WÄRTSILÄ 41508 Instruction Manual Download Page 6

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 

Leif Österroos

General Manager

+358 10 709 2708

Mobile:

+358 40 505 5198

[email protected]

Tapani Syrjänen

Manager

Manager
Field Service

Field Service

+358 10 709 3359

Mobile:

+358 40 502 3562

[email protected]

Maarit Merijärvi

Assistant in Vaasa

+358 10 709 2729

maarit.merijarvi

@wartsila.com

Tiina Mäkinen

Assistant in Turku

+358 10 709 3024

[email protected]

Anders Knip

Manager

Manager
Warranty

Warranty

+358 10 709 2820

Mobile:

+358 400 56 0521

[email protected]

Ralf Guldbrand

Manager

Marine & Offshore

+358 10 709 1859

Mobile:

+358 40 767 8859

[email protected]

Kaj-Erik Holm

Service Manager

Marine & Offshore

+358 10 709 2836

Mobile:

+358 40 837 3882

[email protected]

Reijo Seikkula

Service Manager

Marine & Offshore

+358 10 709 3230

Mobile:

+358 40 769 1787

[email protected]

Kristian Ölander

Service Manager

Marine & Offshore

+358 10 709 3041

Mobile:

+358 40 731 0003

[email protected]

Olav Hägglund

Service Manager

Power Plant < 380

+358 10 709 2862

Mobile:

+358 40 556 4309

[email protected]

Harri Hovi

Service Manager

Service Manager
Power Plant

Power Plant

≥

380

+358 10 709 3350

[email protected]

Tapani Heininen

Service Manager

Electrical & Automation

Systems

+358 10 709 1844

Mobile:

+358 40 518 1961

[email protected]

Tarmo Pitkänen

Workshop Manager

+358 10 709 2890

Mobile:

+358 40 556 3937

[email protected]

Summary of Contents for 41508

Page 1: ...0000 Tlx 74251 wva sf Tel 358 10 709 0000 Tlx 74251 wva sf Fax Service 358 6 356 7355 Fax Service 358 6 356 7355 Fax Spare parts 358 10 709 1380 Fax Spare parts 358 10 709 1380 SURMA ENERGY SURMA ENER...

Page 2: ...IME OF PRINTING HOWEVER THE PUBLICATION DEALS WITH COMPLICATED THE TIME OF PRINTING HOWEVER THE PUBLICATION DEALS WITH COMPLICATED T TECH ECH NICAL MA NICAL MAT TT TERS ERS SU SU IT ITED ED ONLY FOR S...

Page 3: ......

Page 4: ...Manager 358 10 709 3281 358 10 709 3281 Mobile Mobile 358 40 502 6882 358 40 502 6882 klaus westerinen wartsila com klaus westerinen wartsila com Kari Koski Tuuri Kari Koski Tuuri Regional Manager Reg...

Page 5: ...Manager 358 10 709 3406 358 10 709 3406 Mobile Mobile 358 400 526 763 358 400 526 763 krister slotte wartsila com krister slotte wartsila com Ari Reunanen Ari Reunanen Manager Manager W rtsil 46 50DF...

Page 6: ...6 358 10 709 2836 Mobile Mobile 358 40 837 3882 358 40 837 3882 kaj erik holm wartsila com kaj erik holm wartsila com Reijo Seikkula Reijo Seikkula Service Manager Service Manager Marine Offshore Mari...

Page 7: ...ils drawings for more details 4 Exact engine build up in all details is defined by the specification 4 Exact engine build up in all details is defined by the specification number on the name plate loc...

Page 8: ...d Rear side The longitudinal side of the engine opposite the operating side Driving end The end of the engine where the flywheel is located Free end The end opposite the driving end Designation of cyl...

Page 9: ...ingly B for the back of the engine B bank on a V engine Clockwise rotating engine When looking at the engine from the driving end the shaft rotates clockwise Counter clockwise rotating engine When loo...

Page 10: ...side of the fuel cam Marking of the flywheel Theflywheelisdividedin360 startingfrom TDC at firing for cylinder 1 TDC at firing for every cylinder is marked on the flywheel There is a common marking fo...

Page 11: ...w elding point is close to a pproxima tely w ith in a ra dius of 2 m an electronic module SS M 701 SS M 558 CC D P DM C ense etc disconn ect a ll connectors of th e unit Close th e covers of th e ca...

Page 12: ...Appendix B Welding Precautions 200147...

Page 13: ...A5 B2 A2 B6 A6 B8 A8 B4 A4 B7 A7 B3 A3 B1 18V34 A1 B1 A7 B7 A4 B4 A2 B2 A8 B8 A6 B6 A3 B3 A9 B9 A5 B5 A1 B5 A5 B9 A9 B3 A3 B6 A6 B8 A8 B2 A2 B4 A4 B7 A7 B1 Normally the engine rotates clockwise Lubri...

