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WÄRTSILÄ Vasa R22, Instruction Manual

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16.3.1 Removal of injection pump

It is recommended that the engine run a 5 minutes with light fuel
before it is stopped for overhaul of injection pump.

1 Shut fuel supply

to the engine before removing the injec-

tion pump.

2 Remove the fuel feed pipe elbows,

high pressure injec-

tion pipe and leak fuel pipe. Cover immediately all openings
with tape or plugs to prevent dirt from entering the system.

3 Remove the fastening screw (52)

for the cover (35) of the

fuel injection equipment.

4 Remove the pneumatic shutdown cylinder (53)

and the

pipe from the distributing pipe.

Injection pump

30

40

9

24

5

35

21

42

14

16

17

28

7

6

8

5. Delivery valve + spring
6. Discharge valve + spring
7. Element cylinder
8. Plunger
9. Screw
14. Control sleeve
16. Upper spring sleeve
17. Spring
21. Fixing screw
24. O-ring
28. Pressure plate
35. Head piece
42. Venting plug
52. Screw

0 5

862 007

53

52

53. Shutdown cylinder
54. Nut

54

52

A

VIEW A

Fig 16-1

2216519213

22-9601

Injection System

16

L’Orange

16-3

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Summary of Contents for Vasa R22

Page 1: ...al use of engine operators and should always be at their disposal The content of this manual shall neither be copied nor communicated to a third person W rtsil Finland Oy Document ID Installation Engi...

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

Page 3: ...e parts be careful to state engine type specification number and engine number This Manual is supplemented by the Spare Parts Catalogue including sectional drawings or exterior views of all components...

Page 4: ...Designation of bearings The designation of bearings begins from the driving end The thrust main bearing is No 1 If the engine is provided with an extra main bearing a so called shield bearing this is...

Page 5: ...not move if the crankshaft is turned When watching the camshaft and the injection pump it is possible to note that the pump tappet roller is on the lifting side of the fuel cam Flywheel graduation The...

Page 6: ...he cooling water for the engine block cylinder head and turbocharger Low temperature cooling water circuit LT circuit The cooling water for the charge air cooler and the lubricating oil cooler 00 Cont...

Page 7: ...x x x x x x x x x x x Turning 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...

Page 8: ...nto the compressor housing when the silencer is removed and engine running Unexpected movement of valve or fuel rack s due to broken wire or soft hardware failure in the control system Unexpected move...

Page 9: ...e to leakage Failure of pneumatic stop Ejected components due to breakdown of hydraulic tool breakdown of hydraulic bolt breakdown of turbocharger high firing pressures major failure Ejection of press...

Page 10: ...y supply failure engine not fully safeguarded at high oil mist levels due to failure in oil mist detector circuitry engine not fully safeguarded at high oil mist levels due to erratic electrical conne...

Page 11: ...vity of the return connection clamp a bad contact might also cause sparkles and radiation 00B 1 2 Preventing Radiation The welding current and the arc is emitting a wide spectrum of electromagnetic ra...

Page 12: ...precautions must be paid attention to before welding in the vicinity of a WECS 2000 control system Close the covers of the cabinet and all the distributed units Deactivate the system by disconnecting...

Page 13: ...X6 If the welding point is close to approximately within a radius of 2 m an electronic module SSM 701 SSM 558 CCD PDM Cense etc disconnect all connectors of the unit Close the covers of the cabinet Di...

Page 14: ...Appendix B Welding Precautions 200147 00 4...

Page 15: ...only as in line configuration The data figures presented in the Operation Manual refer to both 22 and 22 26 engine if not otherwise instructed 01 2 Main data Basic data VASA 22 VASA 22 26 Cylinder bo...

Page 16: ...80 80 90 Lube oil after engine 10 18 higher 5 8 higher HT water after engine MD 77 85 HF 90 95 MD 95 105 HF 105 110 HT water before engine 5 8 lower 2 3 lower HT water rise over turbo charger 8 12 15...

Page 17: ...fter engine MD 77 85 HF 90 95 MD95 105 HF105 110 HT water before engine 5 8 lower 2 3 lower HT water rise over turbo charger 8 12 15 6 10 LT water before engine 28 38 65 70 Charge air in air receiver...

Page 18: ...ion As a guideline addi tional reduction may be calculated as follows Reduction factor a b c a 0 5 for every C the ambient temperature exceeds stated value in the sales document b 1 0 for every 100 m...

Page 19: ...changeable The exhaust valves also with stellited seats and chromium plated stems seal against the directly cooled valve seat rings The water cooler seat rings made of a corrosion and pitting resistan...

Page 20: ...by the starting air distributor run by the camshaft The four cylinder engine are normally be provided with an air driven starting motor Cross section of W rtsil VASA 22 26 in line engine Fig 01 1 220...

Page 21: ...hen difficulties with filter clogging are experienced fuel incompatibility can be tested by ASTM D 2781 method or similar 02 1 2 Fuel treatment 02 1 2 1 Purification Heavy fuel residuals and mixtures...

Page 22: ...ed to 115 130 C D E before the fuel injection pumps to 98 C F at the centrifuge and to minimum 40 C G in storage tanks The fuel oil may not be pump able below 36 C H To obtain temperatures for interme...

Page 23: ...rsion diagram When converting viscosities from one of the units on the abscissa to centistokes or vice versa keep in mind that the result obtained is valid only at one and the same temperature When co...

Page 24: ...engine weight 0 3 0 20 Carbon residue Conradson weight 22 Asphaltenes weight 14 Flash point closed Pensky Martens min C 60 0 60 0 Pour point upper max C 30 6 The requirements above also correspond to...

Page 25: ...es nozzle rings etc The aggressiveness of the fuels depends on not only the quantity but also of the proportions of sodium and vanadium The worst combination is when the sodium content is about 25 40...

Page 26: ...entific pocket calculator Only the fuel density and viscosity need to be known Shell Calculated Carbon Aromaticity Index CCAI CCAI D 81 141 log10 log10 Vk 0 85 D density kg m3 at 15 C Vk viscosity cSt...

Page 27: ...delines can however be given engines running at constant speed and load 50 can use fuels with CCAI 870 engines running at variable speed and load can use fuels with CCAI 860 820 840 860 880 900 920 94...

Page 28: ...able wear on vital engine compo nents like injection equipment may be experienced 02 1 5 Measures to avoid difficulties when running on heavy fuel Poor fuel quality will however influence wear engine...

Page 29: ...iduals may contain very abrasive catalytic fines silicon and aluminium oxides which if allowed to enter the injection system may wear down injection pumps and nozzles in a few hours Some of the diffic...

Page 30: ...equilibrium remains at an acceptable level Additives The oils should contain additives that give good oxidation stability corrosion protection load carrying capacity neutralization of acid combustion...

Page 31: ...3530 CEPSA Troncoil 4030 CEPSA Troncoil 30340 CEPSA Troncoil 3540 CEPSA Troncoil 4040 Ertoil Koral 30 SAE 30 Ertoil Koral 35 SAE 30 Ertoil Koral 40 SAE 30 Ertoil Koral 30 SAE 40 Ertoil Koral 35 SAE 40...

Page 32: ...il Mobilgard 312 Mobilgard 412 Mobilgard 324 Mobilgard 424 Mobilgard 342 Mobilgard 442 SAE 30 SAE 40 SAE 30 SAE 40 SAE 30 SAE 40 15 15 30 30 40 40 A A A B C A B C A B C A B C Neste NST 30 NST 40 SAE 3...

Page 33: ...ures Never blend different oil brands unless approved by oil supplier and during guarantee time by engine manufacturer 02 2 3 Maintenance and control of the lubricating oil a Centrifuging of the syste...

