Instruction Manual WARTSILLA

Alphabetical index46 02 30 91461

1

Aaccumulator, 074, 161, 167, 1617, 1619

air cooler, 014, 042, 045, 049, 086, 151, 154air cooler tools, 0542cleaning of cooler inserts, 156maintenance of the charge air cooler, 155

antipolishing ring, 1023, 115

Bbearings, 002, 013, 062, 065, 066, 067, 101,

1010, 1019, 1119big end bearing, 063, 113, 1119

inspection of the big end bearing, 1122mounting the big end bearing, 1123removing the big end bearing, 1119

big end bearing screw, 079, 1119

bypass, 043, 1513, 203, 219

Ccams, 087

camshaft, 014, 049, 062, 071, 145camshaft maintenance, 147mounting a camshaft piece, 148removing a camshaft piece, 147

camshaft bearing, 0410

camshaft bearings, 002, 062, 1019camshaft gear, 046, 065, 131

camshaft gear maintenance, 131mounting the camshaft gearing, 139removing the camshaft gearing, 133

centrifugal filter, 043, 1810

common rail, 012, 074, 161

compressor, 154connecting rod, 013, 046, 049, 063, 087, 113,

1119assembling and mounting a connecting rod, 1110connecting rod screw, 079connecting rod tools, 0514removing and dismantling a connecting rod, 115

control mechanism, 042, 221

control oil pump, 076, 175

cooling, 012, 013, 0216, 0311, 042, 043, 181cooling water, 012, 0216, 0311, 042, 043, 084cooling water pump, 186

counterweight screw, 079crank pin, 063crankshaft, 013, 031, 042, 047, 062, 073, 081,

111cylinder head, 013, 046, 0410, 072, 121

cylinder head general maintenance, 121cylinder head tools, 052mounting a cylinder head, 124removing a cylinder head, 121

cylinder head screw, 079cylinder liner, 013, 046, 049, 0410, 062, 1023

cleaning of cylinder liner water side, 1029cylinder liner maintenance, 1023cylinder liner tools, 0518honing a cylinder liner bore, 1029mounting a cylinder liner, 1027removing a cylinder liner, 1023

Eemergency operation, 086, 154exhaust gas, 012, 082, 087, 154exhaust pipe, 201

Ffixing bolt, 043, 079flow control valve, 162flywheel, 004, 073flywheel/thrust bearing, 062, 1010, 113

assembling a flywheel/thrust bearing, 1014dismantling a flywheel/thrust bearing, 1010maintenance of a flywheel/thrust bearing, 1010

fuel, 012, 021fuel characteristics, 024fuel treatment, 021

fuel filter, 042fuel injection line, 167fuel injection pipe, 074, 122fuel injection pump, 014, 047, 048, 161

fuel injection pump element, 162, 164, 166fuel injection valve, 044, 045, 047, 0410, 072,

076, 1222, 1612


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fuel injector, 067, 072, 1616fuel pressure control valve, 174

fuel system, 042, 045, 0410, 171flow fuse, 1618

Ggudgeon pin, 0410, 063, 113, 114, 119, 1110,

1115

Iindicator valve, 1221

injection system, 042, 161injection system tools, 0527

injection tappet, 067intermediate gear, 0410, 065, 131, 136, 139intermediate gear central screw, 079

Llateral screw, 079

leakage detection, 1618leakage detection ring, 1619

lube oil filter, 042

lubricating oil pressure control valve, 187

lubricating oil pump, 047, 068, 077, 1812

lubrication, 012, 014, 0211, 035, 0311, 043,181

lubricating oil, 012, 0211, 0311, 043, 084,1119

Mmain bearing, 002, 013, 062, 101

assembling a main bearing, 106dismantling a main bearing, 101inspection of main bearings and journals, 106main bearing tools, 0521maintenance of main bearings, 101

main bearing screw, 079

main starting valve, 048, 211, 212, 217

Ooil mist detector, 043, 044, 045operation, 031, 036, 039, 086, 087, 154overspeed trip device, 061

Ppiston, 013, 036, 046, 048, 0410, 063, 113

assembling and mounting a piston, 1110piston tools, 0511removing and dismantling a piston, 115

piston ring, 013, 0310, 046, 063, 114, 119,1116

inspection and maintenance of piston rings, 119pneumatic system, 014, 216pressure control valve, 045push rod, 141, 144, 145

Rrocker arms, 066, 072, 141, 143, 144, 145roller, 066, 143rotocap, 044, 046runningin filter, 1812

Ssafety valve, 073, 101, 1222slow turning, 033, 211split gear wheel, 065, 1315

mounting the split gear wheel, 1316removing only the split gear wheel, 1317removing the split gear wheel, 1316split gear wheel maintenance, 1316

SSV, 1622start up and safety valve, 074, 161, 1617

start, 031, 032local start, 032remote and automatic start, 033start after a prolonged stop, 034start after overhaul, 034

start up and safety valve, 161, 1617, 1622starting air distributor, 049, 212, 213starting air system, 012, 211starting air vessel, 215


3

starting valve, 073, 1222, 214

stop, 031, 035automatic stop, 035local stop, 035remote stop, 035

Tthermostatic valve, 048

htwater thermostatic valve, 048ltwater thermostatic valve, 048

thrust bearing screw, 079

turbocharger, 042, 043, 044, 045, 046, 0410,077, 151, 152

allowable operation with damaged turbocharger, 154turbocharger fastening screws, 0710turbocharger maintenance, 152water cleaning of compressor during operation, 154water cleaning of turbine during operation, 152

turning device, 031maintenance of turning device, 032

Vvalve guide, 048, 064, 066, 121, 129, 1212

valve mechanism, 049, 0410, 128, 141assembling the valve mechanism, 144dismantling the valve mechanism, 142inspection of the valve mechanism, 144maintenance of the valve mechanism, 141

valve rotator, 048, 1220valve seat, 049, 064, 121, 1211, 1216

fitting a new exhaust valve seat ring, 1218fitting a new inlet valve seat ring, 1217removing an old seat ring, 1216

valve stem, 064, 1212valve tappet, 066, 141, 143, 144valves, 004, 013, 044, 045, 047, 048, 0410,