Page 14: ...ed valve wear Low ash lubricants with sulphated ash level of max 0 6 w have to be used ash level of max 0 6 w have to be used Add Additiv itives es The oils should contain additives that give good oxi...

Page 15: ...sample should be ample should be sent to the oil supplier for analysis On the basis of the results it is sent to the oil supplier for analysis On the basis of the results it is possible to determine...

Page 16: ...the used oil causing for example precipitation of insolubles Measure and record causing for example precipitation of insolubles Measure and record the quantity added Attention to the lubricating oil c...

Page 17: ...er the use of an approved tion found in the end of this chapter Further the use of an approved cooling water additive or treatment system is mandatory cooling water additive or treatment system is man...

Page 18: ...te orates sol s sole is n e is not ot accepted accepted In an In anemergency if emergency ifcompounded additives compounded additivesare not are notavailable treat available treatthe the cooling water...

Page 19: ...that are not protected The corrosion rate at the attacked areas will even be much greater than it would be with no additive at areas will even be much greater than it would be with no additive at all...

Page 20: ...low low concentration concentration Sodium Sodium silicate silicate not toxic not toxic harmless to handle harmless to handle not active when water not active when water velocity exceeds 2 m s velocit...

Page 21: ...y become too high To compensate for leakage or other losses add treated water In connection with maintenance work calling for drainage of the water system take care of and reuse the treated water The...

Page 22: ...Fuel Lubricating Oil Cooling Water 34SG 200303 03...

Page 23: ...on into respiratory organs Seek medical advice immediately into respiratory organs Seek medical advice immediately Aspiration of liquid product Aspiration of liquid product If aspiration into the lung...

Page 24: ...xposure to spray mists move victim to fresh air keep warm and lying still If effects persists victim to fresh air keep warm and lying still If effects persists seek medical advice seek medical advice...

Page 25: ...eration of the system dust handling as well as during normal operation of the system dust spre sprea a ding must ding must be avoide be avoided d A Appro ppropria priate flue te flue ga ga s dust spil...

Page 26: ...least t least 15 15 minut minut es a es a nd s nd s ee eek medic k medica a l a l a dvic dvice If po e If possible ssible kee keep rinsing u p rinsing u nt nt il il eye sp eye spec ecia ia list ha li...

Page 27: ...ide rubber can Fluoride rubber can be used in most a be used in most a ppl pplic ica a tions up tions up to 27 to 275 5 C wit C without hout a a ny substa ny substa nt ntial degrada ial degrada tion o...

Page 28: ...a lat lat io ion pro n protec tectio tion breat n breat hing ma hing ma sk sk 02 02A 8 A 8 5 5 Firs First aid measur t aid measures es Inh Inh a a li ling Mo ng Move the p ve the pa a tient from the d...

Page 29: ...A Ap pp pe en nd di ix x A A E En nv vi ir ro on nm me en nt ta al l H Ha az za ar rd ds s 2 20 00 03 32 21 1...

Page 30: ...circuits of engines has to meet the following specification pH min 6 5 Hardness max 10 dH Chlorides max 80 mg l Sulphates max 150 mg l S A Arteco N V Technologiepark Zwijnaarde 2 B 9052 Ghent Zwijnaa...

Page 31: ...Products LLC 1111 Bagby Houston TX 77002 Havoline XLi TotalFinaElf Diamant B 16 rue de la R publique 92922 Paris La D fense Cedex France WT Supra Unitor ASA P O Box 300 Sk yen N 0212 Oslo Norway Dies...

Page 32: ...AL 2 4 8 kg 10 24 litres 50 100 litres 1500 ppm as NO2 1500 ppm as NO2 1 6 3 2 w of active compounds measured with a supplier s refractometer Vecom CWT Diesel QC 2 6 10 litres 1500 2500 ppm as NO2 No...

Page 33: ...c The installation operation and maintenance instructions of the manufacturer should always be followed The contact information can be found in the table below International Watertreatment Maritime AS...

Page 34: ...lphated ash in gas engine lubricating oils is a very important property Too high ash content can cause preignition knocking and spark plug fouling while too low ash content can lead to increased valve...

Page 35: ...ASTM D 893b Oxidation Abs cm max 25 IR Nitration Abs cm max 20 IR APPROVED LUBRICATING OIL QUALITIES FOR W RTSIL 34SG NATURAL GAS OPERATION SUPPLIER BRAND NAME VISCOSITY BN SULPHATED ASH w BP Energas...

