WÄRTSILÄ PAAE051728 Instruction Manual Download Page 125

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07. Tightening Torques and Use of Hydraulic

Tools

07.1

Tightening torques for screws and nuts

Note!

See section 07.3 for hydraulically tightened connections!

The position numbers in the tables below refer to the correspond-

ing figures A to K, which are located in the engine according to

Fig 07-1. Always tighten to stated torque shown in the tables. A

loosen screw connection might cause serious damages/human

injury.Threads and contact faces of nuts and screw heads should

be oiled with lubricating oil unless otherwise stated. Note that

locking fluids are used in certain cases.

Note!

Molycote or similar low friction lubricants must not be used for
any screws or nuts. Great risk of over tensioning of screws.

1 Nm = 0.102 kpm

Tightening torques

H, I

Fig 07-1

4007019601

32-200643-01

Tightening Torques and Use of Hydraulic Tools

WÄRTSILÄ 32

07 - 1

Summary of Contents for PAAE051728

Page 1: ...ngine operators and should always be at their disposal The content of this manual shall neither be copied nor communicated to a third person W rtsila Finland Oy Vaasa Factory Tarhaajantie 2 FIN 65101...

Page 2: ...L MATTERS SUITED ONLY FOR SPECIALISTS IN THE AREA AND THE DESIGN OF THE SUBJECT PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS MODIFICATIONS AND CHANGES CONSEQUENTLY THE PUBLISHER AND COPYRIGHT OWNER OF...

Page 3: ...ice Vaasa Tarhaajantie 2 FI 65380 Vaasa P O Box 252 FI 65101 Finland 24hrs Phone 358 10 709 080 Fax 358 10 709 1380 Switchboard 358 10 709 0000 Office hours 7 30 16 30 E mail service solutions wartsil...

Page 4: ......

Page 5: ...verydelivery The system diagram plans fuel oil cooling etc are just indica tive and thus do not cover all installations See installation specific system drawings for more details Exact engine build up...

Page 6: ...ant terms used in this manual are defined as follows see also Fig 00 1 Operating side The longitudinal side of the engine where the operating devices are located start and stop instrument panel speed...

Page 7: ...located at the operating side may be marked with M Manoeuvering and correspond ingly B for the back of the engine B bank on a V engine Clockwise rotating engine When looking at the engine from the dr...

Page 8: ...injection pump it is possible to note that the pump tappet roller is on the lifting side of the fuel cam Marking of the flywheel The flywheel is divided in 360 starting fromTDC at firingforcylinder1...

Page 9: ...ing device engaged during maintenance work 1 x x x x x x x x Crankcase safety expl valves will open if crank case explosion x x x Noise level x x x x x x x x x x x x x x x x Running engine without cov...

Page 10: ...ring unintentional start of el driven pump motor Charger starts to rotate due to draft if not locked during maintenance Somebody sticks his hand into the compressor housing when the silencer is remove...

Page 11: ...nsulation box Inhalation of exhaust gases or fuel gases due to leakage Failure of pneumatic stop Ejected components due to breakdown of hydraulic tool breakdown of hydraulic bolt breakdown of turbocha...

Page 12: ...energy supply failure enginenot fully safeguardedathighoilmistlevels duetofailure in oil mist detector circuitry engine not fully safeguarded at high oil mist levels due to erratic electrical connecto...

Page 13: ...ion in good condition Do not use if insulation is damaged or missing Fumes and gases can be dangerous Use ventilation or exhaust to keep air breathing zone clear comfort able Use helmet and positionin...

Page 14: ...use semiautomatic constant volt age equipment with cold electrode or stick welder with voltage reducing device Provide welder helper and method of welder retrieval from outside enclosure General work...

Page 15: ...ontact might also cause sparkles and radiation 00B 1 2 2 Preventing Radiation The welding current and the arc is emitting a wide spectrum of electromagnetic radiation This might cause damages on sensi...

Page 16: ...eet 00B 2 3 WECS 3000 checklist The following precautions must be paid attention to before welding in the vicinity of a WECS 3000 control system Deactive the system by disconnecting all external conne...

Page 17: ...autions checklist The following precautions must be paid attention to before welding in the vicinity of a UNIC control system Deactivate the system by disconnecting all external connectors from the PD...

Page 18: ...Appendix B Welding Precautions 200640 00 6...

Page 19: ...V32 A1 B1 A4 B4 A3 B3 A2 B2 A6 B6 A10 B10 A7 B7 A8 B8 A9 B9 A5 B5 A1 B5 A5 B9 A9 B8 A8 B7 A7 B10 A10 B6 A6 B2 A2 B3 A3 B4 A4 B1 Normally the engine rotates clockwise Lubricating oil volume in the engi...

Page 20: ...0 r s 4 5 3 0 2 0 720 RPM 12 0 r s 750 RPM 12 5 r s 5 0 5 5 3 0 2 0 HT LT water before HT LT pump static 0 7 1 5 HT water before engine 2 5 static press 1 1 5 static press 2 2 4 LT water before charg...

Page 21: ...stroke diesel engine with direct fuel injection Theengine blockiscastinonepiece Thecrankshaftismounted underslung the engine The main bearing cap is supported by two hydraulically tensioned main bear...

Page 22: ...stems seal against the directly cooled valve seat rings The seat rings made of a corrosion and pitting resistant mate rial are changeable The camshafts are made up from one cylinder pieces with integr...

Page 23: ...tion and automation for common rail system is handled by WECS 2000 and WECS 7500 Alternatively the instrumentation and automation can also be handled by the plant control system The cooling water syst...

Page 24: ...Cross section of W rtsil 32 in line engine Fig 01 1 401010 01 Main Data Operating Data and General Design 32 200634 01 01 6 W RTSIL 32...

Page 25: ...Cross section of W rtsil 32 V engine Fig 01 2 400102 32 200634 01 Main Data Operating Data and General Design 01 W RTSIL 32 01 7...

Page 26: ...01 Main Data Operating Data and General Design 32 200634 01 01 8 W RTSIL 32...

Page 27: ...ts at engine inlet in running conditions cSt Fuel W RTSIL 20 Vasa 32 32LN W RTSIL 32 W RTSIL 46 W RTSIL 46F LFO min 1 8 2 0 2 8 HFO 16 24 16 24 16 24 The maximum limits of fuel characteristics for a c...

Page 28: ...flow rate of rated capacity 60 40 30 25 20 15 Note Recommended centrifuge flow rates see separator manufacturers instruction manual In case pure distillate fuel is used centrifuging is still recommend...

Page 29: ...emperature 28 C Conversion from various current and obsolete viscosity units to centistokes can be made in the diagram Fig 02 2 The diagram should be used only for conversion of viscosities at the sam...

Page 30: ...control An automatic viscosity controller or a viscosimeter at least should be installed in order to keep the correct viscosity of the fuel before the fuel enters the engine fuel system Centistokes 3...

Page 31: ...PMCC C 60 Pour point C 30 Total Sediment Potential mass 0 10 The limits above also correspond to the demands ISO 8217 1996 E ISO F RMH 55 and RMK 551 BS MA 100 1996 RMH 55 and RMK 551 CIMAC 1990 class...

Page 32: ...6 24 cSt at the point of injection At low viscosities the flow past the plunger in the injection pump increases This leads to a decrease in the amount of injected fuel which in bad cases might make it...

Page 33: ...ition quality produces long ignition delays ad vancing the injection timing makes things only worse The fuel will be injected at a lower compression temperature and this will produce an even longer ig...

Page 34: ...uld be noted Sufficient preheating of the engine before start Proper function of the inverse cooling system Proper function of the injection system especially the injection nozzle condition must be go...

Page 35: ...nly of the injec tion pumps and nozzles but also of cylinder liners and piston rings An efficient fuel separation is a must for minimising wear Oxides of vanadium and sodium mainly sodium vanadyl vana...

Page 36: ...its in the fuel system as well as excessive centrifuge sludge i A low flash point high vapour pressure is often seen especially for crude oils The low flash point will not influence the combustion but...

Page 37: ...bility and incompatibility problems precipitation of heavy components in the fuel avoid if possible blending of fuels from different bunker stations unless the fuels are known to be compatible If stab...

Page 38: ...s SAE 40 In W RTSIL Vasa 32 engine type also the use of SAE 30 class lubricating oil is allowed Viscosity Index VI Min 95 Alkalinity BN The required lubricating oil alkalinity is tied to the fuel spec...

Page 39: ...M D 892 92 test method Sequence I 100 0 ml Sequence II 100 0 ml Sequence III 100 0 ml In this test a certain amount of air is blown through the lubricating oil sample The first number in the results i...

Page 40: ...e condition of the lubricating oil and the change interval of the lubricating oil batch Depending on type of application and from the different lubricating oil system arrangements point of view the fo...

Page 41: ...oil consumption by adding max 10 new oil at a time Adding larger quantities can disturb the balance of the used oil causing for example precipitation of insolubles Measure and record the quantity adde...

Page 42: ...nge should always be agreed between the oil company and customer 02 2 4 Lubricating oil for the governor See the Instruction Book for the governor attached An oil of viscosity class SAE 30 or SAE 40 i...

Page 43: ...e the Instruction Book for the turbocharger attached Note IntheABBVTR 4series turbochargers theuseofsyntheticlowfriction lubricating oils is strongly recommended by the engine and the turbocharger man...

Page 44: ...the sample itself Oil samples with no background information are of very limited value The following data are essen tial to note when taking the sample Installation name Engine type and number Engine...

Page 45: ...before closing the last flap on the IATA carton Check the DNVPS Air Courier Directory and use appropriate label for the IATA carton box to ensure that the sample is forwarded to the nearest DNVPS lab...

Page 46: ...facturer for use of anti freeze chemicals Fresh water generated by a reverse osmosis plant onboard often has a high chloride content higher than the permitted 80 mg l causing corrosion Caution The use...

Page 47: ...the areas that are not protected The corrosion rate at the attacked areas will even be much greater than it would be with no additive at all present in the system see schematic graph of the corrosion...

Page 48: ...id nitrite risk of spot corrosion when too low concentration Sodium silicate not toxic harmless to handle not active when water velocity exceeds 2 m s commercial products very expensive increased risk...