Page 34: ...guidance values type analysis for new oil of the brand used Viscosity Should not rise by more than 25 above the guidance value at 100 C Maximum permissible viscosity for a SAE 30 grade oil is 140 cSt...

Page 35: ...s within W rtsil Diesel s limits during the whole oil change interval When changing oil the following procedure is recom mended 1 Empty oil system while oil is still hot Be sure that oil filters and c...

Page 36: ...ty cSt Viscosity Index VI 40 C 100 C Agip Ote 68 64 8 6 107 BP Energol THB 68 Turbinol 68 Bartran 68 65 68 68 8 4 8 7 8 7 99 100 100 Caltex Regal Oil R O 68 Rando Oil 68 Rando Oil HD 68 Rando Oil HDZ...

Page 37: ...change interval 1 500 h Manufacturer Brand name Viscosity cSt Viscosity Index VI 40 C 100 C BP Energol RC 68 68 8 8 104 Shell Madrela AP 68 68 8 5 94 Valvoline Compressor oil 62 90 10 0 92 Synthetic...

Page 38: ...the pump is new or has been overhauled The following greases are recommended BP Energrease LS2 Caltex Regal Starfak Premium 2 Esso Beacon 325 Nyn s FL3 42 Shell Alvania 3 The pump is to be regreased...

Page 39: ...orrosion unsuitable as cooling water If risk of frost occurs please contact the engine manufacturer for use of anti frost additives Caution The use of glycol in the cooling water is not recommended 02...

Page 40: ...surfaces Nitrite borate no increased risk of corrosion at over or under doses innocuous for the skin allowed for use in fresh water generators intended for house keeping purposes tendency to attack z...

Page 41: ...1024 USA Nalco39powder Nalco39 L liquid Nalcool2000 Nalfleet Marine Chemicals P O Box 11 Winnington Avenue Northwich Cheshire CW 8 4DX UK Nalfleet9 108 Nalfleet9 131Cliquid Nalcool2000 Rohm Haas ex D...

Page 42: ...02 Fuel Lubricating Oil Cooling Water 22 9601 02 22 VASA 22...

Page 43: ...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 sul phide etc during pumping...

Page 44: ...d and may be absorbed into the skin Remove contaminated clothing Seek medical advice if irritation develops Eye contact Rinse immediately with plenty of water for at least 15 minutes and seek medical...

Page 45: ...sal plants 02A 3 2 Personal protection equipment Hand protection Impermeable and hydrocarbon resistant gloves nitrile rubber for example Eye protection Wear goggles if splash risk exists Skin and body...

Page 46: ...pills in absorbent material and collect solids in a container Wash floor with water as spillage may be slippery Contact appropriate authorities in case of bigger spills Bulk material can be land dumpe...

Page 47: ...from W rtsil local network office Rinse the sampling line properly before taking the actual sample Preferably also rinse the sample bottles with the oil a couple of times before taking the sample espe...

Page 48: ...valves these will probably contain high levels of water and sediment and the samples will not be representative of the bulk phase 02A 5 2 Dispatch and transportation Place the bottle with the Ziploc b...

Page 49: ...e immediately mounted again Note Never leave the engine running when covers are removed 03 1 1 Manual start 1 Start the prelubricating oil pump to obtain a lubricating oil pressure about 0 5 bar Norma...

Page 50: ...sure of about 0 5 bar In automatically starting engines the priming pump operates continuously thus keeping the engine ready for start At least every second day make sure that the pump is running 2 Pr...

Page 51: ...circulating water pump 2 3 minutes will be enough but the water pump should run for some 5 minutes more 2 Stop the engine by moving the stop lever into stop posi tion The time of slowing down offers...

Page 52: ...exhaust pipe opening The lubricating oil system on a stopped engine should be filled withoileverysecondday bypriming theengine At thesametime turn the crankshaft into a new position This reduces the r...

Page 53: ...0 the water content in air can be read from the diagram 0 029 kg water kg dry air If the air manifold pressure receiver pressure under these conditions is 2 5 bar i e absolute air pressure in the air...

Page 54: ...8 Check that the gossip holes of the oil coolers and the circulating water coolers are open 9 Clean the compressor side of the turbocharger by in jecting water See the instruction manual of the turbo...

Page 55: ...ted value go no go only lubricating oil changes cleaning of centrifugal lubricating oil filters change of lubricating and fuel oil filter cartridges change of parts in connection with maintenance acco...

Page 56: ...03 4 1 Manual start 1 Check the lubricating oil level the circulating water level in the expansion tank the raw water supply the fuel oil level in the day tank troublesome and time consuming job to ve...

Page 57: ...akage from the pipe connections inside or outside the engine 8 Rags or tools left in the crankcase untensioned or un locked screws or nuts those which are to be locked worn out self locking nuts MAY C...

Page 58: ...that running in procedure is performed after following maintenance jobs 1 After piston overhaul follow programme A in Fig 03 2 as closely as possible The piston rings have slided into new positions an...

Page 59: ...rs A After piston overhaul B After change of piston rings pistons or cylinder liners after honing cylinder liners Stop Check big end bearing temperatures End of running in programme Engine may be put...

Page 60: ...03 Start Stop and Operation 22 9632 03 12 VASA 22...

Page 61: ...k that all systems concerned are drained or pressure is released After dismantling imme diately cover holes for lubricating oil fuel oil and air with tape plugs clean clothes or similar 4 When exchang...

Page 62: ...ass 2 0 2 0 5 0 Ash mass 0 05 0 05 0 20 Vanadium mg kg 100 100 600 Sodium mg kg 20 20 50 Al Si mg kg 30 30 80 CCAI 850 850 870 Note If any of specified fuel properties exceed HFO 1 maximum value the f...

Page 63: ...the engine Governor actuator Check oil level in governor 02 2 4 Check oil level and look for leaks use governor manual 22 4 Injection and fuel system Check leak fuel quantity 03 3 1 Check the amount...

Page 64: ...04 6 Interval See table above Turbocharger Water cleaning of turbine 18 9 Clean the turbine by injecting water more often if necessary 03 3 2 04 7 Interval 500 operating hours Circulating water Check...

Page 65: ...ine manufacturer so recommend the intervals between changes can be prolonged in steps of 500 operating hours In dry sump installations the oil change intervals may be in the order of 800 hours or more...

Page 66: ...nozzles Check the effective needle lift Check the springs Replace the O rings Check the nozzle condition in a test pump Recommendation Replace the complete injection valves by new or reconditioned on...

Page 67: ...3 Check axial clearance Cylinder liners Inspect jacket water spaces Inspect the water side of one cylinder liner through the plug in the engine block If the deposits are thicker than 1 mm clean all li...

Page 68: ...valve cone casing and sealings LT water pump Inspect LT water pump 19 3 Dismantle and check Replace worn parts LT water pump driving gear Inspect LT water pump driving gear 19 3 Replace parts if neces...

Page 69: ...ect the cylinder liners 10 4 Measure the bore using form No 2210V013 replace liner if wear limits are exceeded Hone the liners Inspect anti polishing ring if assembled Replace if necessary 06 2 Cylind...

Page 70: ...Average load 75 Average load 75 16 000 20 000 04 14 Interval See table above Camshaft Inspect camshaft bearings 14 3 Replace if necessary 06 2 Camshaft driving gear bearings Inspect camshaft driving...

Page 71: ...rts Recommendation The overhaul should be carried out by the authorised service personnel Engine foundation Check flexible elements of engine foundation Flexible mounted main engine Replace if necessa...