Page 36: ...A247714 2 Engine WDAAA247740 3 Power plant WDAAA243558 TABLE OF CONTENTS THE WHOLE MANUAL FOR A COMPRESSOR STATION 1 General WDAAA247714 2 Engine WDAAA247740 3 Compressor station WDAAA299978 TABLE OF...

Page 37: ...ation to fulfil them In engine part of this manual the description of the engine operation is given in different stages to give the operator a clear view of how the safety system controls the engine R...

Page 38: ...and tends to rise in closed draughtless space Natural gas requires certain concentration to be ignited or burned At 0 C the concentration has to be 5 15 vol lower or higher concentrations do not igni...

Page 39: ...lties or unconsciousness will call for revival actions and medical attention 3 2 Breathing carbon monoxide Generally most of the deaths associated with natural gas accidents are caused by carbon monox...

Page 40: ...close valves on both sides of a pipe caught in the fire This would cause the pressure to rise and eventually the pipe to explode If the gas supply system contains a gas compressor press the gas compr...

Page 41: ...tion velocity to increase to detonation At this point the velocity may reach 2000 m s The reaction continues until either of the reactants have run out or circumstances otherwise turn unfavourable to...

Page 42: ...ve the pre set limits On detecting high pressure the SAV measuring diaphragm and the switching bush move into the release position and the ball mechanism set the valve stem free to close the SAV valve...

Page 43: ...ves and in the pipe between the last shut off valve and the engine is vented to the atmosphere through the solenoid operated vent valves 3 The vent valves V16 and V19 additionally V26 and V29 for PCC...

Page 44: ...rence If the difference is outside the limits the engine will be shut down Opening closing and venting of the fuel gas regulating unit is electrically controlled through the PLC while the gas at the e...

Page 45: ...valves in the fuel gas regulating unit are closed during a normal stop sequence Gas venting is done the following way 1 V14 is opened for 5 seconds to relieve the overpressure between V07 and V15 2 V...

Page 46: ...t operation or could cause injury 3 Ensure that the engine room is well ventilated and gas free 4 Check that the main gas valve manual ball valve on the fuel gas regulating unit is closed 5 Check that...

Page 47: ...nto the engine room it is essential that the engine and the gas supply system are shut down immediately Leave the engine room and do not enter until the room has been properly ventilated to remove any...

Page 48: ...d air with tape plugs clean cloth or the like 6 When exchanging a worn out or damaged part provided with an identification mark stating cylinder or bearing number mark the new part with the same numbe...

Page 49: ...g hours on a new engine and after overhaul those screws that have been opened Note Pump to stated pressure Tighten if possible Do not loosen 07 3 Gas and lub oil filters Check pressure drop indicators...

Page 50: ...sary Gas regulating unit replace the filter cartridges Following intervals for both filters 4000 hours 17 1 17 2 Ignition system Clean and check the condition of the extension 16 4 4 Replace O rings I...

Page 51: ...he engine with the turning gear 03 1 Cooling water spaces Inspect jacket water spaces on engine with cooled turbocharger 15 2 Inspect turbocharger cooling water ducts for possible deposits If the depo...

Page 52: ...e starting motors Check the starting motors gear wheels and flywheel gear rim Check oil level and look for leaks See manufacturers instructions 21 2 Wastegate Check the function of the wastegate valve...

Page 53: ...ods Inspect the small end bearings Inspect the small end bearings Replace if necessary 11 3 3 06 2 Crankshaft Inspect main bearings 10 2 2 Inspect one main bearing If in bad condition check change all...

Page 54: ...ton rings Inspect pistons and replace piston rings 11 3 3 Pull inspect and clean Check the height of the ring grooves use form No 3410V023 Check the retainer rings of the gudgeon pins Replace complete...

Page 55: ...ons 15 5 04 14 Interval 48000 operating hours Camshaft driving gear Replace intermediate gear bearings 13 1 Replace parts 06 2 Crankshaft Inspect crankshaft Inspect the crankshaft for wear 06 2 Engine...

Page 56: ...t ha t a ll th e ma intena nce tools a re ava il able 3 Check th a t necessary spa re pa rts a nd consumable parts a re available 05 1 2 Ordering of Maintenance tools 1 Find the part s th a t int ere...

Page 57: ...sleeve M56 3V86B0039 861010 Pin for tightening of nuts M56 4V86B0002 861011 Flexible hose 800 mm 1 861012 Flexible hose 3000 mm 1 861027 Distance sleeve M42 3V86B0046 861028 Pin for tightening of nuts...

Page 58: ...6017 Dismantling tool for antipolishing ring 2 3V83G0073 836018 Lifting tool 3V83G0078 836019 Extractor 3 842010 Honing equipment 2V84C0031 842025 Honing stones 25x25x250 including holder coarse 84202...