Page 49: ...n the end of this chapter Note Ask the supplier of the treatment product for instructions about treatment procedure dosage and concentration control Most suppliers will provide a test kit for the conc...

Page 50: ...as Cl 5 mg l Suspended Solids 5 mg l Temperature before pump 60 C In order to achieve a safe operation of the Wetpac system and the engine water produced with a fresh water generator distiller has to...

Page 51: ...and soil contamination 02A 2 1 Handling Isolate from ignition sources like sparks from static electricity for example Avoid breathing evaporated fumes may contain hydrogen sulphide etc during pumping...

Page 52: ...ded Seek medical advice after significant exposures In halation of oil mist Seek medical advice Skin contact Hot oil on the skin should be cooled immediately with plenty of cold water Wash immediately...

Page 53: ...g oils may contain significant amounts of harmful metal and PAH polyaromatic hydrocarbons compounds Avoid pro longed or repetitive contact with the skin Prevent any risk of splash ingandkeepawayfromhe...

Page 54: ...ediately with plenty of water continue for at least 15 minutes and seek medical advice Ingestion Do not induce vomiting in order not to risk aspiration into respiratory organs Seek medical advice imme...

Page 55: ...imize splashing Use safety footwear when handling barrels 02A 5 3 First aid measures Inhalation In the event of over exposure to spray mists move victim to fresh air keep warm and lying still If effec...

Page 56: ...dling as well as during normal operation of the system dust spreading must be avoided Appropriate flue gas dust spillage disposal instructions must be applied The dusts collected from the exhaust gas...

Page 57: ...ops Eye contact Rinse immediately with plenty of water for at least 15 minutes and seek medical advice If possible keep rinsing until eye specialist has been reached Ingestion Rinse mouth with water D...

Page 58: ...ature above 275 C 527 F Fluoride rubber can be used in most applications up to 275 C without any substantial degradation or health hazard Use of or test of fluoride rubber at temperatures above 275 C...

Page 59: ...quipment Hand protection impenetrable acidproof gloves neoprene or PVC Inhalation protection breathing mask 02A 8 5 First aid measures Inhaling Move the patient from the danger zone Make sure that he...

Page 60: ...Appendix A Environmental Hazards 200507 02A 10...

Page 61: ...DMB B CIMAC 2003 DB 15 30 ISO 8217 1996 E ISO F DMB ASTM D 975 01 GRADE NO 4 D ASTM D 396 04 GRADE NO 5 6 C BS MA 100 1996 DMC RMA10 RMK55 30 55 CIMAC 2003 DC A30 K700 ISO 8217 1996 E ISO F DMC RMA10...

Page 62: ...BN lubricating oils should be used The intervals between lubricating oil changes may be extended by adding oil daily to keep the oil level constantly close to the maximum level An example of BN deplet...

Page 63: ...OF LUBRICATING OIL BRAND In order to minimize the risk of lubricating oil foaming deposit formation blocking of lubricating oil filters damage of engine components etc the following procedure should b...

Page 64: ...Marine 1040 Servo Marine 2040 SAE 40 SAE 40 10 20 A A B Petrobras Marbrax CCD 410 AP Marbrax CCD 415 Marbrax CCD 420 SAE 40 SAE 40 SAE 40 12 15 20 A A B A B Shell Gadinia Oil 40 SAE 40 12 A Statoil M...

Page 65: ...S SAE 40 Cladium 550 S SAE 40 SAE 40 SAE 40 SAE 40 40 50 55 C D C D C D ExxonMobil Exxmar 40 TP 40 Exxmar 50 TP 40 Mobilgard M 440 Mobilgard M50 SAE 40 SAE 40 SAE 40 SAE 40 40 50 40 50 C D C D C D C D...

Page 66: ...orporation Marilube Oil W 304 SAE 40 30 A B C D ENI S p A Cladium 300 S SAE 40 SAE 40 30 A B C D ExxonMobil Exxmar 30 TP 40 Mobilgard M 430 SAE 40 SAE 40 30 30 A B C D A B C D Indian Oil Corporation S...

Page 67: ...0 23 0 95 ExxonMobil Spartan EP 460 Mobilgear 634 460 437 30 8 27 8 96 96 Shell Omala Oil 460 460 30 8 97 Total Lubmarine Epona Z 460 470 30 3 93 LUBRICATING OILS FOR GOVERNOR ACTUATOR An oil of visco...

Page 68: ...Page 7 7 Document No 4V92A0645 Rev j...

Page 69: ...LITY Raw water quality to be used in the closed cooling water circuits of engines has to meet the following specification Property Limit pH min 6 5 Hardness max 10 dH Chlorides max 80 mg l Sulphates m...

Page 70: ...ton Avenue Northwich Cheshire CW8 4DX UK Nalcool 2000 Nalfleet EWT 9 108 Rohm Haas La Tour de Lyon 185 Rue de Bercy 75579 Paris Cedex 12 France RD11 RD11M RD25 RRS Yhti t Pieks m entie 398A 77570 J pp...

Page 71: ...7 Brix of active compounds measured with a supplier s refractometer WT Supra 50 100 litres 1 8 3 7 Brix of active compounds measured with a supplier s refractometer Dieselguard NB Rocor NB Liquid Coo...

Page 72: ...n closed cooling water system shall always be minimized since heat transfer of water containing glycol has deteriorated significantly Engine type specific requirements have to be always taken into acc...

Page 73: ...ng and disengaging of the turning gear is made by the lever 1 with yellow ball knob The turning gear is spring loaded outwardsinordertopreventitfrommeshingwiththeflywheelwhen out of operation The turn...

Page 74: ...he governor is correct the starting air pressure exceeds 15 bar the starting air system is drained of condensate the drain pipe of the air cooler casing is open no leakage stop lever is in work positi...

Page 75: ...yellow ball kob 5 Check start blocking on the LDU Remove blockings and return to the main page 6 Check that the automation system indicates ready for start 7 Check that the stop lever is in work posi...

Page 76: ...engine is to be stopped for a lengthy time close the indicator valves It is also advisable to cover the exhaust pipe opening The lubricating oil system on a stopped engine should be filled with oil e...

Page 77: ...el in the oil sump oil tank Estimate the appearance and consistency of the oil A simple control of the water content A drop of oil on a hot surface about 150 C e g a hot plate If the drop keeps quiet...

Page 78: ...sure air manifold pressure the dew point will be 55 C from diag If the air temperature in the air manifold is only 45 C the air can only contain 0 018 kg kg from diag The difference 0 011 kg kg 0 029...

Page 79: ...observations LOOK at and LISTEN to the engine 2 Strong gas blow by past the pistons is one of the most dangerous things that can occur in a diesel engine If gas blow by is suspected e g because of a...

Page 80: ...n the speed governor and injection pumps are set correctly especially the injection pump rack position and does not jam that all connections are properly locked and the injection pump racks move freel...

Page 81: ...gine immediately otherwise stop the engine after 5 minutes idling at normal speed Check at least the temperatures of the main and big end bearing and of all other bearings which have been opened If ev...

Page 82: ...r honing of cylinder liners follow programme in Fig 03 3 as closely as possible If the programme cannot be followed do not load the engine fully for at least 10 h Avoid running in at continuous and co...

Page 83: ...d oil preferably when warm through the drain hole 4 2 Rinse the gear box with clean thinly fluid oil 3 Fill the gear box with oil according to the table in section 01 1 through the filling hole 5 unti...

Page 84: ...03 Start Stop and Operation 32 200402 04 03 12 W RTSIL 32...

Page 85: ...additional equipment and chapter 03 1 Before any steps are taken carefully read the corre sponding item in this Manual 2 Note the Risk Reduction in chapter 00A 3 Note the Environmental Hazards in chap...

Page 86: ...or personal injury 04 1 1 How to select application and fuel quality There are two different types of applications defined Average load is above 75 of nominal engine output Average load is below 75 of...

Page 87: ...of the counterweight fastening nuts after 50 running hours Pump to stated pressure Tighten the nuts if possible Do not loosen Gauges and indicators Take readings 03 4 1 Read and record using eg form N...

Page 88: ...gal filter s 18 8 2 Clean more often if necessary Remember to open the valve before the filter after cleaning Control mechanism Maintenance of control mechanism 22 2 Checkforfree movement cleanandlubr...

Page 89: ...al change oil of the coupling Following 1000h intervals check oil level See manufacturers instructions Fuel filter Replace fuel oil filter cartridges Clean the wire gauze and filter housing Replace th...

Page 90: ...nor 02 2 4 Change lubricating oil 22 4 1 Injection valves Inspect injection valves 16 4 4 Test the opening pressure Dismantle and clean nozzles Check the effective needle lift Check the springs Replac...

Page 91: ...veair venting pipe andadapterplugonthe multiduct inspect the water side of oneduct Ifthedepositsarethicker than1mm clean allliners andengineblockwaterspace Improvethecooling water treatment 19 2 19 1...

Page 92: ...ilter Replace lubricating oil filter candles 18 7 2 Drain the filter housing Clean the wire gauze Replace the filter candles 18 2 Lubricating oil coolers Clean lubricating oil cooler 18 5 If the lubri...

Page 93: ...and inspect LT water thermostatic valve 19 4 2 Clean and check the thermostatic element valve cone casing and O rings Lubricating oil pump Inspect the lubricating oil pump 18 3 3 Replace parts if nece...

Page 94: ...alves Inspect the valve rotators Check rocker arms Replace the O rings in the valve guides Replace the O rings at bottom of cylinder head screws at every overhaul 12 2 12 3 Cylinder liners Inspect the...

Page 95: ...ed pump General overhaul of fuel feed pump Dismantle and check replace worn parts See manufacturers instructions Booster servomotor for governor General overhaul of the booster servomotor Replace worn...

Page 96: ...ine fastening bolts Check tightening of engine fastening bolts 07 3 Retight if necessary Exhaust manifold Check expansion bellows 20 1 2 Replace if necessary Flexible coupling Check the flexible coupl...

