
specified in a servicing task.

e Isolate the air-start system, prevent the driven equipment from turning the engine (if
applicable) and set the control lever to 'STOP' before working on any moving parts and
before barring the engine over.

Engine Side Covers - these should be removed for at least 10minutes after the engine
has stopped running.

Noise - engine noise can damage hearing. All personnel should wear ear protectors when
close to a running engine.

Heat - parts of the engine become very hot during running, e.g. exhaust system, air inlet
system, and should not be handled. All heat shields must be in position whilst the engine is
running, unless specified'in a servicing task.

LastIssucd 1/1/93 1-5 Mirrlccs Blachtonc Ltd


Section 1

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ESL 12 & 16 Mk2
INSTRUCTION MANUAL
miii
= BUCKSTOM 0
Lifting many engine components are heavy and may cause injury if dropped or incorrectly
lifted. Lifting equipment should be inspected before use and its safe operating load must
not be exceeded. Care must be taken to support adequately parts to be lifted, whether by
crane or by hand. A list of the weights of the major components is given on page 2-4.
Working beneath suspended loads is dangerous. If it is unavoidable, however, the load
should be additionally supported by an independent means.
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Spillages oil or fuel spillages present a fire hazard and can make surfaces slippery; they
should be cleaned up immediately.
J-TIGHPRESSUREFLUTDS AND GASES - (Fuel Injection System, Air Start System, Air
Priming System and Hydraulic Tensioning Equipment). If misused, there is a danger of
high pressure fluid or gas being injected into the body through the skin (if this should occur,
seek immediately medical attention). Do not connect, disconnect or attempt to rectify any
of these systems whilst pressurised, unless specified in a servicing procedure (e.g. bleeding
the fuel injection system). In this case, wear protective clothing, goggles and gloves and
keep any high pressure flow clear of all parts of the body. When using the hydraulic pack,
ensure that the flexible hoses are not trapped, stretched or kinked, or they may be
weakened. This can lead to component failure.
Cleaning Agents - Always Follow Manufacturers Instructions Carefully
1.4. LEADACID AND ALKALINE BATTERIES
Before commencing work on the battery ensure adequate supplies of clean cold water and
Saline solution are available (Saline solution should be kept in a squeeze bottle for
irrigating the eyes).
When handling batteries and electrolyte the manufacturers instructions should be closely
followed. a
Main Hazards - Electrolvte
The electrolyte is dilute sulphuric acid or potassium Hydroxide which is poisonous and
corrosive.
Gas given off during charging is inflammable and can cause an explosion.
Dead shorting of terminals may cause excessive heating and explosion risk.
Burns to the skin and eyes.
Precautions
Wear protective clothing.

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Last Issued 1/1/93 1-6 Mirrlecs Blackstone Ltd
MB
=BL4CXSTOhE
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 1

Protect the eve&

Use tools with insulated handles.

Do not smoke or permit naked flame hear the battery.

Do not wear nylon coats or overalls as they create static electricity.

Isolate the external circuit before separating cells to prevent arcing.

DOnot spill electrolyte on skin or clothing.

e 1.5. EMERGENCY ACTION

Skin Contact

Wash skin with copious amounts of clean water then cover immediately with dry gauze.

Eve Contact

Wash out the eyes with plenty of clean water followed by a wash of saline solution.

When mixing acid and water for electrolyte put water in the mixing vessel and add the acid
SLOWLY stirring all the time.

a NEVERADD THE WATER TO THEACID OR IT WILL SPLASH DANGEROUSLY,


Use lead lined wooden boxes or earthenware vessels for mixing acid. Due to the
considerable heat evolved during this process, DO NOT USE GLASS OR PLASTIC
VESSELS.

1.6. ENG INE SERIAL NO. - example


86B ESL 12 MK212121 R
7-7 I Il l "7-7-I
Year Month
(Few
Model Intercooled Noof
Cylinders
Mark No. Contract No. Reverse
Rotation
Turbocharged (if fitted)

Last Issued 1/1/93 1-7 Mirrlccs Blackstom Ltd


Section 1 ESL 12 & 16 Mk2
INSTRUCTION MANUAL
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- BLACKSTONE

Figure 5 - Exploded View Of Engine


1.
2.
3.
Cylinder head assembly
Governor
Fuel injection pump assembly
18.
19.
20.
Split gear assembly
Crankshaft balance weight
Sump
e
4. Fuel supply and return manifolds 21. Lubricating oil filter assembly
5. Engine control lever assembly 22. Pump drive assembly
6. Crankcase water drain assembly 23. Holset damper
7. Gear shaft 24. Large end assembly
8. Camshaft end bearing 25. Crankcase end cover
9. Crankca..e door, with explosion relief valve 26. Intercooler
10. Camshaft drive train 27. Intercooler air supply duct
11. Camshaft drive train door 28. 'hrbocharger mounting bracket
12. Camshaft 29. Turbocharger
13. Camshaft door 30. Fuel filter
14. Flywheel 31. Butterfly valve
15. Thrust bearing 32. Exhaust manifold
16. Main bearing shells 33. Exhaust heat shield
17. Main bearing cap 34. Fresh water manifold

Last I m c d 1/1/93 1-8 Mirrlees Blackstone Ltd


@ MB
= BLACKSTONE
ESL 12 & 16 Mk2
INSTRUCTION MANUAL
Section 1

Figure 6 - Section Of Engine, Looking From The Flywheel End

Lastlssued 1/1/93 1-9 Mirrlccs Blackstone Ltd

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