Page 59: ...rod tooth 1 2V83F0063 846000 Lifting tool for big end bearing cap 1 1V84G0191 860100 High pressure pump 1000 bar 2 4V86A0033 861011 Flexible hose 800 mm 2 861012 Flexible hose 3000 mm 2 861027 Distanc...

Page 60: ...3 3V V8 83 3F F0 01 16 63 3 8 83 35 50 08 85 5 S Su up pp po or rt t a ar rm m 3 3V V8 83 3F F0 02 21 17 7 8 83 35 50 08 86 6 M Mo ou un nt ti in ng g s sc cr re ew w M M3 30 0 3 3V V8 83 3F F0 01 18...

Page 61: ...or rt t 3 3V V8 83 3F F0 01 16 66 6 8 83 35 50 08 84 4 S Su up pp po or rt t a ar rm m 3 3V V8 83 3F F0 01 16 63 3 8 83 35 50 08 85 5 S Su up pp po or rt t a ar rm m 3 3V V8 83 3F F0 01 17 77 7 8 83 3...

Page 62: ...romete eter 5 r 5 30 30 mm mm 800 800106 106 Sp Spare are ti tips ps for for pli pliers ers 800 800002 002 s stra traigh ight t 8 80 02 20 00 00 0 T Ta ap p M M1 12 2 8 835 3500 000 0 Li Lif fti ting...

Page 63: ...or for pli pliers ers 800 800002 002 s stra traigh ight t 8 835 3500 000 0 Li Lif fti tin ng g t too ool l 1 1 2V83F0192 2V83F0192 8 835 3500 000 0 Li Lif fti tin ng g t too ool l 2 2 1V83F0221 1V83F0...

Page 64: ...5 Fe Felt lt wa wash sher f er for g or gri rind ndin ing t g too ool l 1 1 4V84B0111 4V84B0111 8 84 41 10 03 30 0 V Va al lv ve e s se ea at t g gr ri in nd de er r 4 4V V8 84 4B B0 01 13 30 0 8 84 4...

Page 65: ...8 84 48 80 00 00 0 V Va al lv ve e c cl le ea ar ra an nc ce e f fe ee el le er r g ga au ug ge e 3 3V V8 84 4K K0 00 03 35 5 86 8601 0100 00 Hi High p gh pre ress ssur ure pu e pump mp 10 1000 00 ba...

Page 66: ...0 00 00 01 1 8 82 20 00 00 00 0 T To or rq qu ue e w wr re en nc ch h 2 20 0 1 10 00 0 N Nm m 4 4V V9 92 2K K0 02 20 07 7 82 8200 0006 06 Ext Exten ensi sion on ba bar r B1 B12 2 5x 5x25 250 0 8 82 20...

Page 67: ...r 834057 834062 Nut for 834057 834063 Extractor for 834057 3V83E0079 846058 Stud remover M56 3V83G0189 846060 Stud remover M48 3V84G0251 860100 High pressure pump 1000 bar 1 4V86A0033 861010 Pin for t...

Page 68: ...o 834050 Hydraulic extractor 1 3V83E0061 834059 Mounting tool 3V83E0135 834060 Mounting tool 3V83E0137 834064 Guiding ring 3V84G0377 860100 High pressure pump 1000 bar 1 4V86A0033 861011 Flexible hose...

Page 69: ...m 4V80L0006 831000 Eye bolt for lifting 4V83B0001 845020 Nozzle cleaning kit complete 845021 Brass wire brush 4V84L0014 845022 Shaft for nozzle needles 4V84L0015 845023 50 nozzle needles 4V84L0013 862...

Page 70: ...012 Torque wrench 8 40 Nm 4V92K0207 831005 Fixing tool for injection valve 2V84G0263 837051 Lifting tool 3V83H0163 837052 Extractor for gas connection pipe 3V83H0162 846057 Assembly tool for gas nozzl...

Page 71: ...t screw 6 1 2 square drive 4V80L0001 806022 Bit hexagon socket screw 8 1 2 square drive 4V80L0001 806023 Bit hexagon socket screw 10 1 2 square drive 4V80L0001 806031 Bit hexagon socket screw 14 3 4 s...

Page 72: ...rench 24 27 807016 Engineers wrench 30 32 807017 Engineers wrench 36 41 807018 Engineers wrench 46 50 807040 Combination wrench AL 36 807051 Box wrench 24 27 809011 Socket wrench 10 x 12 5 with 1 2 sq...

Page 73: ...Maintenance Tools 32 9801...

Page 74: ...s cold engine inlet va lves 0 7 mm exha ust va lves 1 2 mm 06 1 2 Set values for overspeed trip devices Nominal speed Tripping speed OTM module 720 RPM 750 RPM 830 10 RPM 860 10 RPM 850 10 RPM 885 10...