Page 97: ...ion Check flexible elements of engine foundation Flexible mounted Replace if necessary Flexible coupling Check the flexible coupling Dismantle and check flexible coupling according to manufacturers in...

Page 98: ...04 Maintenance Schedule 32 200623 01 04 14 W RTSIL 32...

Page 99: ...before any maintenance work is started 2 Check with the list below that all the maintenance tools are available on the site 3 Check that necessary spare parts and consumable parts are available 05 1 2...

Page 100: ...M56 1 including 800095 3V86B0218 800048 Stud remover M56 3V84G0189 800049 Pin for tightening of nuts M56 4V86B0002 800051 Lifting tool for hydraulic cylinder M56 L engine 3V86B0288 800051 Lifting too...

Page 101: ...ng 2V83G0077 800053 High pressure pump 1000 bar 1 4V86A0033 800056 Flexible hose 3000 mm 1 800103 Assembly tool for piston 3V83F0135 842025 Honong stones 25x25x250 coarse including holder 842026 Honon...

Page 102: ...0 800017 Guiding plug 4V83F0157 800018 Limiter 3V83F0156 800098 Assembly rail 1 2V83F0183 800099 Support 1 3V83F0186 800100 Mounting sledge 1 2V83F0191 800101 Mounting sledge 1 2V83F0189 800102 Mounti...

Page 103: ...V83F0238 800099 Support 1 3V83F0240 800100 Mounting sledge 1 2V83F0191 800101 Mounting sledge 1 2V83F0189 800102 Support arm 3V83F0363 800107 Protecting sleeve for connecting rod 3V83F0249 800108 Supp...

Page 104: ...00021 Stud remover M27x2 4V80D0032 800022 Pin for tightening of nuts M27x2 4V86B0231 800053 High pressure pump 1000 bar 1 4V86A0033 800056 Flexible hose 3000 mm 1 800057 Flexible hose 1100 mm 1 800097...

Page 105: ...ifting tool 1 3V83D0234 800012 Lifting tool 2 2V11T1482 800013 Clamp tool for piston rings 1V84D0011 800105 Measurement tool for piston ring grooves 800106 Spare tips for pliers 800002 straight 800160...

Page 106: ...hydraulic cylinders 1V87B0054 800053 High pressure pump 1000 bar 1 4V86A0033 800055 Flexible hose 800 mm 1 800063 Hydraulic extractor 1 3V83E0061 800096 Distance sleeve M56 3V86B0222 800130 Extractor...

Page 107: ...g of nuts M56 4V86B0002 800056 Flexible hose 3000 mm 1 800094 Box wrench head 24 mm 4V92K0208 800126 Extraction mandrel for valve guide 3V83H0492 800146 Adapter M16 4V83H0520 820000 Torque wrench 20 1...

Page 108: ...hose 3000 mm 1 800062 Mounting removing tool 3V83H0167 800063 Hydraulic extractor 1 3V83E0061 800112 Hydraulic tools M80 for interm gears 1 3V86B0341 800113 Support for hydraulic tool 2V85G0015 80011...

Page 109: ...ipe sleeves 3V80G0043 800066 Locking plate for injection pump tappet 4V83E0121 800073 Lifting tool for injection pump 2V16T0136 800075 Cleaning tool for seal surface for injection valve 2V84B0247 8000...

Page 110: ...7 6L and 12V 800071 Tools for turbocharger EGT 355i 8L 9L 16V and 18V 800071 Tools for turbocharger EGT 357 8L 9L 16V and 18V 800078 Tools for turbocharger TPL 65 6L and 12V 800079 Tools for turbochar...

Page 111: ...nch for centrifugal filter 4V80G0049 800122 Extractor plate for holder of thermostatic element 4V83H0490 800124 Mounting tool for connection piece 2 1V84G0580 800132 Pneumatic test equipment for injec...

Page 112: ...3 Wrench for cylinder pressure sensor 3V80H0026 820000 Torque wrench 100 200 Nm 4V92K0207 832010 Lifting device for guide block 2V14T0372 837055 Extractor for water pump impeller 3V83H0491 846201 Tool...

Page 113: ...hose 800 mm 1 800056 Flexible hose 3000 mm 1 800057 Flexible hose 1100 mm 1 860150 Manometer 4V51L0085 861016 Quick coupling female 4V86A0035 861101 Quick coupling male 4V86A0034 861147 Flexible hose...

Page 114: ...50 bar 1 1V86A0018 800060 Flexible hose 3000 mm 1 860074 Straight male stud 4V34L0135 860076 Quick coupling male 4V86A0012 860079 Quick coupling female 4V86A0012 860080 Flexible hose 3000 mm 4V86A0067...

Page 115: ...100 Nm 4V92K0207 820003 Ratchet handle 20x630 with 3 4 square drive 4V80K0014 820004 Ratchet handle 12 5x300 with 1 2 square drive 820005 Speed brace B12 5x500 820006 Extension bar B12 5x250 with 1 2...

Page 116: ...Key for hexagon socket screw 12 806018 Key for hexagon socket screw 14 806019 Key for hexagon socket screw 17 806021 Bit hexagon socket screw 6 with 1 2 square drive 4V80L0001 806022 Bit hexagon socke...

Page 117: ...ench 30 32 807011 Engineers wrench 10 11 807012 Engineers wrench 12 14 807013 Engineers wrench 13 17 807014 Engineers wrench 19 22 807015 Engineers wrench 24 27 807016 Engineers wrench 30 32 807017 En...

Page 118: ...et wrench 19x12 5 with 1 2 square drive 809015 Socket wrench 24x12 5 with 1 2 square drive 809016 Socket wrench 27x12 5 with 1 2 square drive 809017 Long socket wrench 13x12 5L with 1 2 square drive 8...

Page 119: ...meas backlash of direct driven fuel feed pump 3V17T0007 800137 Tools for meas backlash of direct driven water pumps 3V19T0053 800138 Tool for removing pins in AMP connectors 846059 AMP hand crimping...

Page 120: ...ermo Hunter PT3LF 800119 Multi loop calibrator Jofra MLC 800120 Charger for Jofra MLC 847010 Pressure sensor tester 3V84H0038 848030 Tachometer 848031 Temperature transducer control equipment 848033 C...

Page 121: ...ar not Com mon Rail Electro pneumatic tripping speed Std engines Nominal speed WECS or Plant automation Relay Module 720 RPM 750 RPM 820 10 RPM 860 10 RPM 840 10 RPM 880 10 RPM Tripping speed Common R...

Page 122: ...inder liner diameter top 320 80 bottom 320 30 Cylinder liner outofcylindricity atTDC 0 25 11 Big end bearing clearance 0 210 0 307 Crank pin out of circularity 0 05 Crank pin taper 0 035 100 Big end b...

Page 123: ...ameter clearance 0 072 0 161 Bush diameter bore 40 09 Bearing clearance bush tappet pin before 08 1999 after 08 1999 0 034 0 066 0 059 0 091 Rocker arm bore 75 35 Clearance rocker arm shaft 0 01 0 075...

Page 124: ...1 0 10 0 02 0 17 Axial clerance L32 V32 0 07 0 15 0 10 0 30 Backlash for pump gears L 32 V32 0 10 0 30 0 15 0 40 18A Control oil pressure on Common Rail engines 200 2 5 bar Backlash for control oil pu...

Page 125: ...wn in the tables A loosen screw connection might cause serious damages human injury Threads and contact faces of nuts and screw heads should be oiled with lubricating oil unless otherwise stated Note...

Page 126: ...n crankshaft M20 120 12 9 screws M2 Torque wrench setting M1 with tool combination see Fig below Lubricate threads with engine lubricating oil 600 30 532 5 Flywheel mounting bolts M20 390 20 Note Torq...

Page 127: ...ear wheel screws 117 10 4 Intermediate gear wheel screws Hydraulically tensioned screw see section 07 3 560 30 5 Flange fastening screws 80 5 6 Camshaft flange connection nuts 290 10 Note See section...

Page 128: ...B Governor drive Pos Screw connection Torque Nm 1 Governor drive shaft screw 80 5 1 Fig 07 4 4007149913 07 Tightening Torques and Use of Hydraulic Tools 32 200643 01 07 4 W RTSIL 32...

Page 129: ...ening screws cylinder head multiduct Note Tightening order Recheck the screws Apply Nova Lube or similar heat resistant grease on threads 195 10 7 Fastening screws for flange connections 79 5 8 Fasten...

Page 130: ...16 2 5 215 10 200 10 4 Flange fastening screws 19 3 30 5 5 Locking screws for injection pump adjusting screw 50 5 50 5 6 Fastening nuts for injection pump Lubricate threads and contact surfaces with...

Page 131: ...ew for control valve coil 11 1 4 Fastening screws for control valve 39 4 5 Spring holder fastening screw 9 1 6 Locking screw for roller pin Apply Loctite 2701 on threads see section 07 2 70 7 7 Fasten...

Page 132: ...on Torque Nm 1 Valve tappet housing fastening screw 200 10 2 Guide plate fastening screw Apply Loctite 242 on threads see section 07 2 23 5 1 2 Fig 07 8 4007139837 07 Tightening Torques and Use of Hyd...

Page 133: ...nozzle cap nut Woodward 678 40 Fuel injection pipe of Friction ring type Pos Screw connection Torque Nm 1 Injection pipe cap nut to injection pump 265 10 2 Injection pipe cap nut to connection piece 1...

Page 134: ...Injection nozzle cap nut 600 20 6 Screw for high pressure water connection Lubricate with Molykote G Rapid Plus 100 10 7 Screw for leakage water connection Lubricate with Molykote G Rapid Plus 35 5 8...

Page 135: ...Injection pipe cap nut to connection piece Apply engine oil on threads and seat cones 210 20 3 Connection piece to nozzle holder 160 10 4 Screws for protecting sleeve 80 5 5 Injection nozzle cap nut...

Page 136: ...Fastening nut 80 5 3 Limiter screw for shut off stem 5 1 4 Fastening screw for plug 7 1 Flow fuse 7 Pos Screw connection Torque Nm 1 Fastening nut 25 2 2 Nut 34 2 1 2 3 4 2 1 FLOW FUSE 5 FLOW FUSE 7...