Page 72: ...04 Maintenance Schedule 22 9845 III 04 12 MD HF...

Page 73: ...all the maintenance tools are avail able 3 Check that nessercary spare parts and consumable parts are available 05 1 2 Ordering of Maintenance tools 1 Find the part s that intrests you in the followin...

Page 74: ...ing shell 4V85B0012 851005 Turning tool for thrust washer bearing sheal 3V85B0008 851006 Turning tool for thrust washer bearing sheal 3V85B0017 860000 High presseure pump 4V86A0038 861025 Pin for tigh...

Page 75: ...tool for cylinder liner 841009 Honing tool for cylinder liner 1V T22088 841010 Drilling machine for honing tool 4V84B0136 842025 Honing stones 25x25x250 coarse including holder 842026 Honing stones 25...

Page 76: ...per 2V83F0071 835004 Protecting sleeve for connecting rod lower 3V83F0068 860000 High pressure pump 1000 bar 4V86A0038 861025 Pin for tightening of nuts 4V86B0011 861026 Distance sleeve 4V86B0141 8610...

Page 77: ...0000 High pressure pump 1000 bar 4V86A0038 861025 Pin for tightening of nuts 4V86B0011 861027 Hydraulic cylinder 3V86B0060 861032 Distance piece 3V86B0071 861033 Distance sleeve 3V86B0142 861166 Fexib...

Page 78: ...ng ring 3V74L0037 836007 Dismantling tool for antipolishing ring 3V10T1366 843002 Clamp tool for piston rings 2V84D0010 843003 Piston ring pliers 4V84L0018 843004 Pliers for retaining rings 4V84L0016...

Page 79: ...08 Cleaning tool for injection sleeve bottom 841021 Felt for cleaning tool 4V84B0071 843001 Cirlip pliers DIN 5254 846010 Dismantling tool for valve springs 2V84G0207 848003 Valve clearence feeler gau...

Page 80: ...onnecting pie DIN 3124 807010 Long socket wrench 30x12 5L for nozzle nut DIN 3124 837017 Extractor for injection valve L Orange 3V83H0098 845006 Shaft for nozzle needles 4V84L0015 845008 Brass wire br...

Page 81: ...Code Description Drawing 865001 Maintance tools VASA 22 865002 Blanking tool for turbocharger State engine number turbocharger type and serial number HT number when ordering 22 200222 Maintenance Tool...

Page 82: ...IN3122 808003 Ratcheat handle 12 5x300 with 1 2 square drive DIN3122 808005 Extension bar B12 5x125 with 1 2 square drive DIN3123 820008 Torgue wrench 20 100 Nm 4V92K0207 820009 Torgue wrench 75 400 N...

Page 83: ...filter rotor 4V83L0001 837015 Mounting tool for overspeed trip tool 4V83H0073 837018 Mounting tool for water pump sealing 4V84G0177 841023 Valve seat grinder 4V84B0130 844002 Barring lever 4V84E0001 8...

Page 84: ...hange key for torque wrench 24 mm 4V92K0208 851004 Turning tool for shield bearing shell 4V85B0010 861022 Distance sleeve fo shield bearing 4v86B0065 861030 Hydraulic cylinder for shield bearing 86114...

Page 85: ...No 332001 Guiding pin 4V33C0028 803013 Bit hexagon socket screw 14 with 3 4 square drive 4V80L0001 807912 Socket wrench for balancing shafts 30X20 DIN 3124 808008 Extension lever for balancing shaft 3...

Page 86: ...ck coupling female 4V86A0035 861017 Quick coupling male 4V86A0040 861035 Flexible hose 600 mm 4V86A0013 861036 Flexible hose 3000 mm 4V86A0030 861166 Fexible hose 600 mm including quick couplings 8611...

Page 87: ...ening pressure of fuel injection valve 320 bar Tripping speed of electro pneumatic and mechanical overspeed trip devices Nominal engine speed Electro pneumatic tripping speed Mechanical tripping speed...

Page 88: ...81 Camshaft thrust bearing housing bore 90 000 90 022 Camshaft thrust bearing diameter in situ 75 056 75 108 Camshaft thrust bearing axial clearance 0 22 0 39 Camshaft thrust bearing width 69 740 69 6...

Page 89: ...0 39 1 03 0 62 0 93 12 Valve guide diameter 16 095 16 075 16 200 Valve stem diameter 16 000 15 982 15 97 Valve stem clearance 0 075 0 113 0 20 Valve seat deviation relative guide max value 0 10 Inlet...

Page 90: ...ance roller bush bush tappet pin 0 050 0 114 0 085 0 153 0 15 0 20 17 Fuel feed pump engine driven Shaft diameter 20 009 19 996 Bush diameter bore 20 070 20 050 Bearing clearance 0 04 0 08 0 15 Axial...

Page 91: ...ing shaft gears Crankshaft gear intermediate gear 0 1 0 6 Intermediate gear balancing shaft gear 0 1 0 5 Balancing shaft gear 0 1 0 35 23B 8V Backlash balancing arrangement gears Balancing shaft drivi...

Page 92: ...06 II Adjustments Clearances and Wear limits 22 9601 06 6 VASA 22...

Page 93: ...ess otherwise stated Note that locking fluids are used in certain cases Molycote or similar low friction lubricants must not be used for any screws or nuts due to risk of overtensioning of screws 1 Nm...

Page 94: ...M30 10 9 Lubricate the washers with molykote G n Plus and the threads with oil Use the torque multiplier X 4 800 20 4 Crankshaftflangescrews M24 12 9 20pcs withoutnuts Lubricate the washers with molyk...

Page 95: ...ar Pos Screw connection Torque Nm Alternative 1 1 Nut M12 Note Tighten the screws in two steps 85 5 65 85 Alternative 2 1 Nut M16 Note Tighten the screws in two steps 280 5 210 280 2 Special screw for...

Page 96: ...drive flange connection screws M6 8 8 Apply Loctite 242 on threads see section 07 2 9 1 4 Overspeed trip device fastening screws to camshaft M10 8 8 SK 45 5 5 Overspeed trip housing fastening screws M...

Page 97: ...270 on threads 85 5 2 Injection valve fastening nuts 50 5 3 Starting valve fastening screws Note Tighten the screws in two steps 40 4 20 40 4 Nut for starting valve spindle 14 2 5 Nuts for valve tapp...

Page 98: ...screws 100 5 65 5 100 5 100 5 Note Tightenthescrewscrosswiseinsteps 0 50 80 100 0 30 50 65 0 50 80 100 0 50 80 100 6 Injection pump cover fastening screws 100 5 Note Tightenthescrewscrosswiseinsteps 0...

Page 99: ...le cap nut 110 5 110 5 3 Injection pipe cap nuts 50 3 4 Connection piece to nozzle holder 50 5 5 Nozzle holder to connection piece 65 5 6 Flange screws 25 2 DUAP L RANGE 1 2 5 4 1 2 3 For tightening o...

Page 100: ...g oil pump driving gear 75 5 210 10 2 Fastening screws for water pump driving gear connection with three Inbus Plus fastening screws M8x35 10 9 34 3 Alternative 1 3 Fastening nut for impeller of water...

Page 101: ...multiplier X 4 600 20 J Balancing shafts 4R22 4R22 26 Pos Screw connection Torque Nm 1 Hexagon nut M16 200 10 2 Drive gear wheel fastening screw 120 10 3 Balancing shafts flange connection screws 120...

Page 102: ...main bearings Pos Screw connection Torque Nm 1 Side screws for main bearings 1200 20 Use the torque multiplier X 4 1 Fig 07 11 220767 07 Tightening Torques and Instructions for Screw Connections 22 20...