Page 75: ...ring bore 165 200 165 145 165 25 Camshaft thrust bearing housing bore 85 035 85 000 Assembled bearing bore 75 125 75 060 75 25 Camshaft thrust bearing clearance 0 060 0 144 Camshaft thrust bearing axi...

Page 76: ...50 13 Intermediate gear of camshaft drive bearing clearance axial clearance 0 102 0 179 0 33 0 52 Section 10 2 2a 0 70 Bearing diameter in situ 120 157 120 102 Bearing journal diameter 120 000 119 97...

Page 77: ...0 085 0 190 0 25 Axial clearance 0 20 0 30 Backlash for driving gear R32 V32 0 35 0 49 0 37 0 57 Base tangent length R32 for driving gear V32 86 662 86 064 86 626 86 016 19 Water pump backlash R32 for...

Page 78: ...on Width across flats of hexagon screws mm Key width of hexagon socket head screws mm Torque Nm kpm M8 13 6 23 2 3 M10 17 8 45 4 6 M12 19 10 80 8 1 M16 24 14 190 19 3 M20 30 17 370 37 5 M24 36 19 640...

Page 79: ...V86B78 4 Lateral screws of main bearings and thrust bearing M42 615 635 3V86B78 5 Connecting rod screws 5a M30 tightening in two steps First step Second step 5b M24 tightening in two steps First step...

Page 80: ...serieswith thepressure gaugebeing thelast component thus securing that every cylinder is fed with the correct pressure The non returnvalves inthe hoses are integratedwith thequick cou plings and are o...

Page 81: ...0 otherwise the nut is locked by the cylinder and impossible to loosen 4 Close the release valve and pump pressure to the stated value 5 Screw the nut in counter clockwise direction about half a revol...

Page 82: ...up ST173 Engine speed is not zero Wait until the engine has stopped completely SOB0_1H001SBL STB Engine speed from rotary encoder ST175 Engine speed is not zero Wait until the engine has stopped compl...

Page 83: ...sensor failure SOB0_1E004SF SF Engine load UT793 Sensor broken or wiring fault broken or loose connections Check acc to Fig 08 4 4 20 mA sensor failure MCU SOB0_1S001SF SF Engine speed redundant pick...

Page 84: ...ken or loose connections Check acc to Fig 08 1 PT 100 sensor failure SQA0_1P008SF SF Lube oil pressure inlet PT201 Sensor broken or wiring fault broken or loose connections Check acc to Fig 08 3 4 20...

Page 85: ...ernal temperature measurement of I O board broken Replace I O board SMU0_1T302SF SF Temp in SMU3 2 TE844 Internal temperature measurement of I O board broken Replace I O board SOB0_1S002SF SF Turbo ch...

Page 86: ...as as ur urevol evolt tag age e input to OTM input to OTM Is the Is the voltage alternating voltage alternating or is the LED or is the LED blinking blinking Is the Is the volt volta age gefor for the...

Page 87: ...s hesens ens or or i is s probably OK probably OK I Isfr sfre eque quency ncy increasing increasing I Is s s s ensor ensor distance distance OK OK I Isfr sfre equenc quency y measured measured Is Is 2...

Page 88: ...apacitance 800 1600 pF 800 1600 pF Is any Is any sensor OK sensor OK Che Check tha ck that t KD KDU U hascorrect hascorrect software or change software or change the theKD KDU U Measurethe Measurethe...

Page 89: ...abling Check ignition Check ignition co coil il for for s short hort circuit circuit Checkgreen Checkgreen LED D11 LED D11 on CCU board on CCU board Check relay Check relay K1 in WECS K1 in WECS cabin...

Page 90: ...power supply power supply Check cabling Check cabling Replacefu Replacefus se e Check green Check green LED D LED D11 on 11 on KDU board KDU board Checkvol Checkvoltage tage outpu output i t in n MCU...

Page 91: ...ins 33 34 and 37 38 pins 33 34 and 37 38 Change Change the CCU the CCU Find the broken Find the broken cable unit in the cable unit in the CAN network CAN network Connect pins Connect pins 33 34 and 3...

Page 92: ...n cable unit in the cable unit in the CAN network CAN network Connect pins Connect pins 23 24 and 23 24 and 27 28 27 28 CAN CAN ne network twork probably OK probably OK Is Is resist resistance ance 23...

Page 93: ...Connect CAN terminal res istor If they exist disconnect pins 31 31 and 65 66 Change the DCU boa rd Find the broken cable unit in the CAN network Connect pins 31 32 and 65 66 CAN network probably OK Is...