073, 128, 1221, 1222, 1612, 212, 214adjusting valve clearance, 127assembling of valves, 1215checking and reconditioning valves and seats, 1211dismantling of valves, 129lapping, 1615machine grinding, 1212

vibration damper, 049, 1410vibrations, 088

Wwastegate, 043, 159, 1510, 203, 219water separator, 155WECS, 221, 231


4

46 02 30 91461Table of Contents

Chapter Page

1

0. Contents, instruction, terminology 001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.1. Contents of the instruction book 001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2. General rules 001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3. Terminology 002. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. Main data, operating data and general design 011. . . . . . . . . . . . . . . . . . . . . . 1.1. Main data for WRTSIL 46 011. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. Recommended operating data 012. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. Reference conditions 012. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. General engine design 013. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. Fuel, lubricating oil, cooling water 021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1. Fuel 021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.1. Fuel, general 021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2. Fuel treatment 021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2.1. Purification 021. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2.2. Heating 022. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2.3. Viscosity control 024. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3. Maximum limits of fuel characteristics 024. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.4. Comments on fuel characteristics 026. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.5. Measures to avoid difficulties when running on heavy fuel 0210. . . . . . . . . . . . . . . . . . . 2.1.6. General advice 0210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2. Lubricating oil 0211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.1. Lubricating oil, general 0211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.2. Lubricating oil qualities 0212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.3. Maintenance and control of the lubricating oil 0213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.4. Lubricating oil for the governor 0215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.5. Lubricating oils for turbochargers 0215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2.6. Lubricating oils for turning device 0216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3. Cooling water 0216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1. Cooling water, general 0216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2. Additives 0216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3. Treatment 0218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. Start, stop and operation 031. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1. Turning of the crankshaft 031. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1. Turning of the crankshaft, general 031. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2. Maintenance of turning device 032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2. Start 032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.1. Start, general 032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.2. Local start 032. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3. Remote and automatic start 033. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3. Start after a prolonged stop (more than 8 h) 034. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1. Local start after a prolonged stop 034. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4. Start after overhaul 034. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5. Stop 035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1. Stop, general 035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2. Cooling water pumps 035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3. Local stop 035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.4. Remote stop 035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.5. Automatic stop 035. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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3.6. Normal operation supervision 036. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.1. Normal operation supervision, general 036. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.2. Every second day or after every 50 running hours 036. . . . . . . . . . . . . . . . . . . . . . . . . 3.6.3. Every second week or after every 250 running hours 037. . . . . . . . . . . . . . . . . . . . . . . 3.6.4. Once a month or after every 500 running hours 038. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6.5. In connection with maintenance work 038. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7. Operation supervision after overhaul 039. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8. Runningin 0310. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9. Loading 0311. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Maintenance schedule 041. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1. Maintenance schedule, general 041. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2. Maintenance schedule for HFO operation,