Page 103: ...ross flats of hexagon screws mm Key width of hexagon socket head screws mm Torque Nm kpm M8 13 6 25 2 5 M10 17 8 50 5 0 M12 19 10 85 8 5 M16 24 14 200 20 0 M20 30 17 370 37 5 M24 36 19 640 65 0 07 2 U...

Page 104: ...gines V engines Note Tightenthenutsinsteps 200 0 555 200 0 555 565 565 85 85 861032 861033 861011 3 Main bearing screws M42 540 560 200 861020 861021 4 Shield bearing screws M24 285 295 50 861030 Caut...

Page 105: ...es in the hoses are integrated with the quick couplings and are opened by the pins located in the centre of the male and female parts If these pins get worn the coupling must be replaced because of th...

Page 106: ...lace the couplings Risk of blocking system If exceptionally it is necessary to operate the with couplings not completely intact it is advisable to open the air vent screw to assure that the passage is...

Page 107: ...ase the pressure further to the stated pressure and screw the nut until in close contact with the face again This time the nut should move just the limited angle but approximately the same angle for a...

Page 108: ...e and force Relation between pressure and force for hydraulic extractor Hydraulic oil 2 A B 1 Fig 07 14 2207539205 2000 4000 6000 8000 10000 12000 20000 40000 60000 80000 100000 120000 200 400 600 Bar...

Page 109: ...Too low speed 1b b Automatic shut down device is not in start position 23 c Load limit of control shaft or of governor is set at too low a value 22 d Overspeed trip device has tripped 22 5 22 6 e Sta...

Page 110: ...arge loose screws 06 2 pos 11 07 3 1 pos 2 b Valve spring or injection pump tappet spring broken 12 16 c Inlet or exhaust valve jamming when open d Too large valve clearances 06 1 12 4 e One or more c...

Page 111: ...b c d e c Leaky injection pipe or pipe fittings 16 4 d When idling see point 3g 3 3 1 11 Exhaust gas temperatures very unequal a See points 9a c e b Too low fuel feed pressure too small flow through i...

Page 112: ...water temperature 03 3 1 Fig 03 1 18 Engine looses speed at constant or increased load a Engine overloaded a further increase of fuel supply is prevented by the mechanical load limiter 22 1 Fig 22 6...

Page 113: ...r and blank off the opening in the charge air cooler housing Shut off water supply and return pipes Repair the cooler e g by plugging the leaking tubes 2 If there is not time enough to remove the defe...

Page 114: ...jection pump over a long period the valve push rods of the inlet and outlet valves are to be removed and the indicator valve on the respective cylinder is to be opened once an hour to allow any accumu...

Page 115: ...normal full load temperatures If the turbocharger s surge reduce load further to avoid continu ous surging Operation with piston and connecting rod of one or more cylinders removed should be performed...

Page 116: ...08 Operating Troubles Emergency Operation 22 9601 08 8 VASA 22...

Page 117: ...ushes are in housings directly machined in the block see chapter 14 10 1 2 Cylinder liners The engine block embodies the cylinder liners made of special cast iron and honed to an optimal finish At the...

Page 118: ...closest to the bearing in question 2 Remove the oil pipe to the main bearing cap in question 3 Unscrew the main bearing cap side screw about one turn by using the wrench combination X 4 Fig 10 1 To fa...

Page 119: ...cap is to be removed shift angle position of the handle by inserting the locking pins into the other pair of holes In doing so it is possible to further lower the main bearing cap until it isfreefromt...

Page 120: ...he new bearings with the same bearing numbers as the replaced shells The thrust washers should be changed in pairs to ensure that the flanges of the axial bearing surfaces are of equal thickness Noscr...

Page 121: ...the rear side only to 300 Nm torque 11 Put the distance sleeves 1 Fig 10 1 in place and keep them in position by inserting the pins 2 into the holes of the nuts through the sleeve slots Screw on the c...

Page 122: ...e sleeves and pins 16 Tighten the side screws by using the tool combination Fig 05 15A and Fig 10 1 to the value stated in chapter 07 section 07 1 17 Before starting the engine after a bearing inspect...

Page 123: ...n the crankshaft journal radial oil hole and turn carefully in counter clockwise direction until the edge of the bearing shell levels with the bearing housing mating face Check that the flap at the be...

Page 124: ...e pitch angle of the honing lines in the cross hatch pattern should be about 30 which is achieved by combining for example 40 strokes min with a rotational speed of 100 RPM as coolant a honing oil is...

Page 125: ...all guide and contact faces upper level of the engine block are perfectly clean and intact as well as the corresponding surfaces of the cylinder liner Caution Check that the contraction edge diameter...

Page 126: ...ecessary 6 Check the bore of the liner especially straight in front of the O rings 390 mm from the upper edge of the liner see section 06 2 pos 10 The out of roundness of a replaced liner must not exc...

Page 127: ...crews are provided with clearance holes and compress the flanges the flywheel being in between The power is conveyed by the frictional force between the flanges The engine can be equipped with a power...

Page 128: ...tor position and reading Note During the alignment procedure the crankshaft should be turned in the direction of rotation only 6 Repeat this procedure with the other cylinders 7 The difference between...

Page 129: ...onding values must be based on experiences from the par ticular installation 11 1 3 Control of the the axial clearance Check the crankshaft axial clearance by using a dial micrometer 1 Run the engine...

Page 130: ...ote Always handle the piston with care The piston ring combination includes three compression rings the two top rings of which are chromium plated and one spring loaded chromium plated oil scraper rin...

Page 131: ...ofile connecting rod 8 Release the pressure and remove the hydraulic tool 9 Screw off the nuts 1 and remove the connecting rod screws by the stud tool 803011 10 Lift the big end bearing cap 2 together...

Page 132: ...er the piston rings should not be removed unless the rings and grooves require cleaning measuring etc If the piston rings are to be reinstalled note how they are turned Every time when removing the pi...

Page 133: ...ng rod is not dam aged 11 2 4 Installing the connecting rod and piston 1 Check that the bores for the skirt lubrication are not blocked 2 The gudgeon pins 5 should always be inserted from the same sid...

Page 134: ...ion V engine B bank Turn the crankshaft 95 from the TDC towards the B bank of the cylinder concerned In V engines mount the upper bearings shell and the protect ing rails 835003 and 835004 10 Lower ca...

Page 135: ...case the transmission has been opened it is abso lutely necessary to make sure that the marks of the gears remain in their initial positions 4R22 4R22 26 balancing shaft The second order free forces o...

Page 136: ...hydrau lic tool 11 Pump pressure into the hydraulic tool to remove the bearing bush Pressure must not exceed the value stated in the chapter 07 If the bearing bush is still sticking when the stated p...

Page 137: ...he fastening screws 7 thoroughly and apply Loctite 242 to them 13 Tighten the screws 7 to the stated torque value Lock with the wire 14 Clean the threads of the fastening screws 6 thoroughly and apply...

Page 138: ...aft is turned with cylinder 1 in TDC top dead centre and the balancing shafts with the guiding pins upwards see Fig 11 5 4R22 balancing arrangement Phase 2 Fig 11 4 221156A9205 Cylinder 1 in TDC Backl...

Page 139: ...nd the shaft 5 The whole pack age counterweights gear wheel can now be removed 6 Check the bearing clearance section 06 2 pos 23 B 7 If the bearing clearance exceeds the normal values or if the bearin...

Page 140: ...t on bank A should point straight to the side The scribing mark on the counterweight is now visible through the hole 14 provided the assembly is correct see Fig 11 6 View C and Fig 11 7 2 Turn the cra...