Page 94: ...rboard to 0 position tes tingposition Switch on the CCU power supply by reconnecting connectorX1 Main ga sva lve opening and closing at one second interval in left hand cyl inders controlled by the CC...

Page 95: ...emergency indications CFC0_1S023EST EMG Engine room emergency pushbutton Engine room panel emergency push button activated n a BLN0_1F001SDI EMG Fire fighting alarm Fire detection system is activated...

Page 96: ...or the pressure switch transmitter is broken Check the shut off ventilation valves functionality Check the pressure switch transmitter ZBB0_1P003SDH SHD High inlet gas pressure Too high gas supply pre...

Page 97: ..._1A001AFI ALM Electrical preheating Start Stop fault Electrical preheater activation is not according to given command Check the functionality of the main contactor Check the wiring for running inform...

Page 98: ...alve V018 leaking Pressure lost between gas shutoff valves V015 and V018 during gas leakage test Check the V018 gas shutoff valve for leakages BAG0_1B001MFI ALM Gen anticond heater control center faul...

Page 99: ...k the earth fault reasons BAE0_1F59NBOPR ALM Gen Prot Earth fault U0 trip Earth fault protection activated Check the prot relay event recorder Check the earth fault reasons BAE0_1F67NOPR ALM Gen Prot...

Page 100: ...activated Check the prot relay event recorder Check load fluctuations and reasons for overloading BAE0_1F46AOPR ALM Gen Prot Unbalance load I2 Unbalanced loads unbalanced system faults open conductor...

Page 101: ...ter pump control center fault HT cooling water pump motor overcurrent shortcircu it tripped Check the overcurrent shortcircuit relay SVH0_1M001AFI ALM HT cooling water pump Start Stop fault HT cooling...

Page 102: ...Radiator motor activation is not according to given command Check the functionality of the main contactor Check the wiring for running information and start stop commands VCA0_1M003MFI ALM Radiator gr...

Page 103: ...preheater 2 Start Stop fault Water preheater activation is not according to given command Check the functionality of the main contactor Check the wiring for running information and start stop commands...

Page 104: ...ove tool Hydraulic cylinder combination Screw Hydraulic tool Cylinder Sleeve Pin Action Screw A1 A2 Main bearing and thrust bearing screws 3V86B78 3V86B46 4V86B11 B1 B2 Main bearing screws 3V86B78 3V8...

Page 105: ...o be low ered U se th e stud tool 4V80D12 11 Lower the main bearing cap by pumping oil pressure to the hydra ulic ja ck by t he hydr a ulic pump 12 Remove the lower bearing shell 13 Insert the turning...

Page 106: ...bearings with the bearing numbers The ma in bearing journa ls should be inspected for surfa ce finish Dam aged journa ls i e rough surface scra tches ma rks of shocks etc should be polished If after a...

Page 107: ...nd 12 Lift the distance sleeves 3V86B46 into position on the side screws on the B bank on an V engine One or two nuts can be tightened simultaneously Fig 10 1 A2 13 Screw on the hydraulic tool 3V86B78...

Page 108: ...the hoses of the hydraulic pump 1V86A18 to the hydraulic jack the supplying hose set to the side marked DOWN see Fig 10 2 10 Unscrew the side screws of the flywheel thrust bearing cap U se th e stud t...

Page 109: ...nd the bearing bore The axial location of the shell is to be secured by keeping the bear ing shell end r ecesses a t level w ith t he a xial fa ces in t he engine block see Fig 10 3 4 Insert the shell...

Page 110: ...y pumping oil pressure to the hydr a ulic ja ck w ith t he hydra ulic pump 12 Screw the side screws into the th reads of the bearing cap by hand 13 Tighten the side screws to th e bottom or by using t...

Page 111: ...e end of th e engine ma x 25 mm in t he direction of the free end by using a suita ble lever 6 Check the uncovered part of the bearing bush by means of a mirror All ca msha ft bearing bushes towa rds...

Page 112: ...Fig 10 5 Notice the difference in tool assembly for the bearing next to th e free end of the engine When it is a qu estion of an end bear ing insert th e guide sleeve 2V83H 149 the t hinn er pa rt be...

Page 113: ...scribed The honing is to be carr ied out by m ean s of Pla tea u honing Only ceramic hones with a coarseness of 80 and 400 should be used The hones w ith a coa rseness of 80 should be used for a bout...

Page 114: ...3V83H171 and the hydra ulic tool 3V83E 61 a ccording to Fig 10 6 4 Tighten the hydraulic tool by tensioning the nut of the pull screw 2V83G46 lightly 5 Connect the hoses of the hydraulic pump to the...

Page 115: ...Engine Block with Bearings Cylinder and Oil Sump 34SG 9701...