Page 137: ...ce X Pipe end Power Sleeve PS Apply Loctite 2701 on threads 6 4 0 5 0 C Distance X Pipe end Power Sleeve PS Apply Loctite 2701 on threads 7 8 0 5 0 D Distance X Pipe end Power Sleeve PS Apply Loctite...

Page 138: ...tening screws for SSV valve 110 10 4 Fastening screws for head piece 520 20 5 Reducing plug Apply Loctite 542on threads 1 0 1 6 Air bottle top piece 350 20 7 Air bottle 350 20 8 Fastening screws for l...

Page 139: ...s 169 5 mm 155 Nm 40 Nm 80 5 Piston type 2 Pos Screw connection Torque Nm 2 Piston crown connection screws 1 Lubricate threads and contact surfaces with engine oil 2 Tighten the screws 3 Loosen the sc...

Page 140: ...ws 1 and 3 further with an angle of 7 Loosen screws 2 and 4 8 Tighten screws 2 and 4 9 Tighten screws 2 and 4 further with an angle of 10 Test for the right tightness Screw should not move when tighte...

Page 141: ...ng screw TPL61 TPL65 M20 NA295 NA297 M20 NA355 M24 TPL69 M24 NA357 M24 560 20 560 30 650 30 920 40 920 40 2 Fastening screws for turbo charger bracket L32 M16 V32 M24 195 10 650 30 1 2 Fig 07 17 40071...

Page 142: ...Replace the screws with new treated ones Only Driloc 201 or Driloc 211 should be used 32 2 75 5 150 5 32 2 50 2 2 Impeller screw for HT and LT water pump Pump type WD 90 91 120 Pump type WD 121 Apply...

Page 143: ...g gear Tighten the screws crosswise The screws are treated with locking compound and can be used only once Replace the screws with new treated ones Only Driloc 201 or Driloc 211 should be used 35 2 1...

Page 144: ...ed with lubricating oil or treated with Loctite Screw dimension 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 1...

Page 145: ...for HT water Pos Screw connection Torque Nm 1 Temperature sensor pocket 40 5 2 Temperature sensor pocket 1 2 1 2 Fig 07 21 400745 32 200643 01 Tightening Torques and Use of Hydraulic Tools 07 W RTSIL...

Page 146: ...ond step 250 615 635 3V86B78 4 Connecting rod screws Upper and lower con M27 in two steps First step Second step 400 800 820 2V86B478 5 Counterweight screws M42 in two steps V32 First step Second step...

Page 147: ...eriskofinjurytopersonsanddamagetomaterialduring work on the engine and in the workshop Hydraulic tool lifetime Tool Load cycles approx Piston in cylindrical hydraulic tools see Fig 07 24 1 000 Screws...

Page 148: ...urn valves cylinders and a pressure gauge mounted on thehandpumpbutnotconnectedtothepressuresideofthepump The components are coupled in series with the pressure gauge being the last component thus sec...

Page 149: ...quick coupling the coupling being disconnected from the pressure gauge Keep on pumping until air free oil emerges from the coupling Check the pressure gauge of the hydraulic tool set regularly For th...

Page 150: ...ders in counter clockwise direction about half a revolution 180 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 S...

Page 151: ...ble without breaking the pin Keep the pressure constant at the stated value 5 Open the release valve and remove the hydraulic tool set To ensure that the nut will be properly tightened the pressure ca...

Page 152: ...The piston is prevented from running out of the cylinder by an expansion ring 2 The strength of this ring is limited and it is recommended to be careful when operating at the end of the stroke The ef...

Page 153: ...the engine lubricating system sump must be used in this pump because the drain oil from the tools is led to the sump of the engine 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 2...

Page 154: ...07 Tightening Torques and Use of Hydraulic Tools 32 200643 01 07 30 W RTSIL 32...

Page 155: ...t position 23 c Load limit of control shaft or of governor is set at too low a value Fig 22 1 d Starting fuel limiter wrongly adjusted 23 e Some part of fuel control mechanism jamming and prevents fue...

Page 156: ...Too large valve clearances 06 1 12 2 4 e One or more cylinders badly overloaded 3b c f Injection pump or valve tappet guide block loose 16 3 14 1 3 3 07 1 g Initial phase of piston seizure h Insuffic...

Page 157: ...e or pipe fittings 16 3 d When idling see point 3g 03 4 1 11 Exhaust gas temperatures very unequal a See points 9a c e b Too low fuel feed pressure too small flow through injection pumps see points 2h...

Page 158: ...Automatic stop device has tripped 23 2 3 c Faulty governor or governor drive 22 d Faulty power supply to automation system 23 20 Engine does not stop although stop lever is set in stop position or re...

Page 159: ...continuous surging 08 2 2 Operation with defective turbocharger s A defective turbocharger is to be treated in accordance with the service instructions given in the turbocharger instruction book bloc...

Page 160: ...ow emergency operation 1 Remove the piston and the connecting rod 2 Cover lubricating oil bore in crank pin with a suitable hose clip and secure 3 Fit completely assembled cylinder head but omit valve...

Page 161: ...The vibration conditions are in practice dependent on the type of the installation As a general advice when there are cylinders out of order Reduce load as much as possible Keep the speed in a favoura...

Page 162: ...08 Operating Troubles Emergency Operation 32 200402 01 08 8 W RTSIL 32...

Page 163: ...pending on installation the specific installation data can also be found from separate binder Attachments 09 2 General Power installations All test reports and certificates are collected in series 8 Q...

Page 164: ...Specific Installation Data 2005 01 09 2...

Page 165: ...crankcase covers are equipped with safety valves which relieve the over pressure in case of a crankcase explosion The crankcase is furthermore provided with a vent pipe This pipe should be conducted...

Page 166: ...s 11 Remove the nuts of the main bearing screws 12 Connect the hoses of the hydraulic pump 800059 and to the side marked DOWN on the hydraulic jack see Fig 10 2 Connect the return hose to the side mar...

Page 167: ...hydraulic pressure and the nut turned with pin to contact 1 Tighten simultaneously with 250 bar hydraulic pressure Tighten one or two nuts simultaneously on the same side first step with 250 bar hydra...

Page 168: ...ng must be replaced Never re install a bearing with the nickel barrier exposed in any part of the bearing shell b Bi metal bearings Wear is settled by measuring the thick ness of the lower bearing she...

Page 169: ...end faces of the upper bearing shell with clean lubricating oil The bearing shell can be completely destroyed deformed during the assembly if it is not lubricated carefully 4 Place the end of the bear...

Page 170: ...ol 800051 16 Apply the sleeve and hydraulic cylinder onto main bearing screw B2 by the same procedure 17 Tighten the nuts of the main bearing screws as de scribed in adjacent figure Both screws must b...

Page 171: ...figure Both nuts should be loosened at the same time 9 Remove the hydraulic tools 10 Remove the nuts of the flywheel thrust bearing screws 11 Connect the hoses to the hydraulic pump 800059 and to the...

Page 172: ...t bearing 10 4 2 Assembling of flywheel thrust bearing 1 Clean the bearing shells washers cap and journal very carefully 2 Remove the protecting tape from the main bearing journal oil holes and lubric...

Page 173: ...pling male part to the free end of the hose and place it in the crankcase 11 Lift the main bearing cap by pumping oil to the hydrau lic jack with the hydraulic pump Mount the main bearing nuts by hand...

Page 174: ...s hone the cylinder liner when new piston rings are mounted Normally a light honing is sufficient If the honing is done when the cylinder liner is on its place in the engine block the crankshaft under...

Page 175: ...ng water and remove the cylinder head and piston with connecting rod upper part See sections 12 2 1 and 11 3 2 2 Remove the protecting cover and assemble the lifting tool 800007 see Fig 10 4 3 Unscrew...

Page 176: ...t completely yet to ease the mounting of the temperature sen sors 7 Mount the screw 5 and loosen the water jacket fixing screws only in alternative design 8 Lift the cylinder liner with water jacket 1...

Page 177: ...liner 800123 Fastening tool for cylinder liner 1 Water jacket 2 O ring 3 O ring 4 O ring 5 Screw only in alternative design Distinct mark 800007 800123 1 2 5 3 4 Fig 10 4 4010059601 32 200150 Engine B...

Page 178: ...10 Engine Block with Bearings Oil Sump and Cylinder Liner 32 200150 10 14 W RTSIL 32 34SG...

Page 179: ...be turned by a electrical turning device operating the flywheel Separate instructions for the vibration damper are submitted if the engine is equipped with such 11 2 2 Crankshaft alignment The cranksh...

Page 180: ...crankshaft alignment 7 Turning the crank and read deflections in the marked positions according to Fig 11 1 Starting point for clockwise rotating engine is measuring point A and counter clockwise rot...

Page 181: ...gative max 0 12 mm 0 13 mm if flex coupling d when the last crank pin in the free end is at TDC in case of PTO with support bearing should the reading be positive max 0 13 mm Before re aligning the en...

Page 182: ...g oil for cooling of the crown by means of the cocktail shakereffect The lubricating oil is led from the main bearing through the drilling s in the crankshaft to thebigendbearing andfurtherthroughthed...

Page 183: ...rews by raising the pressure to the value stated in the section 07 3 and proceed with opening the nuts Piston and connecting rod assembly Hydraulic oil DISMANTLING 1 Lift the distance sleeve 2 Lift th...

Page 184: ...connecting rod 17 Repeat the steps above in the other connecting rod on the same crank pin on an V engine 11 3 3 Changing of big end bearings 1 Remove both crankcase covers adjacent to the con nectin...

Page 185: ...lute or and the limiter is are mounted in the crankcase observe extremely cautiousness when using the turning device 12 Rotate the crankshaft towards the operating side to the position 55 from TDC by...

Page 186: ...and tighten the nuts 19 Mount the supporting plate 800099 on the rear side of the engine on the lower crank case cover studs and tighten the nuts see Fig 11 5 20 Remove the nuts 21 Mount the sledge 80...

Page 187: ...e In low temperatures the gudgeon pin may stick but will be easily removed after heating the piston to about 30 C 3 If the rings and grooves require cleaning measuring etc remove the piston rings by u...