Page 141: ...ear wheel 13 Bush 14 The hole 15 Screw 16 Flange 17 Gear wheel 18 Bearing bush 19 Shaft 20 Bush 21 Screw 22 Locking wire 23 Screw 24 Nut 25 Locking wire 26 Screw 27 Counter weight 28 Oil groove A A Vi...

Page 142: ...bushes shall point towards the centre of gravity of the counterweights marked with a distinct mark 2 Mount the bush 20 to the shaft 19 apply LOCTITE 275 on the threads of the fixing screw 21 and tight...

Page 143: ...Diagram for 8V22 balancing system 1 2 3 4 Fig 11 7 2211539545 22 9601 Crank Mechanism 11 VASA 22 11 17...

Page 144: ...11 Crank Mechanism 22 9601 11 18 VASA 22...

Page 145: ...ylinder head The exhaust valves are equipped with valve rotators 6 Also inlet valves can at request be delivered with valve rotators The exhaust valve seats 8 are water cooled Cylinder head The four s...

Page 146: ...injection valve sleeve holds the injection valve in position and separates the injection valve from the cooling water Each cylinder head is individually cooled by a water flow enter ing the cylinder h...

Page 147: ...d take care that the starting air con nection pipe and the air pipe slide into the seals without force 4 Screw on the cylinder head nuts 5 Lift the hydraulic cylinders 861020 in place Screw on the cyl...

Page 148: ...sleeve should be in spected for possible water leakage and replaced if necessary Valve guides should be checked and replaced if worn O rings must be replaced with new ones at every overhaul Sealing su...

Page 149: ...on The cylinder head has four valves fitted two inlet valves and two exhaust valves All the valves are made of surface treated heat resistant steel The valves move in cast iron guides which are press...

Page 150: ...ainers and the springs can now be removed 5 Check that the valves move easily in the guides Caution Note in which guide each valve was situated before removing them Tool assembly for dismantling valve...

Page 151: ...urred the O ring for the corresponding valve seat ring must be changed Blow by increases the temperature and the O ring is burned which will result in water leakage into the cylinder 4 Before grinding...

Page 152: ...is 5 2 mm after that the valve must be replaced by a new one 2 Seat ring for the inlet valve The seat angle of the inlet valve seat ring is 20 with a tolerance of 0 15 The seat can be ground until the...

Page 153: ...haust valve seat ring the tool 834002 is required 3 Check the bore diameters in the cylinder head 4 Cool the seat ring in a thermostat controlled freeze box to 15 30 C Note The seal rings will be dama...

Page 154: ...sequently the force needed to close the valve is relatively low The valve has a left handed screw and is opened and closed respectively as fol lows Fig 12 5 Use the T handle wrench 808001 to open and...

Page 155: ...to open and close the indicator valve Open and close indicator valve The cock moves upward when closing clockwise Always use the special handle when closing Fig 12 5 2212558932 22 9601 Cylinder Head...

Page 156: ...12 Cylinder Head with Valves 22 9601 12 12 VASA 22...

Page 157: ...half of the engine speed in the same direction as the engine 13 2 Intermediate gears and camshaft gear The intermediate gear wheels are case hardened The wheels have a common shaft and are fixed to ea...

Page 158: ...ired movement is reached and turn the crankshaft as much as it is necessary 5 Check the valve timing of one cylinder and the fuel in jection timing 6 Mount the cover 30 13 2 3 Removing of camshaft dri...

Page 159: ...2 Split gear wheel 4 Axial screws 5 Intermediate wheel 6 Intermediate wheel 7 Nut 8 Screw 10 Screw 11 Bearing pin 12 Intermediate bush 13 Screw 14 Flange 15 Screw 16 Locking wire 18 Camshaft gear 19 S...

Page 160: ...Then turn 60 to the TDC for cylinder No B1 55 for 16V22 d V engines the gearing of the B bank installed the gearing of the A bank removed Turn the crankshaft to the TDC at ignition for cylinder No B1...

Page 161: ...the fixing of the camshaft and the gear in relation to each other Tighten the screws 21 to torque according to section 07 1 These screws are treated with locking compound and may be refused twice befo...

Page 162: ...t angles with the crank of cylinder No 1 and fasten the screws 4 and 8 by hand 4 Tighten the axial screws 4 to a torque of 10 Nm and check that contact is established between the gear wheel and the cr...

Page 163: ...10 Mount the end cover half Measuring split gear wheel 10 W2 W1 W3 W4 D3 D 1 D 2 Fig 13 3 2213529445 22 9601 Camshaft Driving Gear 13 VASA 22 13 7...

Page 164: ...13 Camshaft Driving Gear 22 9601 13 8 VASA 22...

Page 165: ...all joints drop forged rocker arms 3 pivoted in a rocker arm bearing bracket 13 and a yoke 14 guided by a yoke pin in the cylinder head Fig 14 1 Valve mechanism 2 3 4 5 8 10 6 7 11 12 13 14 1 A 1 Nut...

Page 166: ...rotators Oil is returned to the crankcase in a free flow through the protecting sleeves for the push rod 14 1 3 Maintenance of valve mechanism Normally the valve mechanism needs no maintenance but in...

Page 167: ...e position 7 The tappet rollers bushes and pins are separated by push ing out the pin 12 14 1 3 3 Inspection of valve mechanism parts 1 When cleaning the components pay special attention to the angula...

Page 168: ...nd the guide blocks from the cylinder concerned 2 Unscrew the flange connection screws 3 from both ends of the camshaft piece by using the tool combination in Fig 05 15B 3 Remove the cover 6 from the...

Page 169: ...injection pumps on all cylinders towards the free end 14 3 Camshaft bearings 14 3 1 Inspection of the camshaft bearing When the camshaft bearing journal has been removed the inner diameter of the bea...

Page 170: ...the middle of the engine Caution Before moving the camshaft axially unload the pressure of the cams by removing the rocker arm brackets and injection pumps 4 Tighten the hydraulic cylinder by light t...

Page 171: ...screw 4 Connect the hoses of the hydraulic pump to the hydrau lic tool 5 Pump pressure to the hydraulic tool to the bearing bush The pressure must not exceed 600 bar 6 Open the pump valve disconnect t...

Page 172: ...14 Valve Mechanism and Camshaft 22 9601 14 8 VASA 22...

Page 173: ...air cooler When the airis cooled the density of the air is further increased The turbocharger can be divided into two basic sections The turbine wheel that is driven by the exhaust gas and the compres...

Page 174: ...is fastened to the engine block at the free end of the engine with screws Turbocharger and air cooler 15 1 2 Turbocharger maintenance Maintenance of the turbocharger is carried out according to the i...

Page 175: ...f the turbine does not have much effect on the exhaust gas temperature level hard deposits have probably been built up on the nozzle ring and the turbine blades in the turbocharger and they have to be...

Page 176: ...4 7 0 5 VTR 214 9 1 0 Cleaning should take place regularly according to chapter 04 Maintenance Schedule Depending on the results obtained the interval between two washings may be increased or reduced...

Page 177: ...00 RPM with fixed propeller Run the engine for five minutes on this load before the washing is started Maximum allowed exhaust gas temperature after cylin der is 380 C 2 Open the valves 1 and check th...

Page 178: ...the water required within 4 10 seconds This water quantity is 0 3 dm3 For injection the measuring cup on the turbocharger bracket should be used the latter being pressurized e g by charge air Under n...

Page 179: ...f the nominal output of the engine with the turbocharger rotor removed For removing of the rotor see instructions in the turbocharger manual It is to be noticed that the blocking of the rotor is not r...