Common rail engines 042. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. Maintenance tools 051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1. Maintenance tools, general 051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1. Use of this list 051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.2. Ordering of maintenance tools 051. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2. Cylinder cover 052. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3. Piston 0511. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4. Connecting rod 0514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5. Cylinder liner 0518. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6. Main bearing 0521. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7. Injection equipment 0527. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8. Camshaft 0534. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9. Miscellaneous tools 0536. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10. Miscellaneous tools for air cooler 0542. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11. Optional tools 0543. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. Adjustments, clearances and wear limits 061. . . . . . . . . . . . . . . . . . . . . . . . . . 6.1. Adjustments 061. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2. Clearances and wear limits (at 20C) 062. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1. Clearances and wear limits for V46 062. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Tightening torques and use of hydraulic tools 071. . . . . . . . . . . . . . . . . . . . . 7.1. Tightening torques for screws and nuts 071. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.1. Camshaft 071. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2. Cylinder head 072. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3. Crankshaft 073. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.4. Common rail equipment 074. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.5. Injection valves 076. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.6. Control oil pump 076. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.7. Engine driven lub. oil pump 077. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.8. Other tightening torques 077. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.9. General torques 078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2. Use of locking fluids 078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3. Hydraulically tightened connections 078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.1. General 078. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.2. Hydraulically tightened connections, Vengines 079. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3.3. Dismantling hydraulically tightened screw connections 0711. . . . . . . . . . . . . . . . . . . . . . 7.3.4. Reassembling hydraulically tightened screw connections 0712. . . . . . . . . . . . . . . . . . . 7.3.5. Maintenance of high pressure tool set 0712. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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7.4. Use of hydraulic extractor cylinder 0713. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5. Use of low pressure pump for lifting purposes in the crankcase 0714. . . . . . . . . . . . . . . . 7.6. Torque calculations 0715. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8. Operating problems, emergency operation 081. . . . . . . . . . . . . . . . . . . . . . . . . 8.1. Problem, possible reason 081. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2. Emergency operation 086. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1. Operation with defective air cooler(s) 086. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.2. Operation with defective turbocharger(s) 086. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.3. Operation with defective cams 087. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.4. Operation with removed piston and connecting rod 087. . . . . . . . . . . . . . . . . . . . . . . . . 8.2.5. Torsional vibrations and other vibrations 088. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. Specific installation data 091. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. Engine block with bearings, cylinder and oil sump 101. . . . . . . . . . . . . . . . 10.1. Engine block 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2. Main bearings 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.1. Maintenance of the main bearings 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.2. Dismantling of a main bearing 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.3. Inspection of main bearings and journals 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2.4. Assembling the main bearing 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3. Flywheel / thrust bearings 1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.1. Maintenance of flywheel / thrust bearings 1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.2. Dismantling of flywheel / thrust bearing 1010. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3.3. Assembling the flywheel / thrust bearing 1014. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4. Camshaft bearings 1019. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.1. Maintenance of camshaft bearings 1019. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.2. Inspection of the camshaft bearing bushing 1019. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.3. Removing the camshaft bearing bushing 1019. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4.4. Mounting of camshaft bearing bushing 1020. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5. Cylinder liner 1023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.1. Maintenance of the cylinder liner and antipolishing ring 1023. . . . . . . . . . . . . . . . . . . . . 10.5.2. Removing the cylinder liner 1023. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.3. Mounting the cylinder liner 1027. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.4. Honing of the cylinder liner bore 1029. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.5. Cleaning of the cylinder liner water side 1029. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. Crank mechanism: Crankshaft, connecting rod, piston 111. . . . . . . . . . . . 11.1. Crankshaft 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.1. Crankshaft alignment 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1.2. Measurement of thrust bearing axial clearance 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2. Connecting rod and piston 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2.1. Removing and dismantling of piston and connecting rod 115. . . . . . . . . . . . . . . . . . . . 11.2.2. Inspection and maintenance of piston rings and gudgeon pin bearing 119. . . . . . . . . 11.2.3. Assembling and mounting of piston and connecting rod 1110. . . . . . . . . . . . . . . . . . . . . 11.2.3.1. Assembly of a piston having the upper part fastened with studs 1111. . . . . . . . . . . . 11.2.3.2. Assembly of a piston having the upper part fastened with screws 1113. . . . . . . . . . . 11.2.3.3. Assembling of the piston and connecting rod 1114. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3. Big end bearing 1119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.1. Removing the big end bearing 1119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.2. Inspection of the big end bearing 1122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3.3. Mounting of the big end bearing 1123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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12. Cylinder head with valves 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.1. General 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2. Cylinder head 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2.1. General maintenance of the cylinder head 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2.2. Removing the cylinder head 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2.3. Mounting the cylinder head 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2.4. Adjusting valve clearance 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.2.5. Checking of cylinder tightness 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3. Exhaust and inlet valves 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3.1. Dismantling the valves 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3.2. Checking and reconditioning valves and seats 1211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3.3. Machine grinding 1212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.3.4. Assembling of valves 1215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4. Valve seats 1216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4.1. Removing an old seat ring 1216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4.2. Fitting a new inlet valve seat ring 1217. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.4.3. Fitting a new exhaust valve seat ring 1218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5. Valve rotator (Rotocap) 1220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.5.1. Rotocap maintenance 1220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6. Indicator valve 1221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.6.1. Indicator valve, operation and maintenance: 1221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.7. Safety valve 1222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.8. Starting valve 1222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.9. Injection valve 1222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. Camshaft driving gear 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1. General 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2. Intermediate gear and camshaft gear 131. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2.1. Intermediate gear and camshaft gear maintenance 131. . . . . . . . . . . . . . . . . . . . . . . . . 13.2.2. Removing the camshaft gearing 133. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2.3. Mounting the camshaft gearing 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3. Split gear wheel 1315. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3.1. Split gear wheel maintenance 1316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3.2. Removing the split gear wheel 1316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3.3. Mounting of the split gear wheel 1316. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.3.4. Removing only the split gear wheel 1317. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. Valve mechanism and camshaft 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1. Valve mechanism 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1.1. Maintenance of valve mechanism 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1.2. Dismantling of valve mechanism 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1.3. Inspection of valve mechanism 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.1.4. Assembling of valve mechanism 144. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2. Description of camshaft 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2.1. Maintenance of camshaft 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2.2. Removing the camshaft piece 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2.3. Mounting the camshaft piece 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.2.4. Vibration damper 1410. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. Turbocharging and air cooling 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.1. Description 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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15.2. Turbocharger 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2.1. Description (TPLturbocharger) 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.2.2. Turbocharger maintenance 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3. Water cleaning of turbine during operation 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3.1. Description 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3.2. Cleaning device for turbine and compressor 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3.3. Cleaning procedure 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4. Water cleaning of compressor during operation 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.4.1. Cleaning procedure 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5. Allowable operation with damaged turbocharger 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6. Air cooler 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6.1. Maintenance of charge air cooler 155. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.6.2. Cleaning cooler inserts 156. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7. Waste Gate valve 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7.1. Waste gate and waste gate control 1510. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.7.2. Maintenance of the Waste Gate valve 1512. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8. Charge air Bypass valve 1513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8.1. General 1513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8.2. Operation 1513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8.3. Bypass control 1513. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.8.4. Testing of the bypass system 1514. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16. Injection system 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.1. Description 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2. Fuel injection pump 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.1. General 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.2. Maintenance of fuel injection pump 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.2.1. Removing of fuel injection pump 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.2.2. Removing the fuel injection pump element 164. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.2.3. Mounting the fuel injection pump 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.2.2.4. Mounting the fuel injection pump element 166. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3. Injection line 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3.1. Description 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3.2. Maintenance of high pressure fuel pipes 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3.2.1. Preparations before any work with the high pressure pipe system 168. . . . . . . . . . 16.3.2.2. Removing the high pressure fuel pipes 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3.2.3. Checking the high pressure fuel pipes 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.3.2.4. Mounting the high pressure fuel pipes 1610. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4. Injection valves 1612. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.1. General description 1612. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.2. Maintenance of fuel injection valve 1613. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.2.1. Removing the fuel injection valve 1614. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.2.2. Changing of fuel injection nozzle 1615. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.4.2.3. Mounting of fuel injection valve 1615. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5. Testing of fuel injectors 1616. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.5.1. Checking the maximum needle lift of the nozzle 1616. . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6. Accumulator 1617. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6.1. Leakage detection 1618. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6.2. Accumulator maintenance 1619. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6.2.1. Removing the accumulator 1620. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.6.2.2. Mounting the accumulator 1621. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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16.7. Start up and safety valve (SSV) 1622. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7.1. Maintenance of the SSV 1623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7.1.1. Removing the SSV 1623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7.1.2. Dismantling and assembling the SSV 1623. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.7.1.3. Replacing the solenoid valve without removing the complete SSV 1624. . . . . . . . . . 16.7.1.4. Replacing the SSV air bottle without removing the complete SSV 1624. . . . . . . . . . 16.7.1.5. Mounting the SSV 1625. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17. Fuel system 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.1. General description 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2. Maintenance of fuel system 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2.1. Draining of fuel system 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2.2. Venting of fuel system 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2.3. Adjustment of pressure control valve 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.3. Low pressure system (preheating system) 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.4. Control oil system 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5. Control oil pump 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5.1. General description 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5.2. Maintenance of control oil pump 176. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5.3. Removing of control oil pump 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5.4. Mounting of control oil pump 178. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5.5. Replacing or checking the condition of pressure adjusting unit 178. . . . . . . . . . . . . . . 17.6. Control devices for fuel system 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.6.1. Pressure relief valve 179. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18. Lubricating oil system 181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1. Description 181. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1.1. The engine lubricating oil circuit 183. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1.2. General maintenance 187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2. Lubricating oil pressure regulating valve 187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.1. Description 187. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2.2. Maintenance 189. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3. Centrifugal filter 1810. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.3.1. Cleaning 1811. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.4. Runningin filter 1812. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5. Engine driven lubricating oil pump 1812. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5.1. Oil pump maintenance 1813. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5.2. Removing the pump from the engine 1813. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.5.3. Mounting the pump to the engine 1814. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19. Cooling water system 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1. Description 191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.1. HTcircuit 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.2. LTcircuit 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.3. Venting and pressure control 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.4. Preheating 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.5. Maintenance 194. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1.6. Cleaning 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2. Water pump 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.2.1. Water pump maintenance (WD200) 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20. Exhaust system 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1. Description 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.1.1. SPEXpiping 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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20.2. Maintenance 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2.1. Change of expansion bellows 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2.2. Assembling the expansion bellows between turbocharger and exhaust pipe 202. . . 20.2.3. Suspension of the insulation box 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2.4. Waste gate 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2.5. Charge air bypass valve 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21. Starting air system 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1. Description 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2. Main starting valve 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3. Starting air distributor 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3.1. Description 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3.2. Starting air distributor maintenance 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4. Starting valve 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4.1. Description 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4.2. Starting valve maintenance 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5. Starting air vessel and pipings 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6. Pneumatic system 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6.1. General description 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6.2. Maintenance of the pneumatic system 218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6.2.1. Check 218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.6.2.2. Maintenance 218. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.7. Waste gate control 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.8. Bypass control 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22. Control mechanism 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Instruction setTable of Contents23 Instrumentation and automation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1