Page 188: ...rpose a ball anvil micrometer should be used For bimetal type bearing the wear limits given in chapter 06 2 must be applied When replacing a big end bearing both the upper and the lower bearing shell...

Page 189: ...by using the turning device manu ally until the big end halves can be placed on the crank pin 5 Mount the mounting flute through the crank case open ings on the crankcase cover lower studs and tighten...

Page 190: ...the nuts 15 Mount the mounting support 800102 on the upper crank case stud see Fig 11 5 Tighten the nut 16 Remove the mounting flute and supporting plate by opening nuts 17 Lift the hydraulic tools 80...

Page 191: ...the cylinder liner 27 Lower the piston connecting rod upper part carefully into the cylinder liner 28 Turn the lower part 5 of the connecting rod straight up wards Mount the shim 2 29 Rotate the crank...

Page 192: ...33 Mount the anti polishing ring Note Check that the connecting rod is movable axially after tight ening 11 Crank Mechanism Crankshaft Connecting Rod Piston 32 200020 11 14 W RTSIL 32...

Page 193: ...DF 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 these p...

Page 194: ...e 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 comprising all su...

Page 195: ...rack 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 the gudgeon pin bor...

Page 196: ...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 to...

Page 197: ...the design of large channels for combustion air and exhaust gases In a heavy fuel engine the correct material tem peratures are a crucial factor to ensure long lifetime of the components being in con...

Page 198: ...to the multiduct Any possible air or gas in the cooling water is vented from the top of the multiduct The valvemechanism islubricated from the lube oil system The oil is led through a pipe from the v...

Page 199: ...cylinder head includes a thorough visual check including water cooling spaces Possible scale for mation in cooling spaces can disturb the cooling effect and there fore it has to be cleaned see chapter...

Page 200: ...sion is deeper than 0 1mm then change the screw Note Corrosion depth in threads can be hard to determine therefor it is recommended to change the screws whenever in doubt 1 Lubricate the threads of th...

Page 201: ...tening in two steps is recommended see section 07 3 9 Mount the injection pipe according to section 16 2 10 Connect the connector of the temperature sensor and lock it with the screw 11 Fit the rocker...

Page 202: ...ter clockwise to the middle position between a and b i e c and lock the counter nut of the adjusting screw 5 Put a feeler gauge corresponding to the valve clearance between the surface of the yoke and...

Page 203: ...ocated at the top of the guide bore The valves are provided with one valve spring per valve and valve rotating devices or valve spring retainers Valve seat rings are fitted in the cylinder head for bo...

Page 204: ...oning of inlet valve and valve seat ring is recommended to be done by grinding or by machining If there is only slight pitting lapping is adequate Valve and seat ring grinding see section 12 3 5 4 Rec...

Page 205: ...alve from the seat at intervals while lapping 4 Remove the smallest possible amount of material because the sealing faces have hardened during operation and are valuable It is not necessary to grind o...

Page 206: ...seat and weld it to the seat by means of electric beam welding Preferably the valve disc should be machined to a diameter 95 100 mm to get a better welding 2 Press or knock out the ring but be careful...

Page 207: ...ter soap solution option Molyk ote 55 O ring grease before mounting Note The soap used in water soap solution should have a pH 7 and a mixture ratio 1 2 The new model has only one O ring and it has to...

Page 208: ...he exhaust valve seat by using one of following methods Put the seat rings into a guiding bush and press in the seat with a guided arbor A special tool 800148 is also available This tool can be ordere...

Page 209: ...inder head upper bore see Fig 12 8 7 Mount the O ring 8 Mount the exhaust valve seat by using one of following methods Put the seat rings into a guiding bush and press in the seat with a guided arbor...

Page 210: ...n the valves and check for free movement 5 Put on the springs and rotators Replace the valve rota tors if they are worn or damaged 6 Compress the springs with the tool set 7 Put in the valve cotters a...

Page 211: ...topping the engine the indicator valves should be opened only half a turn Then the tightening caused by a temperature decrease cannot have an effect 3 When opening the indicator valve for measuring th...

Page 212: ...to be measured as a mean value of at least 32 cycles It is recommended to measure the Pf by using Kistler Engine tester type 2507A or 2515A 848033 and sensor type 7613B or 7613C Operation and adjustme...

Page 213: ...n and other necessary components See section 12 2 2 Remove the spark plug mount the distance sleeve 3V84H85 848052 with seal ring and tighten to the stated torque 3 Connect the pressure gauge and valv...

Page 214: ...valve clearance is zero that would also cause an direct pressure drop Carbon particles trapped between the valve and the seat when the engine is stopped could also prevent the valve to close properly...

Page 215: ...pressure drop can be observed The reason for this is because the running in of piston rings is not yet performed Note Keep pre lubricating pump running during test Note The turning gear should be eng...

Page 216: ...Appendix A Testing of cylinder tightness 32 200142 A 4 W rtsil 20 32 34...

Page 217: ...wheel 1 is fixed between camshaft extension piece 2 and extension piece 8 by axial screws 11 For the speed governor drive a helical gear wheel 13 is located at the end of the camshaft Lube oil nozzle...

Page 218: ...learances see section06 2 An early detection of any tooth damage can prevent serious damage 13 2 2 Basic adjustment of valve timing The basic adjustment of the valve and injection timing is done by ch...

Page 219: ...inder Turn the crankshaft as much as necessary to obtain the stated value see section 07 3 The bigger intermediate gear wheel should then rotate while the smaller intermediate gear wheel should stand...

Page 220: ...f all cylinders see section 14 1 3 1 Gear wheel for camshaft 2 Extension piece 3 Bigger intermediate gear wheel 4 Bearing bush 5 Smaller intermediate gear wheel 6 Gear wheel for crankshaft 7 Crankshaf...

Page 221: ...ved Do not damage the camshaft piece or engine block 15 Remove the camshaft gear wheel 1 16 Remove the extension piece 2 17 Unscrew the cover fastening screws 18 Remove in termediate gear wheel cover...

Page 222: ...r 33 Remove also the O rings 29 and 30 Note Before removing the screws 31 and cover 33 ensure that the gear wheels 3 and 5 are supported with suitable method Othewise great risk damaging the gear whee...

Page 223: ...on 13 2 2 13 Mount the oil pipe and the sleeve inside the engine block Replace the O rings with a new ones and tighten the screws 14 Mount the thrust bearing 10 and governor drive gear 13 Tighten the...

Page 224: ...gear wheel 1 Clean the parting surfaces of the wheel halves and the contact faces of the gear wheel and the crankshaft 2 Lower the bearing cap for main bearing No 1 see chapter 10 section 10 3 1 3 Lub...

Page 225: ...and use a dial indicator to get an indication for the diameters The maximum permissible difference between the measured values is 0 05 mm 10 Lift the bearing cap for main bearing No 1 see chapter 10 s...

Page 226: ...13 Camshaft Driving Gear 32 200546 02 13 10 W RTSIL 32...

Page 227: ...r arm bearing bracket 5 yokes 4 guided by a yoke pin 15 at the cylinder head Valve mechanism SECTION A A A A 1 2 3 4 5 6 7 8 12 9 11 13 10 14 1 Screw 2 Rocker arm 3 Retainer ring 4 Valve yoke 5 Rocker...

Page 228: ...ker arm is in position to supply oil only when it is in the open valve position When the rocker arm is in valve closed position is the surface between rocker arm and shaft lubricated Oil which is pass...

Page 229: ...d inspect all parts of the valve tappet When cleaning pay special attention to the oil holes 3 Measure the valve tappet boring and the tappet 9 as well as the tappet roller 18 for wear 4 Change the O...

Page 230: ...nder camshaft pieces 5 and separate bearing journals 3 The camshaft pieces have inte grated cams The camshaft is driven by the crankshaft through a camshaft drive consisting of gear wheels at the driv...

Page 231: ...and governor drive housing Push the other parts of the camshaft towards flywheel end as much as possible 6 Remove the camshaft piece by means of the tool Camshaft 14 2 3 Mounting of camshaft piece 1...

Page 232: ...Forvisualinspec tion of the camshaft bearing bush has the camshaft piece and bearing journal to be removed according to section 14 2 2 14 3 2 Removing of camshaft bearing bush 1 Remove the camshaft pi...

Page 233: ...ulic pump 800053 to the hydraulic tool 5 Pump pressure to the hydraulic tool to mount the bear ing bush The pressure must not exceed the value stated in chapter 07 Fig 07 14 6 Open the pump valve for...

Page 234: ...V83H165 3V83H166 3V83G45 3V83E61 3V83H164 Bearing 3V83H61 Hydraulic cylinder 3V83H164 Guide sleeve 3V83H165 Distance piece 3V83H166 Pressure plate 4V83G45 Screw Fig 14 4 4014049601 14 Valve Mechanism...

Page 235: ...etal bellows 1 The exhaust pipes from the cylinders are also connected to the charger with metal bellows The exhaust pipe after the turbocharger should be arranged according to the installation instru...

Page 236: ...m the compressor side of the turbo charger without removing the whole unit from the engine Note When reassembling use new seals Maintenance of the turbocharger is carried out according to section 15 3...

Page 237: ...pose the rotor cartridge and the nozzle ring have to be removed from the turbocharger When washing with water the water must be injected into the exhaust system with the engine running at reduced outp...

Page 238: ...r in marine main engine installations reduce the speed to between 400 and 600 RPM Run the engine for ten minutes on this load before the washing is started Note Observe the above mentioned limits for...

Page 239: ...ing the step 6 above and continue with step 8 8 After termination of water injection the engine must run for at least five minutes before the load is increased 9 Close all valves and disconnect the ho...

Page 240: ...ected while the engine is running and 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 at least 75 load Cl...

Page 241: ...the change in charge air pressure and in the exhaust gas temperature 9 Run the engine for 5 minutes more after the compressor has been cleaned with water Doing so it is ensured that all the parts in t...

Page 242: ...entioned instruction W rtsil strongly recommends both turbochargers on a V en gine should be blanked also at above mentioned emergency cases In case only the other turbocharger in a V engine is blanke...