Page 116: ...W32DF W34SG KS type 1 Four 4 M16 screws X 1 X X Mahle type 2 Two 2 M22 screws X X X Wecometal type 3 Four 4 M14 screws X X Note 1 On W32 KS piston crown there is only an inner support surface For thes...

Page 117: ...positlayerscancause overheating of the piston crown 11B 3 2 Crack detection test A crack detection test by use of liquid penetrant or preferably mag netic particle detection method should be performed...

Page 118: ...ack detection test Crack detection test of the entire piston skirt with use of liquid penetrant must be made Special attention must in this regard be given to the upper part of the piston skirt and to...

Page 119: ...11B 4 5 Assembling of pistons All types If the inspections are resulting in a conclusion that a piston can be reused the same pair of crown and skirt must be assembled together again It is not allowed...

Page 120: ...y weight at the free end of the engine and a specially balanced flywheel After a possible removal it is important that the supplementary weight is correctly re installed Fig 11 1 Supplementary weight...

Page 121: ...e crankshaft alignment should be carried out immediately after the engine is stopped and rapidly but carefully Only the crankcase cover for the cylinder being measured should be opened and it should b...

Page 122: ...ig 11 2 Dial indicator position and reading 9 Adjust the transducer to a reading somewhere between 0 500 and 0 500 and push Zero 10 Rotate the crank and read deflections in the marked posi tions accor...

Page 123: ...d the driven machinery a control measurement of the main bearings should be made Note In an engine having a normal ambient temperature the corre sponding values must be based on experiences from the p...

Page 124: ...e parts to allow removal of piston and connecting rod parts All connecting rod bolts are hydraulically tightened The piston is of the composite type with an aluminum forged skirt and a forged steel cr...

Page 125: ...6 Screw the tension screws on the connecting rod studs until plastic plugs and studs are in contact 7 Lift the hydraulic cylinders into position and mount the strap nuts see Fig 11 9 8 Connect the hos...

Page 126: ...d at the highest possible load i e at a high compressor speed Note Clean the compressor air side of the turbocharger at as high load as possible full rated load For an efficient washing it is importan...

Page 127: ...h a small hole pipe 6 Fig 15 1 at the bottom of the cooler housing after the insert and at the opposite end plate of the air manifold Examine regularly that the pipe is open by checking the air flow w...

Page 128: ...ecommend that cleaning tank should be equipped with perforated pipes on the bottom for the best cleaning effect see Fig 15 4 During cleaning steam or pressurised air should be connected to the pipes t...

Page 129: ...Air cooler cleaning tank Steam or air Perforated pipes Cooler insert Fig 15 4 3215869701 Turbocharging and Air Cooling 32 200310 08...

Page 130: ...is by passing the exhaust gases past the turbocharger The wastegate valve is working as a regulator and adjusts the air fuel ratio to the correct value regardless of varying site conditions ambient t...

Page 131: ...of the solenoid valve 6 is to prevent air leakage through the I P converter to the actuator when the engine is stopped The control logic is carried out in the engine control system and no external reg...

Page 132: ...ate control system Actuator position 1 2 6 8 1 Actuator 6 Solenoid valve 8 I P converter 2 Butterfly valve 9 Positioner 9 Fig 15C 2 3215102200147 OPEN SHUT 32 200247 Turbocharging and Air Cooling Appe...

Page 133: ...osition 2 Tighten the screws 15 and 16 3 Calibrate the wastegate I P converter see section 15 C 0 5 4 Mount the yellow indicator and the cover Indicator reading on the cover should same as on the cam...

Page 134: ...he solenoid 6 during the whole calibration procedure 3 Connect the mA calibrator to the I P converter See Fig 15C 5 4 Set the mA to equal 30 degrees on the cam 14 See table 1 below 5 Adjust the zero a...

Page 135: ...Wastegate I P converter 20 Zero adjustment screw 21 Span adjustment screw 3 2 1 OUT IN S Z 20 21 mA mA Fig 15C 5 3215105200243 Appendix C Turbocharging and Air Cooling 32 200247...

Page 136: ...y ignition source for the main fuel charge in the cylinder The prechamber is located in the center of the cylinder head Working principle 16 2 Prechamber 16 2 1 Description The prechamber 13 is casted...

Page 137: ...is cooled in a separa te centra l cooler Cooling water system B A C A C B 1 2 3 4 5 6 7 9 8 10 15 12 14 13 11 1 Expansion tank 2 Venting box 3 Alarm switch 4 Alarm switch 5 Manometer 6 Manometer 7 Cha...