23.1 WECS 2000, Control and monitoring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-323.1.1 General about WECS 2000, Control and monitoring system . . . . . . . . . . . . . . . . . . . . . 23-323.1.2 Description of the system in general, WECS 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-323.1.3 Functional descriptions, WECS 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4

23.1.3.1 Speed measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-423.1.3.2 Safety system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5

23.1.3.2.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-523.1.3.2.2 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-623.1.3.2.3 Start blockings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-623.1.3.2.4 Shut-downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-623.1.3.2.5 Shut-down backup system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-723.1.3.2.6 Load reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7

23.1.3.3 Instrumentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-823.1.3.3.1 Local Display Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-8

23.1.3.3.1.1 Meter page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-923.1.3.3.1.2 History page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1123.1.3.3.1.3 Status pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-12

23.1.3.3.2 Backup instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1323.1.3.3.3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-13

23.1.3.4 WEnCoM-functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1523.1.3.5 Modbus communication link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-17

23.1.4 Functional testing, WECS 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1823.1.4.1 Testing of overspeed trip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-18

23.1.4.1.1 Testing of the overspeed trip by running the engine . . . . . . . . . . . . . . . . . 23-1823.1.4.1.2 Testing of the overspeed trip by using a signal generator . . . . . . . . . . . . 23-19

23.1.4.2 Testing of pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2023.1.5 Hardware, WECS 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-20

23.1.5.1 External Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2023.1.5.1.1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2123.1.5.1.2 Hardwired connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-22

23.1.5.2 WECS System Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2223.1.5.2.1 WECS cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-23

23.1.5.2.1.1 WECS 2000 Main Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2423.1.5.2.1.2 Main Control Unit (MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-25

23.1.5.2.1.2.1 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2523.1.5.2.1.2.2 Mother Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2623.1.5.2.1.2.3 DC/DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2723.1.5.2.1.2.4 Processor Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2923.1.5.2.1.2.5 Memory Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3023.1.5.2.1.2.6 LAN Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3123.1.5.2.1.2.7 Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-33

23.1.5.2.1.3 Relay Module (RM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3523.1.5.2.1.3.1 Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-36

23.1.5.2.1.4 Local Display Unit (LDU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-38

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23.1.5.2.1.5 Local Control Panel and Back Up Insrtruments . . . . . . . . . . . . . . . 23-3923.1.5.2.1.5.1 Connectors for external systems . . . . . . . . . . . . . . . . . . . . . 23-40

23.1.5.2.2 Distribution Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4023.1.5.2.2.1 SMU board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4123.1.5.2.2.2 DCU Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-44

23.1.5.2.3 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4623.1.5.2.3.1 Sensors for monitoring and alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 23-46

23.1.5.3 Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4723.1.5.4 ABB TPL Turbocharger Speed Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . 23-48

23.1.6 Software, WECS 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-4923.1.6.1 Standard start/ stop sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-51

23.2 WECS 7500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5223.2.1 WECS 7500 System layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5223.2.2 WECS 7500 Structure and modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-54

23.2.2.1 Module location and wiring harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5423.2.2.2 Main controller (MCM 700) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5523.2.2.3 Rail pressure controller (CCM 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5523.2.2.4 Cylinder controller (CCM 10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5623.2.2.5 Power module (PMOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5623.2.2.6 Communication module (CMOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-58

23.2.3 Common Rail control functionality, WECS 7500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5923.2.3.1 General about the Common Rail functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6023.2.3.2 Engine in Stop mode, WECS 7500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6223.2.3.3 Engine in Start mode, WECS 7500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6223.2.3.4 Engine in run mode, WECS 7500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-63

23.2.3.4.1 Fuel injection quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6323.2.3.4.2 Fuel injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6523.2.3.4.3 Common Rail fuel pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-65

23.2.3.5 Engine in stop, shutdown and emergency stop mode . . . . . . . . . . . . . . . . . . . . . 23-6723.2.3.5.1 Engine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6723.2.3.5.2 Engine shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-6823.2.3.5.3 Engine emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-68

23.2.3.6 PWM control of injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7023.2.3.7 Speed measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-70

23.3 Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7423.3.1 Resistance versus temperature relationship for platinum resistance element Pt

100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7423.3.2 Electromotive forces of thermocouple Nickel Chromium / NickelAluminium

(NiCrNiAl) Type K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-7523.4 Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-77


Chapter Page

10

Contents, instruction, terminology 00 46 98 48

00 1001

0. Contents, instruction, terminology

0.1. Contents of the instruction book

!! " " " #

$ # % " "

& '( In all correspondenceor when ordering spare parts, be careful to state engine type and en-gine number.) * + ( " , -

0.2. General rules

. engine log book " $ / " #

& 0 "

) ( 1 " '" (

2 0

Contents, instruction, terminology00 46 98 48

00 2 002

0.3. Terminology 3

Manoeuvring side: # " , "#-

Rear side: #"

Driving end: Free end: " Designation of cylinders: 0

*4 5$ /% 22) " 61 "

0 0

3

Terminology

Designation of bearings 7 % 8 % %

9889 989

9889 ,- 989

3 9889 989

: 3 9:+9


00 3003

Designation of bearings

Manoeuvring side and rear side. / " 979 99

,1 61-

Clockwise rotating engine. "#

Counterclockwise rotating engine.