Page 243: ...flange 7 with O rings and tighten screws Note The oil flow to and from the damaged turbocharger must be blocked in the turbocharger bracket by using suitable plugs flanges 10 Mount the blanking cover...

Page 244: ...he cooler may be leaky and must be dismantled and pressure tested 2 At longer stops the cooler should be either completely filled or completely empty as a half filled cooler increases the risk of corr...

Page 245: ...ide 8 Remove the nuts 14 and 15 of the air inlet boxes 16 and 17 after making proper arrangement to support the boxes 9 Mount eye bolts with straps on the top of the air inlet boxes 16 and 17 Prepare...

Page 246: ...15 7 14 Remove the air cooler fastening screws 18 and 30 top screws 18 last see Fig 15 6 Note Take care that the load of the cooler is carried by the lifting tool 30 Screw 18 Screw 23 Screw 24 Stud 25...

Page 247: ...de the air cooler to the floor Place e g 2 pieces of I bars under the cooler Air cooler assembly A A Section A A 33 O ring 34 Distance sleeve 35 Screw 35 34 33 Fig 15 7 4015260408 25 End cover 26 Air...

Page 248: ...ct is achived if the cleaning tank is equipped with perforated pipes see Fig 15 9 During cleaning steam or pressurized air is fed through the pipes When cleaning is com pleted the cooler should be flu...

Page 249: ...HT HT circuit Valve 1 open valve 2 closed 1 5 bar LT LT circuit Valve 3 open valve 2 closed 1 5 bar LT and HT HT circuit Valve 1 and 2 open valve 3 closed 8 0 bar 2 stages air cooler L engine Circuit...

Page 250: ...T out HT circuit 2V84H0151 2 stage cooler V engines 3V84H0157 2 stage cooler V engines 3V84H0190 2 stage cooler L engines 1V84H0180 1V84H0187 1 stage cooler 3V84H0159 3V84H0186 3V84H0144 Pressure in t...

Page 251: ...e no obstacles for the mounting before applying the glue compound 4 Lower the cooler assembly 5 Apply glue compound e g Easy Work RTV 345 on all metallic surfaces bellows surfaces 6 Apply approved sea...

Page 252: ...s is very important for keeping fuel consumption and operating costs down An increasing pressure drop Dp over the charge air cooler on the air side causes an increasing thermal load and increasing fue...

Page 253: ...U tube manometer Fig 15 12 401508200050 32 200549 10 Turbocharging and Air Cooling 15 W RTSIL 32 15 19...

Page 254: ...15 Turbocharging and Air Cooling 32 200549 10 15 20 W RTSIL 32...

Page 255: ...gine Fuel return channel from each injection pump Lubricating oil supply to the valve mechanism The arrangement with the multihousing represents the ultimate in safe fuel system It also gives a compac...

Page 256: ...hange the helix position where the ports are closed on the up stroke and hence increasing or reducing the effective stroke The fuel rack is connected to the regulating mechanism of the gover nor If th...

Page 257: ...of the cam 4 Remove necessary pipes injection pipe fuel leak pipes and lube oil pipe Disconnect the fuel rack 5 Open the fuel pipe connections between the injection pump concerned Open hexagon socket...

Page 258: ...re Tighten the screws to the stated torque accord ing to chapter 07 5 Mount the lubricating oil pipes B2 B1 Alternative Design 1 2 3 5 6 7 8 9 10 12 13 14 15 16 17 19 18 19 20 21 22 23 24 Z 11 26 27 2...

Page 259: ...ned Move the fuel line connecting sleeves on the adja cent fuel pipes by using the tool 800039 11 Mount the locking plates and tighten screws 12 Tighten the nuts 31 to the stated torque according to c...

Page 260: ...face of the tappet housing see Fig 16 2 4 Open the locking screws 23 and adjust the distance X to the correct value see section 06 2 by turning the screw 24 5 Tighten the screws 23 to the torque given...

Page 261: ...6 8 Turn the pump and open the screws 1 and 2 in cross wise steps of 30 9 Remove the head piece 3 and remove the fuel delivery valve 28 with spring and pressure relief valve 30 with spring 10 Remove t...

Page 262: ...ne of plunger vanes The marked plunger vane must slide into the fuel rack side of the control sleeve i e correspond to the marks on the fuel rack and the cham feredtoothofcontrolsleeve 20 Press the pu...

Page 263: ...ust be locked 16 2 6 Cleaning of fuel injection pump Small fuel leakages through the injection pump may in some cases block the fuel drain line and or prevent free movement of the fuel rack W rtsil ha...

Page 264: ...tres of clean light fuel oil through the injec tion pump while moving the fuel rack back and forth 9 Close the air supply to the washing device 6 10 Remove the hose 3 and adapter 2 and mount the plug...

Page 265: ...e mounting the injec tion pipe also in case only the injection pipe has been removed because there is a risk of the connection piece coming loose when removing the pipe The injection pipe is covered b...

Page 266: ...2 Removing of injection valve 1 Open the cylinder head and hot box covers 2 Remove the injection pipe 1 see Fig 16 4 3 Unscrew the connection piece 2 and loosen the pro tecting sleeve 4 if necessary...

Page 267: ...holder by turning the cap nut 14 using tool 800037 until it is loosened Keep the nozzle together with the holder body don t let it follow up with the nut If there is coke between the nozzle and the nu...

Page 268: ...n systems Seat surfaces sliding surfaces needle shaft and sealing faces against the nozzle holder should be carefully checked 7 Clean the nozzle holder and the cap nut carefully if ne cessary dismantl...

Page 269: ...elow the stated opening pressure keep pressure constant for 10 seconds and check that no fuel drops occur on the nozzle tip A slight dampness may be acceptable 15 Check the needle guide tightness incr...

Page 270: ...on the test pump can give good performance on an engine Fot tests of the nozzle function with fully amount of fuel injected a special booster unit is developed and can be ordered as an optional tool...

Page 271: ...rews loosened i e to adjust the valves first just before putting them in the engine s 4 When pumping with the hand test pump device the pres sure increases inside the chamber 2 At the certain point th...

Page 272: ...ricating oil or grease 3 Fit the injection valve into the cylinder head bore and tighten the nuts by hand Note the guiding pin position 4 Put new O rings on the connection piece and on the protecting...

Page 273: ...in a cylinder attached to the multihousing The piston forces the fuel rack to a nofuel position Theforceoftheoverspeedtripdeviceisstronger than the torsion spring in the regulating mechanism For main...

Page 274: ...16 Injection System 32 200627 01 16 20 W RTSIL 32...

Page 275: ...ment lifetime and thus on the engine performance 17 1 1 Functional description The fuel is pressurized by the pump 13 and filtered by the filter 6 seeFig 17 1 The pressure controlvalve 15 maintainscor...

Page 276: ...ng pump 14 Safety valve 5 Temperature sensor P1 Fuel feed pressure P2 Safety valve adjustment P3 Circulation pressure P4 Safety valve adjustment P5 Fuel feed pressure 6 Fuel filter 15 Pressure regulat...

Page 277: ...e leakage Always vent the filter s when cartridges or filter candles have been renewed 17 4 Adjustments of fuel feed system A long lasting and safe functionality of the diesel engine demands an approp...

Page 278: ...t the pressure regulat ing valve 15 2 Close the valves 16 and adjust the pressure P4 on the safety valve 14 located on the pump Note The purpose of this safety valve is only to protect the pump Open t...

Page 279: ...tarted and stopped on HFO and Crude Oil The preheating systems for the engine and the fuel feed system should always be switched on also during engine stop However if the engine for some reason is sta...

Page 280: ...Fuel System 32 200508 07 17 6 W RTSIL 32...

Page 281: ...utomatic filter 7 to the main distributing pipe in the oil sump through the hydraulic jacks in this respect acting ordinary pipes to the main bearings and through bores in the connecting rods to the g...

Page 282: ...valve 4 on the pump The pressure can be adjusted by means of a set screw Fig 18 2 pos 5 on the control valve It is very important to keep the correct pressure in order to provide efficient lubricatio...

Page 283: ...valsdeterminedbyexperiencefrom the installation concerned see chapter 04 and 02 section 02 2 3 While the oil is still warm drain the oil system as well as the oil cooler and filter Clean the crankcase...

Page 284: ...nd lubricat ing oil pump 4 Remove prelubricating oil pump unit 5 Mount lifting eye bolts to the lubricating oil pump unit 6 Remove lubricating oil pump unit Note Before removing the unit leave a coupl...

Page 285: ...6 section 06 2 and replace worn parts 2 Remove worn bearings from the sleeves and the housing by driving them out with a suitable mandrel 3 Mount new bearings freezing is recommended so that the beari...

Page 286: ...ear wheel 1 has been changed check the back lash after mounting 18 3 6 Mounting 1 Clean all sealing surfaces carefully and replace the O rings with new ones 2 Mount the lubricating oil pump unit 3 Mou...

Page 287: ...arranged to give a pressure depending on the speed according to operating pressures recommended at various speeds chapter 01 If for some reason the pressure should increase strongly in the pressure p...

Page 288: ...mod ule from the engine and then the lube oil cooler to clean more carefully 3 Always when cleaning check for corrosion and test by hydraulic pressure It is preferable to change the tube stack too ea...

Page 289: ...marks mentioned above 3 Mount the O rings on the free tube sheet LT side Lube oil cooler 4 Move the tube stack towards the lube oil thermostatic valve side as far as needed to expose the O ring groov...

Page 290: ...s e g thrichlorethylene These products should be handled with care as they are often extremely volatile toxic and or narcotic Solvent emulsions Heavy fouling e g oil coke can often be dissolved only b...

Page 291: ...ow through the cooler Thermostatic valve for oil system 18 6 2 Maintenance Normally no service is required Too low an oil temperature depends on a defective thermostat too high a temperature may depen...

Page 292: ...s through the inlet flange and turbine 9 to the right end of the filter candles 13 a partial stream of about 50 is passed through the central connection tube 12 to the left end of the filter candles T...

Page 293: ...leaned the overflow valves 3 are opened at a differential pressure of 2 bar upwards and the oil is only filtered through the protective filter 2 second filter stage However before this situation arise...