Page 138: ...of a charge air cooler 7 and a lube oil cooler 15 not mount ed on the engine thr ough w hich a pump 8 identical to th e HTpump pumps the w a ter The circuit tempera ture is controlled by a temperatur...

Page 139: ...Sa ve the discha rged w at er an d use it a gain 19 2 2 Cleaning In completely closed systems th e fouling w ill be minima l if the cooling w a ter is t reat ed a ccording t o our inst ructions in ch...

Page 140: ...entioned in chapter 02 section 02 3 The cleaning agent s should conta in additives inhibitors to prevent corrosion of the metal surfaces Always follow the manufacturer s instructions t o obta in the b...

Page 141: ...s 10 2 Loosen the fastening screws 6 3 Pull off the impeller by usin g the t ool 32 83H01 4 When re assembling the impeller coa t t he threa ds with Loc tit e 242 a nd t ight en th e nut t o torq ue s...

Page 142: ...ces are corroded uneven or worn Avoid touching the sealing faces with fingers 5 Reassemble the details in proper order a nd inst a ll the impel ler a ccording t o pos a a bove c Replacing of bearings...

Page 143: ...earing housing according to Fig 19 3 and oil the outer surfa ces of the bearings P ress the sha ft into th e housing by both th e inn er a nd outer ring of the bear ing 15 w ith a suita ble pipe Mount...

Page 144: ...ws a litt le a nd check tha t t he gea r w heel is in th e right position 23 Tighten the screws to torq ue a ccording t o cha pter 07 24 Re install the seal 12 see pos d below 25 Mount the slinger 11...

Page 145: ...tion The LT a nd H Tcircuits a re equipped with tempera ture control valves Temperat ure ra nges a ccording t o cha pter 01 section 01 2 The va lves a re norma lly mounted outside of th e engine 19 4...

Page 146: ...l ta ke over with only a slight cha nge in opera t ing temperature Since flow is diverted either to by pass or heat exchanger failure of an element would cause no change in pressure drop The content s...

Page 147: ...opening th e cover 2 Check the element by heating it slowly in water Check at w hich t empera tures t he element sta rts opening a nd is fully open The correct va lues ca n be found in cha pter 01 th...

Page 148: ...aft rotaryencoder MCU Main gas pressure Main gas press ref PCC gas pressure PCC gas press ref Profibus kW sensor CCU2 CAN Main gas controlvalve PCC gas controlvalve Duration ref Timing ref CCU1 Fig 23...

Page 149: ...is based on a PID controller which compares the actual pressure with a mapped pressure reference table In this table the reference is engine load dependent The reference is offset according to the ch...

Page 150: ...k Ignition system layout 23 10 2 Ignition control The reference for ignition timing and the dwell time duration and a separate offset adjustment in timing and duration for each cylinder is determined...

Page 151: ...r because primary current limiting is not necessary The primary current is switched on when the input line Ignition Control goes active low and will be switched off when the signal goes inactive If th...

Page 152: ...ignition coil high voltage extender and spark plug Ignition module driver and high voltage Ignition control Dwell time Spark position Secondary voltage Primary current Secondary current Fig 23 19 3223...

Page 153: ...tween these signals constitutes the input to a PID control ler The regulation output of this controller will accordingly vary to sustain the reference level This output will either control the opening...

Page 154: ...nchronizing sequence For synchronising the system s speed increase decrease binary inputs are used When the engine reaches rated speed an external device activates the synchronising sequence Commands...

Page 155: ...n operating against a grid utility In the latter case load control is however recommended 23 11 5 Load control The load control function is enabled if kW mode is selected This mode can only be activat...

Page 156: ...ithm of WECS will also affect the gas admission duration The cylinder exhaust gas control is not active in diesel and backup operating mode If the engine is in gas operating mode and the load level is...

Page 157: ...Profibus cable connector of the MCU rack inside the MCU 23 13 1 Maintenance of the DIN43650 Hirschmann type connectors Locate the DIN43650 Hirschmann type connector which is mounted on the main gas p...

Page 158: ...get it tight again 3 Repeat the steps 1 and 2 for all the Cannon connectors of the main gas admission and prechamber control valves Note If the locking wire is broken it has to be replaced with a new...

Page 159: ...nd tighten all the screws of every Phoenix connector in CCU 2 Once all of the screws have been tightened press down all the Phonix connectors by finger tips This is because some of them may have risen...

Page 160: ...n the MCU cover and press down one by one all the green row connectors in the MCU rack inside the MCU cabinet Just push on them to see if they are all the way in Do not pull the connectors out or the...

Page 161: ...g hours or every 6 month maintain the electrical connector contact surfaces with contact lubricant The contact treatment greases listed below can be ordered from W rtsil The recommended chemicals are...

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WÄRTSILÄ 41508, Instruction Manual

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