" 1

Bottom dead centre, " BDC

Top dead centre, " TDC #

/ "

Top dead centre at firing: / " 1 # / 3

- ; ( "

'(

"" "" "

/ ( "" " #

TDC atscavenging.- # * /


00 4 004

- / TDC at fir-ing. "" "

; " 1 , #- " ?8 #

61 TDC at firing 0 / &) ; " 61 " ?8 #


00 5005

Example of reading the flywheel


00 6 006

W46 02 16 A Risk Reduction 00A

00A-1

00A Risk Reduction


00A-2

This page is intentionally left blank.


00A-3

00A.1 General

Read the engine manual including this appendix before installing, operating orservicing the engine and/or related equipment.

Failure to follow the instructions can cause personal injury, loss of life and/orproperty damage.

Proper personal safety equipment include proper work clothing, e.g. overalls, gloves,hard hat, safety glasses and ear protection must be used in all circumstances.Missing, imperfect or defective safety equipment might cause serious personal injuryor loss of life.

This appendix contains listed general identified hazards, hazardous situations orevents, which are to be noticed during normal operation and maintenance work.


00A-4

00A.2 Identified hazard, hazardous situation or event

Identified hazard, hazardoussituation or event

Chapter of engine manual3 4 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Dropping parts during maintenancework

X X X X X X X X X X X X X X X

Turning device engaged duringmaintenance work 1)

X X X X X X X X

Crankcase safety expl. valves willopen if crank-case explosion

X X X

Noise level X X X X X X X X X X X X X X v XRunning engine without covers X X X X X X X X X XIn case of major failure, risk ofejected parts

X X X X X X X X

Contact with electricity duringmaintenance work if power notdisconnected

X X X X X X X

Electrical hazard if grounding ofelectrical equipment is incorrect

X X X X X

Ejection of components / highpressure gas due to high firingpressures

X X X X X X X

Risk of ejected parts due to breakdown of turbo-charger

X X

Overspeed or explosion due toair-gas mixture in the charge air 2)

X X X

Ejection of fuel injector if notfastened and turning deviceengaged

X X X

Fire or explosion due to leakage onfuel / gas line or lube oil system

X X X X X X

Inhalation of exhaust gases due toleakage 3)

X X X

Inhalation of exhaust gas dust X X X X X X XExplosion or fire if flammable gasor vapor is leaking into theinsulation box. 4)

X X

Touching of moving parts X X X X X X X X X X X X X X X

1) Warning light when turning device engaged.2) Suction air to be taken from gas free space.3) Require proper ventilation of engine room and plant.4) Require proper ventilation and/or gas detector in the engine space and the engineroom.


00A-5

00A.3 General identified hazards, hazardous situations orevents

00A.3.1 Hazards that may be due to moving parts

Running engine without covers, coming in contact with moving parts

Touching pump parts during unintentional start of el. driven pump motor

Charger starts to rotate due to draft if not locked during mainteance

Somebody sticks his hand into the compressor housing when the silencer isremoved and engine running

Unexpected movement of valve or fuel rack(s) due to broken wire or soft /hardware failure in the control system

Unexpected movement of components

Turning device engaged during maintenance work

Turning device not engaged e.g. Turning device removed for overhaul, duringmaintenance work could cause rotating crankshaft

Mechanical breakage (of e.g. speed sensor) due to erratic actuator assembly toengine or electrical connections

00A.3.2 Hazards that may be due to incorrect operating conditions

Overspeed or explosion due to air-gas mixture in the charge air

Overspeeding due to air-oil mist mixture in the charge air

Malfunction of crankcase ventilation

Oil mist detector will trip if water is present in lubricating oil

Crankcase explosion if oil mist is mixed with fresh air during inspection after anoil mist shut down

Crankcase safety explosion valves will open if there is a crankcase explosion

00A.3.3 Hazards that may be due to leakage, break-down or improperassembly of components

Fuel or gas pipe will burst and spray fuel / gas

Leakage of:

Fuel in joints on low and/or high pressure side

Lube oil

High pressure water on DWI engines

HT water


00A-6

Charge air

Exhaust gas

Pressurized air from air container, main manifold or pipes

High pressure gas and sealing oil on GD engines

Fire or explosion due to leakage on fuel line

Fire due to oil, fuel or gas leakage

Explosion or fire if flammable gas or vapor is leaking into the insulation 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 turbocharger

High firing pressures

Major failure

Ejection of:

Pressurized liquids and gases from the block and pipings

High pressure fluid due to breakdown of hydraulic tool

Gas due to high firing pressures

Pressurized gases from high pressure gas system

High pressure fluid due to breakdown of HP sealing oil pipe

High pressure air during maintenance of oil mist detector main air supplypiping

Cooling water, fuel or lube oil if sensor is loosened while the circuit ispressurized

Springs during maintenance work

Oil spray if running without covers

Ejection of fuel injector if not fastened and turning device en gaged

00A.3.4 Hazards that may be due to electricity or incorrectconnections within electrical components

Fire or sparks due to damage or short circuit in electrical equipment

Contact with electricity during maintenance work if power not disconnected

Electrical hazard if grounding of electrical equipment is incorrect


00A-7

Electrical shock if electrical equipment has a lead isolation break or connectordamage or is dismantled with power connected

Overheating of control system component due to erratic electrical connections

Incorrectly wired or disconnected emergency stop switch

Overload of control system components due to damaged control circuitry orincorrect voltage

Engine not controllable if failure in the shutdown circuitry

Unexpected start up or overrun

Crankcase explosion if:

Engine not safeguarded at high oil mist levels, due to energy supply failure

Engine not (fully) safeguarded at high oil mist levels, due to failure in oilmist detector circuitry

Engine not (fully) safeguarded at high oil mist levels, due to erratic electricalconnector or leakage in pipe connection

00A.3.5 Other hazards and hazardous situations where itsespecially important to use personal safety equipment

Slip, trip and fall, Incorrect lifting methods

Water additives and treatment products (see 02A. Environmental Hazards)

Touching the insulation box, turbo-charger, pipes, exhaust manifold or (other)unprotected parts without protection during engine operation

Dropping parts during maintenance work

Starting maintenance work too early i.e. causing risk when handling hotcomponents

Neglecting use of cranes and/or lifting tools

Not using proper tools during e.g. maintenance work

Contact with fuel oil or oily parts during maintenance work (see appendix 02A)

Noise level

Touching or removing Turbocharger insulation

Preloaded fixation springs during check / replacement of sensor


00A-8


W46 02 17 B Welding Precautions 00B

00B-1

00B Welding Precautions


00B-2



00B-3

00B.1 Precautions General

Main principles: Prevent uncontrolled current loops

Prevent radiation

Prevent sparks and hot metal slag hazards

CAUTION! If convenient, disconnect all global signals like power supply, datacommunication etc.