Page 294: ...ul and when opened 18 7 2 1 Filter candle inspection and cleaning 1 Drain the filter open the plug 16 then open the plug 14 thereafter discharge oil Do not refill the system with drained oil because i...

Page 295: ...assemble the filter in the reverse sequence to that described above 18 8 Centrifugal filter 18 8 1 Description Aby passfilterofthecentrifugaltypeisprovidedasacomplement to the automatic filter The fil...

Page 296: ...the filter 1 Shut off the filter by closing the valve 17 see Fig 18 7 Centrifugal filter 2 Slacken off filter cover clamp 6 and remove 3 Unscrew the cover nut 10 and lift off the filter body cover 9...

Page 297: ...O ring 12 for damage Renew if necessary 8 Clean and wash out the central stand tube ensuring that the strainer holes are not blocked 9 Reassemble the rotor complete and tighten the top nut 8 tighteni...

Page 298: ...be limited to the max value about 2 bar by unscrewing the adjusting screw to the end position in order to prevent the electric motor from being overloaded when running with very cold oil Note Be caref...

Page 299: ...ver the bearing bush for the driving gear wheel with a suitable mandrel and the other by machining 3 Mount new bearings freezing is recommended so that the bearings are two 2 mm below the cover and ho...

Page 300: ...egulating valve for prelubri cating oil pump 18 10 1 Description The pressure regulating valve see Fig 18 9 is integrated in the prelubricatingoilpumphousingandregulatestheoilpressurebefore the engine...

Page 301: ...ntral cooler The both circuits are provided with temperature control valves Cooling water system 1 2 12 9 5 6 7 10 11 13 3 8 4 1 Lube oil cooler 2 LT thermostat valve 3 Central cooler 4 Water pump 5 P...

Page 302: ...ting pipe from the multiducts are connected to a box 12 From this box the vent pipe leads to the expansion tank 11 from which the expansion pipe is connected to the inlet pipe of the pumps 7 and8 Asta...

Page 303: ...the cooling water Save the discharged water and use it again Remember to close the drain and open the cooling water connec tions before the engine is started again 19 2 2 Cleaning In completely closed...

Page 304: ...mentioned in the end of chapter 02 See the list of approved cooling water additives and treatment systems The cleaning agents should contain additives inhibitors to prevent corrosion of the metal surf...

Page 305: ...plete pump from the engine Check the pump at intervals according to the recommendations in chapter 04 or if water and oil leakage occurs immediately Check that the telltale hole is open every now and...

Page 306: ...ding to pos a above Do not forget the thin washer between the spring and the O ring c Replacing of bearings and shaft seal 1 Remove the pump from the engine 2 Disassemble the impeller and mechanical s...

Page 307: ...ble pipe Mounting of bearings 14 Fit the bearing retainer 11 and tighten the screws 15 Before re installing the gear wheel all contact surfaces should be cleaned and oiled 16 Re install the gear wheel...

Page 308: ...uit is provided also with a fixed thermostatic valve mounted inside the upper part of pump cover to maintain the HT outlet water temperature 19 4 2 LT thermostatic valve The LT thermostatic valve is i...

Page 309: ...3 see Fig 19 5 3 Remove the cover 11 by opening the screws 12 4 Remove the plug 1 and push the control piston 6 against the spring force until the retainer ring 2 can be removed 5 Remove the element h...

Page 310: ...defective element and renew O rings 10 Re assemble the valve in reverse order 19 4 2 2 Adjustment 1 Turn the adjusting screw 13 inclockwisedirectionuntilthe guiding pin 10 and thermostat element 8 co...

Page 311: ...flow through the pump and engine at all times with no pump restriction when the engine is cold No adjustments are ever required on the HT thermostaticvalve The temperature is permanently set at the fa...

Page 312: ...ed The high force available on heating is the basis of the fail safe feature in which failure of the element would cause the engine to run cold Water flow in HT thermostatic valve 19 4 4 Maintenance N...

Page 313: ...hermostatic element or in chapter 01 the lower value for the water tem perature is the opening temperature the higher for the fully open valve The set point marked on the element is the value when the...

Page 314: ...19 Cooling Water System 32 200050 19 14 W RTSIL 32...

Page 315: ...l flow of gases to the turbocharger withoutanydisturbinggaspulsestotheothercylindersconnected to the common pipe The multiduct between the cylinder head and the exhaust pipes acts as a bracket for the...

Page 316: ...ows 1 Remove necessary sheets on the insulation box 2 Remove the screws and remove the expansion bellows 3 Check that the exhaust pipe flanges are parallel and positioned on the same centre line to av...

Page 317: ...m When the main starting valve opens the starting air passes partly through the flame arrester 6 and the air block to the starting valves in the cylinder heads Partly it passes to the starting air dis...

Page 318: ...led through drillings to a small pilot valve with a pilot piston 22 This valve can be manually operated by the push button 21 or pneumatically operated by a solenoid valve for remote or automatic sta...

Page 319: ...ng air distributor 21 3 1 Description Fig 21 1 The starting air distributor is of the piston type with precision machined interchangeable liners 16 The liners as well as the pistons are of corrosion r...

Page 320: ...r fixation and sealing 8 Clean the bore carefully so that the new liner can be inserted by hand Otherwise there is a risk of deformation of the liner and sticking of the piston 9 Apply Loctite 242 on...

Page 321: ...l out the starting valve 3 Open the self locking nut 32 and remove the spring 37 and the spindle 34 4 Clean all parts 5 Check sealing faces of the valve and valve seat If nec essary lap the valve by h...

Page 322: ...e they should then be coated with a suitable anti corrosive agent Let them dry long enough At the same time inspect the valves of the starting air vessels Too strong tightening may result in damages o...

Page 323: ...vessel 45 using the draining plug 301 311 46 3 44 2 9 5 40 45 4 43 42 19 6 41 PT PT 301 311 Only if Wastegate arrangement 2 Non return valve 3 Drain valve 4 Main starting valve 5 Starting valve 9 Blo...

Page 324: ...the button 1 see Fig 21 5 Should there be a mechanical malfunc tion open the valve using a special tool Check that the bores 2 and 3 in the seat are open and the gasket 4 is intact Change the valve if...

Page 325: ...e will not be damaged even though there should be some kind of a fluid in a cylinder The system see Fig 21 6 is built on the engine and consists of 301 311 46 3 44 47 2 9 5 40 45 4 43 42 19 6 41 49 21...

Page 326: ...is some kind of fluid in a cylinder the engine stops during these revolutions Otherwise both the slow turning valve 21 and the main starting valve 4 are automatically activated until the engine reach...

Page 327: ...gine can be stopped by means of the stop lever 16 When the stop lever is moved to stop position the lever 17 actuates the lever 9 forcing the regulating shaft to stop position The engine is provided w...

Page 328: ...3 Check and adjustment 22 3 1 Stop lever stop position a Check Set the terminal shaft lever 3 in the maximum fuel position and the stop lever 16 in the stop position Check that the fuel rack position...

Page 329: ...9 Lever 10 Control shaft 11 Load limiter 12 Lever for control shaft 13 Adjustable link rod 14 Adjusting screw 15 Fuel rack 16 Stop lever 4 Screw 17 Lever for stop lever 18 Dog A VIEW A B VIEW B C C S...

Page 330: ...cessary Apply a suitable grease and take care not to damage the seal ring when mounting the piston 2 a Check of stop position Set the stop lever in the work position and the terminal shaft lever in th...

Page 331: ...drillings in the bracket to the bearings and to a nozzle for lubricating the gears Check at recommended intervals radial and axial clearances of bearings gear clearance oil drillings and nozzle to be...

Page 332: ...ngth to fit between the levers 3 and 12 see Fig 22 3 Do not forget to secure the nuts 7 Check according to section 22 3 Governor shaft settings Governor shaft Governor shaft Control shaft Control shaf...

Page 333: ...shaft lever in the max fuel position Press the STOP button on the engine Stop sequence is activated approximately 1 min Note The starting air supply should be open Check that the fuel rack positions i...

Page 334: ...ntenance a Three way solenoid valve If the solenoid is out of order replace it by a new one If the valve does not move clean all channels Check the valve piston If air is leaking to the cylinders chan...

Page 335: ...iplexer Units SMU 2 depends on the cylinder configuration All sensors on the engine are connected to the DCU s and the SMU s while the signals to and from the external system are connected to the Main...

Page 336: ...display Data communication with external systems e g alarm and monitoring systems Control outputs for standby functions Emergency functions shutdown override blackout start 1 1 2 3 5 4 4 6 7 8 9 10 11...

Page 337: ...ping overspeed The idea is to limit the revolutions when the propelles is rising above sea level in rough sea The second engine speed pick up is connected to the Relay Mod ule whichislocatedintheWECSc...

Page 338: ...for the following conditions these are all configurable i e they may vary depending on the installation engine not preheated low HT water temp engine outlet low fuel oil pressure low starting air pres...

Page 339: ...evel is set slightly higher than the level in the WECS configuration and the function is latching 23 2 3 5 Load reduction IfloadreductionsetpointsaredefinedinWECStheyarespecified in the installation s...

Page 340: ...water temperature outlet a TE432A HT water temperature CAC outlet a TE471 LT water temperature CAC inlet a TE472 LT water temperature CAC outlet a TE482 LT water temperature LOC outlet a TE511 Exhaust...

Page 341: ...by actually running the engine at overspeed if that is possible Otherwise the testing has to be done by simulating the engine speed with a signal generator The overspeed trip should stop the engine wh...

Page 342: ...m the camshaft gear The rotation speed of the camshaft gearishalf ofthe engine rotationspeed The frequency corresponding to the overspeed can be easily calculated when the teeth number of the camshaft...

Page 343: ...pressure transducers with a shut off valve and a test pressure connection The pressure transducers is disconnected from the pressure measurement with the shut off valve The pressure calibration devic...

Page 344: ...emperature calibrator required oven All temperature sensors are fitted into special pockets and can thus be lifted off for checking also during operation 1 Unscrew the sensor 2 Put it in the calibrato...

Page 345: ...croswitch breaks The correct tem perature is stated in the engine specifications and printed on the switchitself Ifnecessarythe switchmustbeadjustedorreplaced Also check connection and wiring for dama...