Page 180: ...at no foreign particles can enter the air inlet passage 3 When the engine is loaded follow carefully the exhaust gas temperatures do not exceed 500 C It is to be noted that the exhaust gas temperature...

Page 181: ...s is imperative for a long and trouble free operation of the engine and must be done at regular intervals 1 Remove the cooling water pipes Loosen the cooler in sert flange screws and withdraw the inse...

Page 182: ...o a chemical cleaning bath for at least 24 hours Upon completion follow the recommendations given for the air side 5 Check the gaskets before reassembling the headers 6 Mount the cooler on the engine...

Page 183: ...22 200520 Turbocharging and Air Cooling 15 VTR Turbocharger 15 11...

Page 184: ...duct and the exhaust pipes to the gas inlet casing through metal bellows The exhaust pipe after the turbocharger should be arranged according to the installation instructions Turbocharger and air cool...

Page 185: ...ded to use the service net of the engine manufacturer or the turbocharger manufacturer 15 1 3 Water cleaning of turbine during operation applies to engines running on heavy fuel Water cleaning of turb...

Page 186: ...y vary from one installation to another and will depend on the type of fuel used as well as on running conditions Under average conditions with engines running on residual fuels experience shows that...

Page 187: ...er output and as soon as possible repeat the readings taken under step 1 for comparative purposes Water washing of the compressor side during operation see enclosed separate manual for the turbocharge...

Page 188: ...e thread or the hole 7 for the lifting tool is visible If necessary use the screws in the two threaded extractor holes in the flange b Apply the lifting tool and lift off the insert c Clean the air si...

Page 189: ...15 III Turbocharging and Air Cooling 22 8604 15 6 VTR 161 251 Turbochargers...

Page 190: ...up by the camshaft via the roller tappet and pulled back by the spring acting on the roller tappet recip rocate intheelement ona predetermined stroketo feed fuel under pressure The plunger also contro...

Page 191: ...ipping 16 2 2 General description The injection pump body consists of a cast housing provided with flanges for fastening against the engine block The tappet with roller is located at the bottom of the...

Page 192: ...ring the system 3 Remove the fastening screw 52 for the cover 35 of the fuel injection equipment 4 Remove the pneumatic shutdown cylinder 53 and the pipe from the distributing pipe Injection pump 30 4...

Page 193: ...trol shaft and fuel control rack with the screw and nut Note Center the joint by applying force between the fuel control rack and connection piece see chapter 22 Check that the joint moves easily 5 Re...

Page 194: ...in the funnel constant by refilling and turn the crankshaft slowly in the engine rotating direction Watch when fuel stops emerging Read the position of the crankshaft See chapter 06 9 Repeat pos 2 8 o...

Page 195: ...clean fuel or special oil and keep them always together the plunger being inserted in the cylinder Note Normally further dismantling is not necessary The details must be protected against rust and es...

Page 196: ...mfered tooth of the control sleeve 10 Reinstall the tappet assembly The guiding groove of the tappet must correspond to the fixing screw 21 11 Screw in and tighten the fixing screw 21 12 Check that th...

Page 197: ...ould be adjusted sothatthenormalleakfuelcontinuously flows through it The switch gives alarm only when the flow is abnormal a broken injection pipe When removed the injection line details have to be p...

Page 198: ...s wire brush Don t use steel wire brush 2 Release the nozzle spring 8 tension by opening the counter nut 10 and screwing up the adjusting screw 9 see Fig 16 2 3 Remove the nozzle from the holder by op...

Page 199: ...tems Seat surfaces sliding surfaces needle shaft and sealing faces against the nozzle holder should be carefully checked 6 Clean the nozzle holder and cap nut carefully if neces sary dismantle the noz...

Page 200: ...asure time for a pressure drop of 50 bar The time must not be below 3 seconds A time longer than 20 seconds indicates fouled spindle 15 If the tests according to pos 10 14 give satisfactory re sults t...

Page 201: ...cylinders 2 In line engine Open the camshaft gear wheel cover and the cover 30 see Fig 13 1 in chapter 13 V engine Open the camshaft gear wheel cover on one bank as well asthe cover 30 onthe B bankort...

Page 202: ...arate instructions The engine is normally equipped with an electrically driven fuel feed pump 9 and a duplex filter 8 to provide correct flow pressure and filtration irrespective of the number of engi...

Page 203: ...en overhauling cylinder heads for example The high pressure system with injection pump and injection valve is described in chapter 16 17 2 Maintenance When working with the fuel system always observe...

Page 204: ...tion see Fig 17 2 and the filter side will be slowly filled Vent the filter side Set the three way valve and slow filling valve in normal position both filter sides in use A sudden change over of the...

Page 205: ...hot if the system is closed for a lengthy time 2 Adjustment of pressure control valve 11 Adjust the valve 11 to 6 bar 3 Adjustment of pressure control valves 12 Shut off the valve 15 Check that the r...

Page 206: ...low through the filter The fuel flows first through a cartridge 3 made of special paper filtering off particles larger than 10 to 15 m then through an insert 4 of pleated wire gauze around a firm perf...

Page 207: ...ge s and throw away Pa per cartridges cannot be cleaned Always keep a sufficient quantity of cartridges in stock 6 Clean and rinse filter housing carefully with gas oil 7 Fit new paper cartridges and...

Page 208: ...100 hours of operation and the running in filter housing should be left empty The running in filter housing functions as a damper for pressure peaks in the fuel system when the filter element is left...

Page 209: ...17 Fuel system 22 9601 17 8 VASA 22...

Page 210: ...circuit flows through thisheatexchangertherebyheatingthelubricatingoil Atlowloads the warm lubricating oil will heat the LT water via the lubricating oil cooler An electrically driven prelubricating...

Page 211: ...lity oils approved by the engine manufacturer according to chapter 02 section 02 2 Always keep a sufficient quantity of oil in the system The oil dipstickshowsthemaximumandminimumlimitsbetweenwhich th...

Page 212: ...ystem Dirt metal particles and similar may cause serious bearing damage When dismantling pipes or details from the system cover all openings with blank gaskets tape or clean rags When storing and tran...

Page 213: ...ce see chapter 06 section 06 2 pos 18 Lubricating oil pump 18 3 4 Assembling 1 Clean and oil all details carefully before assembling Check that the O ring in the cover is intact and in correct positio...

Page 214: ...pump 18 4 Lubricating oil pressure control valve and safety valve 18 4 1 Description The pressure control valve is mounted on the lubricating oil pump and controls the oil pressure before the engine...

Page 215: ...oving parts Check them for wear and re place worn or damaged parts by new ones 2 Clean the valve carefully Check that the draining bore 13 is open Fig 18 2 3 Check that no details are jamming Do not f...

Page 216: ...e the end covers 1 and the fixation plates 12 3 Remove the free O rings 5 4 Mark the position of the tube stack relative to the jacket 5 Move the tube stack to one side until the second O ring is acce...

Page 217: ...coke Requires high temperature Always pour degreasing agent slowly into hot water never the contrary Rinse carefully with water after treatment Hydrocarbon solvents Include the whole range from light...

Page 218: ...onsists of a number of heat transfer plates arranged so that every other passage between the plates is accessible for one ofthe two liquids Adoublegaskethasachannel to the atmosphere between the gaske...

Page 219: ...r is hot wait until it has cooled to about 40 C 3 Drain the cooler 4 Slacken the nuts in turn diagonally Note Duringopening theslantofthepressureplatemustnotexceed 10 mm 2 turns nut 5 Dismantle the pl...