00B-4

00B.2 Preventing uncontrolled current loopsWelding current path must always be checked, there should be a direct route fromthe welding point to the return connection of the welding apparatus.

The highest current is always following the path of lowest resistance. In certain casesthe return current can therefore proceed via grounding wires and electroniccomponents in the control system.

To avoid this, the distance between the welding point and the return connectionclamp of the welding apparatus should always be shortest possible and withoutelectronic components in the returning loop path.

Attention must be paid to the security of the return connection clamp, a bad contactmay also cause sparks and radiation.


00B-5

00B.3 Preventing Radiation

The welding current and the arc emits a wide spectrum of electromagnetic radiation.This may cause damages to sensitive electronic equipment.

To avoid this damage, all cabinets and terminal boxes must be kept closed duringwelding procedures. Sensitive equipment can also be protected by means ofshielding with a conductive metal plate.

Also avoid having the cables of the welding apparatus laying in parallel with wiresand cables of the control system. The high welding current is easily inductingsecondary currents in other conductive materials.


00B-6

00B.4 Preventing damage due to sparks

Sparks are commonly projected around from the welding arc. Few materialswithstand the heat from these sparks. Therefore all cabinets and terminal boxesshould be kept closed during welding procedures.

Sensors, actuators, cables and other equipment out on the engine must be protectedby means of proper protection.

Sparks can also be a problem after they have cooled down, i.e. causing short circuits,sealing problems etc.


00B-7

00B.5 Precaution checklists

00B.5.1 Checklists General

The checklists (preferable glued to a plastic plate) in this chapter should be put intothe engines cabinet for respective system type. The checklist must be easily visibleand accessible when opening the cabinet.

00B.5.2 Basic ECU (Despemes/Spemos) checklist

The following precautions must be paid attention to before welding in the vicinity ofa basic ECU system:

Close the cover of the cabinet

Deactive the system by disconnecting all external connectors (X1...X4)

If convenient, protect cables, sensors and other equipment from sparks with aproper metal sheet

00B.5.3 WECS 2000 checklist

The following precautions must be followed before welding in the vicinity of aWECS 2000 control system:

Close the covers of the cabinet and all the distributed units

Deactivate the system by disconnecting all external connectors (X1...X6)

If convenient, protect cables, sensors and other equipment from sparks with aproper metal sheet

00B.5.4 WECS 3000 checklist

The following precautions must be followed before welding in the vicinity of aWECS 3000 control system:


Do not connect the welding apparatus return line to the aluminium profilecontaining CCUs, KDUs and ignition modules

The profile is used as a common ground for these modules.

Open all terminal fuses (F1...F20) in the cabinet

Close the covers of the cabinet and all the distributed units

If convenient, protect cables, sensors and other equipment from sparks withproper metal sheet


00B-8

00B.5.5 WECS 7000/8000 checklist

The following precautions must be followed before welding in the vicinity of aWECS 7000 or 8000 control system:


If the welding point is close to (approximately within a radius of 2 m) anelectronic module (SSM-701, SSM-558, CCD/PDM, Cense etc.) disconnect allconnectors of the unit

Close the covers of the cabinet

Disconnect the interconnections between the harnesses and the cabinet

If convenient, protect harnesses, cables, sensors and other equipment fromsparks with a proper metal sheet

Main data, operating data and general design 01 46 02 30

01 1011

1. Main data, operating data and general de-sign

1.1. Main data for WRTSIL 46Cylinder bore 460 mmStroke 580 mmPiston displacement per cylinder 96.4 l

Firing orderEngine type Clockwise rotation Counterclockwise rotation4L46 1342 12436L46 153624 1426358L46 13258674 147685239L46 124689753 13579864212V46 A1B1A5B5A3B3A6B6A2

B2A4B4A1B4A4B2A2B6A6B3A3B5A5B1

16V46 A1B1A3B3A2B2A5B5A8B8A6B6A7B7A4B4

A1B4A4B7A7B6A6B8A8B5A5B2A2B3A3B1

18V46 A1B8A7B6A4B3A2B9A8B5A6B1A3B7A9B4A5B2

A1B2A5B4A9B7A3B1A6B5A8B9A2B3A4B6A7B8

Main data, operating data and general design01 46 02 30

01 2 012

1.2. Recommended operating dataApply to normal operation at nominal speed.

Normal values Limits Alarm Stop

Temperatures,CLub. oil before engine 6065 70 80 (xx)Lub. oil differential high, after engine 1013HT water after engine 8595 105 110HT water differential low, before engine 515HT water, rise over turbocharger(only VTR and Napierchargers)

812

LT water before engine 2838Charge air in air receiver 4060 75Exhaust gas after cylinder See test records 490 550 (xx)Preheating of HT water 70

Gauge pressures (bar)Lub. oil before engine 4,0 3,0 2,0Lub. oil before turbocharger: VTR

TPLNapier

0,51,51,252,252,33,3

0,41,02,1

HT water before engine 3,04,5 (x) 2.0LT water before charge air cooler 3,04,5 (x) 2.0Fuel before engine 910 4,0Starting air max. 30 18Charge air See test records

Other pressures (bar)Fuel in common rail See test recordsControl oil 250 225

(x) Depending on engine speed and installation.(xx) Load reduction

1.3. Reference conditionsReference conditions according to ISO 3046/I:Air pressure 100 kPa (1.0 bar)Ambient temperature 298 K (25C)Relative air humidity 30 %Cooling water temperature before charge air cooler 298 K (25C)Should the engine be designated to operate outside of the above stated conditions,the output will be as per the sales contract. The engine manufacturer can give ad-

Main data, operating data and general design 01 46 02 30

01 3013

vice about the correct output reduction. As a guideline, the derating calculationis as follows:

(a + b + c) x Rated Outputa = 0.5 % for every C the ambient temperature exceeds stated value in the salesdocuments.b = 1 % for every 100 m level difference above stated value in the sales docu-ments.

c = 0.4 % for every C the cooling water of the charge air cooler exceeds statedvalue in the sales documents.