Page 346: ...indiction Backup lubrication oil pressure indication Backup high temperature cooling water temperature indication The three backup instruments are independent from the rest of the system Local control...

Page 347: ...ions THE MAIN PAGE Displayofcriticalengineparametersandenginestatusinformation Critical engine parameters engine speed and load fuel rack position exhaust gas temperatures Engine status information en...

Page 348: ...pages The number of pages varies depending on the number of sensors in the WECS One status page shows values of logical sensor groups like for example main bearing temperatures Separate information p...

Page 349: ...ems F7 Fuel and lubricating oil systems Some status pages are divided into several pages When a page is divided an arrow is displayed in the upper right corner Use the UP and DOWN keys to scroll pages...

Page 350: ...lemented according to the recommendations in the external system connected to the MCU Depending on engine type and size the amount of sensors included for the WEnCoM functions may vary 23 4 1 1 Cylind...

Page 351: ...ve is monitored with a sensor measuring the exhaust gas temperature behind the exhaust gas valve see Fig 23 9 A burned spot on the valve disc will in time result in an increasing temperature fluctuati...

Page 352: ...tem for trend diagrams Exhaust gas valve 1 temperature Exhaust gas valve 2 temperature Exhaust gas temperature calculated average of valve 1 and 2 Exhaust gas temperature deviation from engine average...

Page 353: ...the Mother Board the Processor Board the DC DC Converter the Memory Unit the LAN Board and three Interface Boards MCU Frame ERROR FULL CHARGING AC ON STATUS B A CTS0 RTS0 RXD0 TXD0 GND CTS1 RTS1 RXD1...

Page 354: ...try Refer to Fig 23 11 when reading the following sections Layout of the Mother Board Caution Install the MCU boards to the slots which are dedicated to them If a board is in a wrong slot and power is...

Page 355: ...side of this supply is fully isolated from the MCU case and electronics and may thus be fed without any need of external isolation The output voltage level from the switcher is adjusted by the MCU sof...

Page 356: ...GING AC ON directly powered from the AC source RESET SHUTDOWN I C BUS ID EEPROM Control logic On Off control Isolated primary switcher Power On Off Step up switcher Step down switcher Inverting switch...

Page 357: ...the Processor Board RESET STATUS RESET DMC50 RESET STATUS RESET CTS0 RTS0 RXD0 TXD0 5 CTS1 RTS1 RXD1 TXD1 10 RD A SD A RD A SD A 15 RD B SD B RD B SD B 20 CASE DMC50 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Page 358: ...A and B have both a LED for indicating their activity The indicator is green or red depending on the type of activity The STATUS LED is also located on the front panel of the Memory Unit CARD B CARD A...

Page 359: ...53 54 55 41 42 43 44 45 B2 B5 B3 B4 A4 A5 B1 46 47 48 49 50 A1 A2 A3 GND TXD RXD TXD A B A TXD GND RXD TXD RXD B 31 32 33 34 35 1 2 3 4 ON OFF DML 50 Fig 23 17 080302X9516 PicoBus I C Bus DC DC RS 23...

Page 360: ...an 8 bit parallel open collector input output digital port In the WECS the Interface Board is mainly used for switch and relay connections See Figure Fig 23 19 for the construction of the Interface B...

Page 361: ...I O Analog I O Analog I O Analog I O PicoBus DMB50 VB 12 VDC Filter Filter Filter Filter Filter Control Electronics CPU Memories Controllers A DC etc Buffer and control Fig 23 20 030302C9525 32 200115...

Page 362: ...he host processor by a separate command The SMU also performs linearization of temperature sensors and error check ups The SMU is connected to the host processor through one serial line channel This c...

Page 363: ...ed operating voltages for itself from the 24 V level The switching power supply of SMU is isolated accepting input voltage ranging from 7 to 50 V DC The SMU Board floats from other electronics of the...

Page 364: ...to DCU Board Power Supply Driver Receiver Control Electronics CPU Memories Controllers A DC D AC etc RS 485 port Driver Receiver 8 bit digital I O 2 freq inputs 10 analog channels Fig 23 23 030304B95...

Page 365: ...Card type II slot for SRAM and FLASH memory cards The DCU Board convertsall the required operating voltages 5 V 12 V for itself from the floating 7 V level which is fed from theSMU sisolatedswitching...

Page 366: ...e DCU LED Color LED indication POWER green continuously ON while the unit is receiving its power CAN yellow blinks during CAN transmission STATUS green blinking indicates software operation FLASH yell...

Page 367: ...r is resin moulded into a tubular housing of nickel plated brass with external thread of M18 x 1 5 mm The cable is connected by means of a four pole Euchner BS4 connector To install the sensor turn th...

Page 368: ...s proportional to the rotation speed of the charger and connected to the WECS The metal housing of the sensor is M12 x 1 25 mm The cable is connected by means of a four pole Euchner BS4 connector To i...

Page 369: ...r Turbocharger type Measure A in Fig 23 28 Pulses Napier 155 200 mm 2 Napier 295 267 mm 2 Napier 355 367 mm 2 Napier 457 200 mm 6 Napier 557 200 mm 6 To install the sensor screw carefully the sensor c...

Page 370: ...is provided by the Relay Module Layout of the Relay Module Unlike the other units of the WECS the Relay Module has no processor or software Consequently the Relay Module is a totally hardware driven...

Page 371: ...block power supply block Trimmers The Relay Module includes six trimmers to set delays and set points Indication LED s The Relay Module has an indication LED for each functional block All supply volta...

Page 372: ...down reset button is being pressed Stop relay red Stop relay is active Local start blocking yellow Local start blocking signal from the external system is active Local start green Local normally local...

Page 373: ...pendent of the operating system VRX provides a simple high level interface for the programmer The applications are usually involved in producing and consuming data Data is collected processed and dis...

Page 374: ...MUNICATIONS COMMUNICATIONS EXTERNAL SMU MEAS ALARMS INTERNAL SMU MEAS ALARMS SMU DCU DML MCU DCU SMU SMU DMI DMC WENCOM SCALE CALC CALC CLI CLI LDU LDU can serial serial can SAFETY MSR HLR MSR HLR FAS...

Page 375: ...to paragraphs according to hardware Therefore it is easy to find instructions of the needed component or unit The controls and indicators of the system are not needed in normal operation It is recomme...

Page 376: ...DC DC Converter MCU internal voltages are turned off enabling removal or replacement of the MCU units 23 7 2 4 DC DC Converter DPS50 Board There are four LED indicators mounted on the front edge of th...

Page 377: ...charge current The battery voltage is floating at the temperature compensated level Compensation is done in software and it is based on the Processor Board temperature sensor unless otherwise configur...

Page 378: ...e to internal watchdog or when the recessed RESET control of the Processor Board is pressed During normal operations the RESET LED should be off ERROR FULL CHARGING AC ON STATUS B A CTS0 RTS0 RXD0 TXD...

Page 379: ...irst be established If the card is not applicable the LED alternates between red and green GREEN ON CONTINUOUSLY A normal reading writing op eration is being carried out RED FLASHING The PC Card is no...

Page 380: ...rol causes the DCU to stop program execution and commence self tests The RESET control is also used during the software loading procedures 58 F2 24 STATUS 46 12 38 CH1C 37 36 35 CH1E CH1H CH1L 39 CH3E...

Page 381: ...g indicates that the software is oper ating Flash LED The FLASH LED is continuously ON when the FLASH voltage is connected i e during software or configuration loading Reset LED The RESET LED is conti...

Page 382: ...hutdown i e it has been closed Local hardwired reset button has not yet been pressed MCU Stop Shutdown MCU stop signal is active and is causing a stop of an engine LUBE OIL SHUTDOWN LUBE OIL SHUTDOWN...

Page 383: ...LED WECS watchdog signal is missing Stop Shutdown Override LED Stop shutdown override signal from the external system is active Shutdown Reset LED Shutdown reset button is being pressed Stop Relay LED...

Page 384: ...Failure LED s The lube oil shutdown switch the optional shutdown switch and the energized stop solenoid have failure LED s because of their special character Lube Oil Shutdown Switch Failure LED Lube...

Page 385: ...not stop related functions of the RM is ON U2 LED U2 voltage MCU and test instruments is ON U3 LED U3 voltage DCU chain 1 is ON U4 LED U4 voltage DCU chain 2 is ON U5 LED U5 voltage LDU is ON Backup...

Page 386: ...intain the electrical connector contact surfaces with contact lubricant The contact treatment greases listed below can be ordered from W rtsil The recommended chemicals are Electrolube SGB20S 20 ml Sy...

Page 387: ...WECS 2000 has a blackout start input that can be activated by the external control system within 5 minutes of lost pre lubrica tionpressureorblackout After5minutestheblackoutstartinput is inhibited Th...

Page 388: ...gency stop can be suppressed by activating the shutdown over ride input to WECS Shutdown override can be enabled in any mode of operation it will in any case block or release the stop solenoids The st...

Page 389: ...can be deactivated by activating the shutdown override Note Shutdown solenoids will be reactivated if the shutdown over ride is deactivated and shutdown reset has not been given before that Shutdown...

Page 390: ...e the problem is to replace the broken module with a spare Relay Module If WECS problems are limited into one DCU or SMU it is also possible to turn off that DCU or SMU by disconnecting connector 31 3...

Page 391: ...f the shutdown solenoids are deactivated according to the instruction in this letter the speed governor will also be in RUN mode allowing engine starting and running Note It is not possible to interru...

Page 392: ...23 9 Error code Explanation 1000 Timeout before reply received 1001 Checksum error in the received message 1002 STX not found in the start frame or data length is zero 1003 Data field is too wide 100...

Page 393: ...isplay Frame Electroluminescent Display ELD Display Mother Board Display Mother Board CoreModule XT Display PC Board MiniModule VGA MM VGA Display Driver Board Distribution Unit DCU SMU DCU Distribute...

Page 394: ...23 Instrumentation and Automation 32 200115 II 23 60 W RTSIL 32...

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WÄRTSILÄ PAAE051728, Instruction Manual

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