Page 220: ...0 5 mm Should the cooler tend to leak the compression may be A 0 5 mm 8 Procedure if measure A has not been attained with maximum tightening torque 9 Check the number of the plates and measure A 10 Ch...

Page 221: ...screwing the pipe after the valve 2 Remove the thermostatic element and withdraw the element 3 Check the element by heating it slowly in water Check at which temperatures the element starts opening an...

Page 222: ...oth filters are used at the same time to provide maximum filtration Fig 18 7 C shows the valve 9 in this position When changing cartridges during operation one side can occasionally be closed e g clos...

Page 223: ...rience from the installation concerned will give the most suitable intervals between changes of car tridges Change of the cartridges and cleaning should if possible be done during stoppages By closing...

Page 224: ...an oil through the nozzles provides a driving torque to the rotor and the oil returns through the filter housing to the engine oil sump The filter is provided with a cut off valve 15 which opens at ab...

Page 225: ...necessary 8 Reassemble the rotor complete align the location pins and tighten the nut 2 Do not forget the O ring 7 as this will cause leakage of the rotor which in turn will cause unbalance and damag...

Page 226: ...hem 8 rotating with the shaft and the other one 6 being stationary Fig 18 9 18 10 2 General maintenance Lubricating interval see chapter 04 After 3 6 years the shaft seal may have to be replaced due t...

Page 227: ...g Fig 18 9 Prelubricating pump Note Always clean the ball bearing in fresh gas oil Protect the bearing when the pump parts are being cleaned as the used washing liquid contains dirt particles that may...

Page 228: ...embly 4 Put the coal ring into position the smaller sealing face upwards and the grooves matching the marks 5 Place the front plate 10 over the drive screw shaft jour nal 6 Force the ball bearing inne...

Page 229: ...18 Lubricating Oil System 22 9601 18 20 VASA 22...

Page 230: ...rom the oil system via the oil cooler The system outside the engine can vary widely Fig 19 1 shows a system with separate coolers 14 and 16 for the LT and HT circuit The system can also be built with...

Page 231: ...er 15 through which a pump 8 identical to the HT pump pumps the water The circuit temperature is controlled by a temperature control valve 10 maintaining the LT circuit tem perature at a load dependen...

Page 232: ...cturer to obtain correct and trouble free service The cooling water should be treated according to the recommen dations in chapter 02 section 02 3 to prevent corrosion and deposits If risk of frost oc...

Page 233: ...s may be necessary if the deposits seem to be greasy see chapter 18 section 18 5 4 Deposits consisting of primarily limestone can be easily re moved when treated with an acid solution Contrarily depos...

Page 234: ...al shaft seal Thering 6 rotatesalongwiththe shaft and issealedagainst it with the O ring 7 The spring 5 presses the rotating ring against a fixed ring 8 which is sealed against the housing with the O...

Page 235: ...flows out through the draining holes 26 b Disassembling and assembling mechanical shaft seal 1 Remove the impeller according to pos a above 2 Carefully dismantle all seal details The sealing rings ar...

Page 236: ...ctor willonlydamagetheshaft axialscratches 6 Loosen the bearing retainer 23 and drive out the shaft and bearing In doing this also the seal 14 will come loose 7 Check the seals 13 and 14 and the beari...

Page 237: ...heel all contact surfaces should be cleaned and oiled 17 Reinstall the gear wheel 18 Reinstall the conical ring elements 25 Reinstall the ring elements exactly as situated in Fig 19 4 Mounting of gear...

Page 238: ...and the volute casing according to pos a and b above 19 4 Temperature control system 19 4 1 General description The HT thermostatic valve is a conventional valve with one set point In some special en...

Page 239: ...o port A by pass to B and cooling to C The springs 10 force the valve 8 to the left by pass position At high load low temperature operation there is no control air A B C A B C LOW LOAD COLD ENGINE sta...

Page 240: ...e control of the valve The pin 18 shows the position of the valve The drain bore 15 gives an indication of leakage of water or air Fig 19 6 Thermostatic valve 19 4 2 2 Maintenance Check the valve acco...

Page 241: ...ng 19 is damaged and has to be replaced by a new one for proper function of the thermostatic valve if there is no pressure Check the signal from the switch 3 in Fig 19 5 if the signal is not correct C...

Page 242: ...ve 6 If there is pressure the position control system is faulty 7 If the pressure disappears when opening the connection 14 the drain hole of the three way valve 2 Fig 19 5 can be clogged Clean the dr...

Page 243: ...ar and corrosion 10 Mount the elements and the valve in reverse order 19 4 2 5 Check of the thermostatic element The elements can be checked by heating up slowly in water Put a strong rubber ring long...

Page 244: ...ion in which the water is positively made to flow in the direction required When the engine is started up and is cold the HT thermostatic valve causes all of the water to be positively by passed back...

Page 245: ...nt contents 9 which remains in a semi solid form and is highly sensitive to temperature changes Most of the expansion takes place during the melting period of approximately two minutes over a temperat...

Page 246: ...ions are provided with a possibility for manual override 19 4 5 Maintenance Normally no service is required Too low a water temperature depends on a defective thermostat too high a temperature may dep...

Page 247: ...19 Cooling Water System 22 9601 19 18 VASA 22...

Page 248: ...e supporting bracket 3 The disc springs 2 maintain a positive force between the bracket and the pipe Fig 20 1 The complete exhaust system is enclosed by an insulation box built up of insulated sandwic...

Page 249: ...8R22 8R22 26 and 16V22 differencies in exhaust gas temperatures between the cylinders might occur The exhaust manifold in these engines is a so called pulse charging system with pulse converters two...

Page 250: ...nditions and the fuel quality are equivalent to these in the acceptance test Exhaust gas and valve temperatures 300 tA C 1 2 Cylinder 3 4 5 6 7 8 100 77 50 Clockwise rotating engine 300 tA C 1 2 Cylin...

Page 251: ...120 C higher than the mean temperature of the other cylinders The temperature difference between the cylinders should not be balanced by readjusting the fuel pump racks which causes un even loading o...

Page 252: ...before the main starting valve The main starting valve may be operated either with the lever 1 at manual starting or with a solenoid valve 8 at remote or automatic starting of the engine Starting air...

Page 253: ...cription The starting air for the engine is led to the space 12 and through holes in the sealing piston 11 also to the rear side of the piston which means that the piston normally is closed At manual...

Page 254: ...requires in principle no main tenance If the coil has broken e g because of overvoltage replace the coil by a new one If the valve is probable to be clogged by dirt it canbedismantledforcleaning ifca...

Page 255: ...ft it is then possible to see whether the pistons follow the cam profile Caution If the control air pipes have been connected prior to checking the crankshaft will rotate 21 4 Starting valve in the cy...

Page 256: ...The filter 20 Fig 21 1 on the engine should be inspected and cleaned with intervals according to chapter 04 Drain the filter from condensate with the built on drain valve 21 6 Pneumatic system 21 6 1...

Page 257: ...solenoid is controlled by a switch in the charge aircircuit Setpoint seechapter19 Temperaturecontrolsystem 21 6 2 Maintenance The system is built up of high class components Usually it requires no oth...

Page 258: ...e filter after each 8000 h Solenoid valve Fig 21 3 1 4 Fig 21 4 B In case of disturbance in the electric function of the valve test the valve by pushing the button 1 Should there be mechanical malfunc...

Page 259: ...e on the engine that prevents undesirable starting during turning Air is led through a start limiting valve 6 Fig 21 5 that prevents the passage of control air if the cover to the turning opening at t...

Page 260: ...the normal start button of the engine for venting without starting the engine Warning When using the start button of the engine when venting as described above connection on the valve 7 must absolute...