1.4. General engine designThe engine is a turbocharged intercooled 4stroke diesel engine with direct fuelinjection.The engine block is cast in one piece. The main bearings are underslung. Themain bearing cap is supported by two hydraulically tensioned main bearingscrews and two horizontal side screws. The cooling water header is cast into theengine block. The crankcase covers, made of light weight metal, are sealedagainst the engine block by means of rubber seals. The lubricating oil sump iswelded.The cylinder liners are designed with high collars and drilled cooling holes. Thecooling effect is optimized to maintain the correct temperature on the inner sur-face.The main bearings are 3metal bearings and can be removed by lowering themain bearing cap. A hydraulic jack is provided for every main bearing to lowerand lift the main bearing cap.The crankshaft is forged in one piece and balanced by counterweights as re-quired.The connecting rods are drop forged. The design is a three piece marine design.The small end bearing is stepped to achieve large bearing surfaces. The big endbearings are 3metal bearings.The piston upper part ring grooves are hardened. Cooling oil enters the coolingspace through the connecting rod. The cooling spaces are designed to give an op-timal shaker effect. Part of the oil going to the cooling space is led to piston skirtlubrication through nozzles situated in the piston.The piston ring set consists of two chromeplated compression rings and onechrome plated, springloaded oil scraper ring.The cylinder head, made of special cast iron, is fixed by four hydraulically ten-sioned screws. The head is of the double deck design and cooling water is forcedfrom the periphery towards the centre thereby ensuring efficient cooling to theimportant areas.The inlet valves are stellite plated and the stems are chromium plated. The valveseat rings are made of a special cast iron alloy and are changeable.The exhaust valves seal against the directly cooled valve seat rings. The valvesare made of Nimonic in engines using HFO as fuel or they have Stellite seats andchromiumplated stems in case of using MDO.

Main data, operating data and general design01 46 02 30

01 4 014

The seat rings, made of a corrosion and pitting resistant material, are replace-able.The camshafts are made up from onecylinder sections with integrated cams.The bearing journals are separate pieces and thus it is possible to remove a cam-shaft piece sideways.The injection pumps have separated roller followers. The pumps and pipings arelocated in a closed space, so called hot box, for heavy fuel operation.The charge air coolers are equipped with removable inserts.The internal lubricating oil system is provided with a welded oil sump, lubri-cating oil connections and a centrifugal type filter.The starting system: The air supply to the cylinders is controlled by the startingair distributor which in turn is operated by the camshaft.

Fuel, lubricating oil, cooling water 02 46 02 22

02 1021

2. Fuel, lubricating oil, cooling water

2.1. Fuel

2.1.1. Fuel, generalThe engine is designed to operate on heavy fuel (residual fuel) with a maximumviscosity of 55cSt at 100C (approx. 730cSt at 50C, approx. 7200 Redwood No.1 seconds at 100F) and will operate satisfactorily on blended (intermediate)fuels of lower viscosity as well as on distillate fuel. Avoid the use of fuels havinga lower viscosity than 2.8 cSt at engine inlet as such fuels may cause fuel injectionpump plunger or fuel nozzle needle seizure.The maximum limits of fuel characteristics for a certain engine are stated in thedocumentation delivered with the engine.Blended fuels (residuals and distillate) with a viscosity between approx. 4 and7cSt at 100C (12 and 30cSt at 50C, 75 and 200 Redwood No. 1 seconds at100F) containing between 30 and 60% distillate should, however, be avoideddue to the risk of precipitation of heavy components in the blend, with filter clog-ging and large amount of centrifuge sludge as a consequence.When difficulties with filter clogging are experienced, fuel incompatibility canbe tested by the ASTM D474093 or the ISO 103072/83 test method.

2.1.2. Fuel treatment2.1.2.1. PurificationHeavy fuel (residuals, and mixtures of residuals and distillate) must be purifiedin an efficient centrifuge before entering the day tank. The fuel is to be heatedbefore centrifuging.Recommended temperatures, depending on the fuel viscosity, are stated in thediagram. (Fig. 2.1.)Be sure that the correct gravity disc is used. Never exceed the flow rates recom-mended for the centrifuge for the grade of fuel in use. The lower the flow rate thebetter the efficiency.

Recommended centrifuge flow rateFuel in use

Max. viscosity (cSt at 100C) 10 15 25 35 45 55Approx. viscosity (cSt at 50C) 50 90 205 350 530 730Centrifuge flow rate (% of rated capacity)

60 40 30 25 20 15

Recommended centrifuge flow rates, see separator manufacturers in-struction manual.

NOTE !

Fuel, lubricating oil, cooling water02 46 02 22

02 2 022

In case pure distillate fuel is used, centrifuging is still recommended as fuel maybe contaminated in the storage tanks.Rated capacity of the centrifuge may be used provided the fuel viscosity is lessthan 12 cSt at centrifuging temperature.Marine Gas Oil viscosity is normally less than 12cSt at 15C.

2.1.2.2. HeatingSee diagram, Fig.2.1. Keep the fuel temperature about 10C above the minimumstorage temperature indicated in the diagram in order to minimize the risk for waxformation, and the temperature after the final heater 5 to 10C above the recom-mended temperature before injection pumps to compensate for heat losses be-tween heater and engine.


02 3023

Fuel oil viscositytemperature diagram

oC10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

3

4

56789

1012141620253040506080

100

200300400600

10002000

5000

Centistokes

F

D

E

CK

BG

H

A

14 cSt at 40oC

GAS OILMARINE DIESEL OIL

11 cSt at 40oC

5.5 cSt at 40oC

APPROX. PUMPING LIMIT

VISCOSITY BEFORE

80 cSt at 50oC180 cSt at 50oC

380 cSt at 50oC

700 cSt at 50oC

40 cSt at 50oC

FUEL PUMPS

CENTRIFUGINGTEMPERATURE

TEMPERATUREMINIMUM STORAGE

MAX. TEMP

RECOMMENDED

460252

Fig. 2.1. Example: A fuel oil with a viscosity of 380 cSt (A) at 50C (B) or 80C at 80C(C) must be preheated to 115140C (DE) before the fuel injection pumps, to98C (F) at the centrifuge and to minimum 40C (G) in storage tanks. The fueloil may not be pumpable below 36C (H).To obtain temperatures for intermediate viscosities, draw a line from the knownviscosity/temperature point in parallel to the nearest viscosity/temperature linein diagram.