Page 261: ...21 Starting Air System 22 9601 21 10 VASA 22...

Page 262: ...emergency situation The indicator 17 indicates the fuel rack position The engine can be stopped by means of the stop lever 14 When the lever is movedtostop position thelever 16 actuatesthelever 15 fo...

Page 263: ...maximum 0 5 mm of the injection pump fuel rack positions c Check regularly see recommendations in chapter 04 adjust ment of the system stop position overspeed trip devices starting fuel limiter see se...

Page 264: ...ck positions to be 4 mm WORK STOP 1 Fuel rack 4 Connection piece 5 Screw 6 Torsional spring 7 Follower 8 Control lever 9 Torsional spring 10 Control shaft 11 Lever 12 Bearing 13 Lever 14 Stop lever 15...

Page 265: ...position release the overspeed trip device manually check the fuel rack positions to be less than 5 mm b Adjustment of stop position the stop position is adjusted and locked by the engine manu facture...

Page 266: ...f less than 5 mm cannot be obtained check for wear c Check and adjustment of tripping speed see section 22 6 Electro pneumatic overspeed trip device 22 26 22 3 5 Starting fuel limiter a Check of limit...

Page 267: ...ver against the limitation piston 1 Tighten the fastening screw in this position check according to pos a above c Check of function see section 22 7 22 3 6 Indicator of fuel rack position Check that t...

Page 268: ...spring pins Check at recommended intervals the radial and axial clearances of the bearings the gear clearance the oil drillings and the nozzle to be open that the gears and serrated coupling sleeve a...

Page 269: ...arrangement for covernor 4 Lock the fastening screw and mark the position of the terminal shaft lever with a mark on the shaft corresponding to that of the lever 5 Move the stop lever into the stop po...

Page 270: ...ch 8 indicating released overspeed trip device may be provided 22 5 2 Check of tripping speed Check the tripping speed at idle by increasing the engine speed above the nominal speed by quickly turning...

Page 271: ...can be replaced through the opening of the plug In V engine only 7 9 16 17 10 11 13 12 13 18 19 14 1 2 3 11 8 4 6 5 3 Latch 4 Spindle 5 Spring 6 Lever 7 Lever 8 Switch 9 Plug 10 Control shaft 11 Screw...

Page 272: ...ing to chapter 06 section 06 1 There are two separate air inlets one for starting air and one for the electro pneumatic overspeed trip device The line for the electro pneumaticoverspeed trip deviceis...

Page 273: ...stment of tripping speed Adjustments will be made in the box of the electronic speed measuring system see the instructions for speed measuring system chapter 23 22 6 5 Maintenance a General regularly...

Page 274: ...itation is cut off The pressure is relieved through the nozzle 5 On main engines started up to a lower speed a lower de energizing speed may also be used 22 7 2 Check and adjustment of limitation a Ch...

Page 275: ...n return valve 8 does not close Dismantle the valve and clean If the valve does not however keep tight replace it by a new one leaky three way valve 2 If the valve does not receive voltage or receives...

Page 276: ...on The instruments require no service Erroneous or damaged instruments should be repaired or changed at the first opportu nity The rubber elements for suspension of the instrument panel are to be chec...

Page 277: ...equipment Vasa 22 28 2 P103 P301 E701 E705 S710 L202 T401 T402 24 18 P204 P403 P402 T601 T202 P202 P203 P102 20 23 17 25 29 11 30 22 25 Fig 23 1 2223519428 23 Instrumentation and Automation 22 9601 23...

Page 278: ...gh HT water temperature after the engine T402 b Stop switches The following switches for automatic stop are mounted on the engine as standard for too low lube oil pressure P201 for too high cooling wa...

Page 279: ...for too low prelube oil pressure is set for rising pressure and thus this method does not give the correct value A rough check can however be made when taking into considera tion that the switch will...

Page 280: ...sure before the engine inlet LT water fuel oil after the filter starting air c Miscellaneous transducers for turbocharger speed detector for crankcase smoke one per cylinder load indicator The instrum...

Page 281: ...ty of 110 V DC 0 3 A or 24 V DC 1 A 23 2 2 3 Turbocharger speed A magnetic sensor is attached against the end of the turbocharger shaft sensing its speed The sinusoidal voltage from the sensor is ampl...

Page 282: ...40 V DC smoothed alt 40 160 V DC Output voltage 12 V 0 5 V Output current 500 mA Output ripple max 100 mV Ambient temperature 25 71 C Short circuit proof by current limitation Isolation voltage 2 kV 5...

Page 283: ...cy output can be used for measuring the speed digi tally There is an on card precalibrated test function which simu lates a certain engine speed and can be used for checking the system nDE measuring c...

Page 284: ...ights up Test points TP1 The pulse train from the speed sensor or the calibrating frequency when TP3 is bridged TP2 The unbuffered output from the frequency voltage con verter 0 10 V DC depending on t...

Page 285: ...ple or to the open circuit principle The relays can be programmed for either delay on operate or release or without delay The third relay channel can be programmed with self holding demanding externa...

Page 286: ...ator TP3 at card C2 Relay card C3 c Technical specification Inputs Supply voltage 12 V 0 12 V Current consumption max 60 mA Control voltage 0 10 V DC Outputs 3 relays each having two changeover contac...

Page 287: ...stment procedures The analog output re adjustment can be done by means of the potentiometers P701 and P711 P701 nTC1 P711 nTC2 When turning the potentiometer clockwise the output will in crease and vi...

Page 288: ...lay card c Tehcnical specification Inputs Control in 0 10 V DC Supply voltage 12 V 0 12 V Current consumption 60 mA Outputs 3 relay functions each having one change over contact Switchpoint 0 100 of m...

Page 289: ...g the sensor Turn the engine until the top of a cog is visual in the sensor mounting hole Screw the sensor com pletely in Unscrew the sensor 2 5 mm and tighten it well to the shown sensing displacemen...

Page 290: ...nd of the turbocharger shaft is prepared for this type of sensors When the turbocharger rotates and the above mentioned holes pass the sensor head a sinusoidal voltage is generated The cable is connec...

Page 291: ...No delay Relay 2 Optional or 115 RPM P602 TP2 LED 2 Diagram A Set point 115 RPM on 4 cyl engines with start motor Delay P605 P605 mid LED 2 0 30 s diagram C Set point 20 s offdelay on 4 cyl engines wi...

Page 292: ...7 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 C5 C4 C3 C2 C1 GND Volts DIAGR A VASA 22 2 4 6 8 10 12 200 rpm 400 600 800 1000 12001400 C2 TP4 C3...

Page 293: ...Operating voltage 29 3 30 1 Output 12 V 24 17 COM 26 15 12 V 13 START Is the green LED lighting Supply on terminals 29 30 Defective fuse Power supply ready for operation Replace the fuse Replace the...

Page 294: ...sc about 4 2 V DC START Output 0 10V DC Power supply OK Pulse input from the sensor or osc n card ready for operation Replace the card Test program 5 Test program 1 Output 0 10V DC TP2 Short circuit o...

Page 295: ...10V DC from n Replace the card Test program 2 Check and adjust if necessary The relays operate at any speed of the engine Relay card ready for operation DE Fig 23 12 2223639512 23 Instrumentation and...

Page 296: ...41 42 Card connector 23 14 Voltage output Terminal 8 9 37 38 Card connector 8 2 START Analog output 0 10V DC Supply voltage OK Pulse output n card ready for operation Check the censor Test program 1...

Page 297: ...tput signal changing state when the eng is turned Output signal channing state depending on sensing gap Remount the sensor to a sufficient sensing gap Adjust the sensor for symmetrical output when the...

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