Example: Known viscosity 60 cSt at 50C (K). The following can be read alongthe dotted line: viscosity at 80C = 20 cSt, temperature at fuel injection pumps7497C, centrifuging temperature 86C, minimum storage tank temperature28C.

Conversion from various current and obsolete viscosity units to centistokes canbe made in the diagram, Fig. 2.2. The diagram should be used only for conversionof viscosities at the same temperature. The same temperatures should then beused when entering the viscosity/temperature point into the diagram (See Fig.2.1.)


02 4 024

Viscosity conversion diagram

Centistokes

3

456789

1012141620253040506080

100

200300400600

10002000

5000

10 20 50 100 200 500 1000 2000 5000 10000Sec. Saybolt Furol1 2 5 10 20 50 100 200 500 1000oEngler10 20 50 100 200 500 1000 2000 5000 10000Sec.Redwood I10 20 50 100 200 500 1000 2000 5000 10000Sec. Saybolt Universal 460253

Fig. 2.2.

When converting viscosities from one of the units on the abscissa to centistokesor viceversa, keep in mind that the result obtained is valid only at one and thesame temperature. When converting the viscosity in any unit at a given tempera-ture to a viscosity at another temperature a viscositytemperature diagram orconversion rule must be used.

2.1.2.3. Viscosity controlAn automatic viscosity controller, or a viscosimeter, at least, should be installedin order to keep the correct viscosity of the fuel before the fuel enters the enginefuel system.

2.1.3. Maximum limits of fuel characteristicsThe WRTSIL 46 diesel engine is designed and developed for continuous op-eration, without reduction in the rated output, on fuels with the following proper-ties:


02 5025

Fuel characteristics, maximum limitsKinematic viscosity cSt at 100C

cSt at 50CRedwood No. 1 sec. at 100F

557307200

Kinematic viscosity, min. cSt at engine inlet 2.8Density kg/m3 at 15oC 0.991Density kg/m3 at 15oC 1.010 1)

Water % volume 1.0Water, before engine % volume 0.3Flash point, min. (PMCC) C 60Pour point C 30Total Sediment Potential % mass 0.10

The limits above also correspond to the demands of: ISO 8217: 1996(E), ISOFRMH 55 and RMK 55 BS MA 100: 1996, RMH 55 and RMK 55 CIMAC 1990, H 55 and K 551)

Provided the fuel treatment system can remove water and solids.

Four types of fuels are defined for the WRTSIL 46 engine: HFO 1, heavy fuel oil of normal quality HFO 2, heavy fuel oil below normal standard quality DO, diesel oil or LFO, light fuel oil NG, natural gasThe maintenance intervals are decided by the characteristics of the used fuel, seechapter 4. Maintenance Schedule.

The differences between HFO 1 and HFO 2 are seen below:

Fuel characteristics, maximum limitsHFO 1 HFO 2

Sulphur % mass 2.0 2.05.0Ash % mass 0.05 0.050.20Vanadium mg/kg 100 100600Sodium mg/kg 50 50100Sodium, before engine mg/kg 30 30Aluminium + Silicon mg/kg 30 3080Aluminium + Silicon before engine mg/kg 15 15Conradson carbon residue % mass 15 1522Asphaltenes % mass 8 814CCAI 850 850870


02 6 026

Foreign substances or chemical waste, hazardous to the safety of the installationor detrimental to the performance of the engines, should not be contained in thefuel.

If any of specified fuel properties exceed the maximum value of HFO 1,the fuel should be classified as HFO 2.

2.1.4. Comments on fuel characteristicsa) The viscosity is not a measure of the fuel quality, but determines the complexity

of the fuel heating and handling system, as a heavy fuel oil has to be heated toreach a viscosity of 1624cSt at the point of injection. At low viscosities, the flowpast the plunger in the injection pump increases. This leads to a decrease in theamount of injected fuel, which in bad cases might make it impossible to reach fullengine output.The standard engine fuel system is laid out for max. 55cSt at 100C fuel (approx.730cSt at 50C, approx. 7200 Redwood No.1 seconds at 100F).

b) The density influences mainly on the fuel separation. Separators can remove wa-ter and to some extent solid particles from fuels having densities up to 991kg/m3at 15C. There are also separators on the market that can clean fuels with densitiesof up to 1010kg/m3 at 15C. The separator capability must be checked before pur-chasing a fuel with a very high density, as a bad separation will lead to abnormalwear due to unremoved particles and water. The separator disc must be chosenaccording to the fuel density.

Fuels having a low viscosity in combination with a high densityusually have bad ignition properties.

c) Ignition quality. Heavy fuels may have very low ignition quality. This may causetrouble at start and low load operation, particularly if the engine is not sufficientlypreheated. Low ignition quality may also result in a long ignition delay and cancause a fast pressure rise and very high maximum pressures. This increases themechanical load and can even damage engine components such as e.g. pistonrings and bearings severely. Deposits on the piston top, on the exhaust valves, inthe exhaust system, on the turbine nozzle ring and turbine blades can also be ex-pected. The turbocharger fouling will lead to decreased turbocharger efficiency,and increased thermal load.A symptom of low ignition quality is Diesel knock, i.e. hard, high pitched com-bustion noise. The effects of diesel knock are increased mechanical load on com-ponents surrounding the combustion space, increased thermal load, increased lu-bricating oil consumption and contamination.

Although low ignition quality produces long ignition delay, ad-vancing the injection timing makes things only worse; fuel is in-jected at a lower compression temperature and this will producean even longer ignition delay!

NOTE !

CAUTION !

CAUTION !


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Ignition quality is not defined, nor limited, in marine residual fuel standards. Thesame applies to ISOFDMC marine distillate fuel.The ignition quality of a distillate fuel can be determined by several methods, i.e.Diesel Index, Cetane Index, Cetane Number.The ignition quality of a heavy fuel oil can be roughly determined by calculatingthe Calculated Carbon Aromaticity Index (CCAI) from the viscosity and densityof a fuel.

Determining of CCAI (Calculated Carbon Aromaticity Index):CCAI = 81141log10log10(k+0.85)where = density (kg/m3 at 15C)

k = kinematic viscosity (cSt at 50C)

An increased CCAI value indicates decreased ignition quality.

CCAI can also be determined (but with limited accuracy) by th

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Instruction Manual WARTSILLA