6W26.pdf

26

Installation IHC CO1243

Engine type W26

Engine number 26896, 26897, 26898

This manual is intended for the personal use of engine operators andshould always be at their disposal. The content of this manual shall neither be copied nor communicated to a third person.

For Inte

rnal

Use O

nly

Copyright by Wärtsilä Corporation

All rights reserved. No part of this publication may be reproduced or copied in any form orby any means (electronic, mechanical, graphic, photocopying, recording, taping or otherinformation retrieval systems) without the prior written permission of the copyright owner.

THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVEINFORMATION WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THETIME OF PRINTING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICALMATTERS SUITED ONLY FOR SPECIALISTS IN THE AREA, AND THE DESIGN OF THE SUBJECT-PRODUCT IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES.CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CAN NOTACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS INTHIS PUBLICATION OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUALITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THISPUBLICATION. THE PUBLISHER AND COPYRIGHT HOLDER SHALL UNDER NO CIRCUMSTANCESBE HELD LIABLE FOR ANY FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANYOTHER DAMAGE OR INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION ORTHE INFORMATION CONTAINED HEREIN.

For Inte

rnal

Use O

nly

Wärtsilä Italia S.p.A. Service

Bagnoli della Rosandra, 334 34018 S. Dorligo della Valle Trieste, Italy

Telephone: +39 040 319 5000 Telefax: +39 040 319 5647 Telex: 460274/5 GMI

The Wärtsilä Engine Documentation GeneralThe Engine documentation has been split up in five binders:

- Instruction Manual - Spare Parts Catalogue - Service Bulletins - Record Book of engine Parameters- Sub-suppliers Manual

The users of the documentation are assumed to be trained operating and maintenance personnel, with an understanding of the construction and use of the engine.

ContentsThe content of the binders is as follows:

Instruction Manual ¶ General Description of the engine ¶ Description of main engine parts ¶ Main Data ¶ Description of the various gas-, fluid- and control systems¶ Operation directives ¶ Maintenance schedule, -tools and -instructions

Spare Parts Catalogue¶ Spare Parts Catalogue (of the engine)

Service Bulletins ¶ Division with separate tabs for filing standard forms and all commercial and technical, product

related after sales documents which are mailed customer specific.

Record Book of Engine Parameters ¶ Engine Test protocol ¶ Statement of Compliance EIAPP – Technical file ¶ Record forms ¶ General Installation documents

Sub-suppliers Manual ¶ Documentation as received from Sub-suppliers if not incorporated in another way in the engine

documentation.

For Inte

rnal

Use O

nly

Contact Informations WÄRTSILÄ

i

Service Department

Wärtsilä Italia S.p.A., Business Unit ServiceBagnoli della Rosandra, 33434018 San Dorligo della ValleTrieste − ITALY

24h Phone

Nights and weekends, please call mobile phone for service engineer or spare parts

+39 335 784 1217

DIRECT DIAL NUMBERS

SALES SUPPORT TECHNICAL SERVICE

Fax: +39 040 319 5216 Fax: +39 040 319 5767

North, Central and East Europe

Phone: +39 040 319 5071

Wärtsilä 64 engines

Phone: +39 040 319 5080

Americas

Phone: +39 040 319 5072

Wärtsilä 38B engines

Phone: +39 040 319 5081

Middle East and South Asia

Phone: +39 040 319 5073

Wärtsilä 26 engines

Phone: +39 040 319 5082

Southern Europe and Africa

Phone: +39 040 319 5074

Sulzer Z engines

Phone: +39 040 319 5083

Italy

Phone: +39 040 319 5075

GMT engines

Phone: +39 040 319 5084

For Inte

rnal

Use O

nly

Contact InformationsWÄRTSILÄ

ii

ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏ



ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏ

ÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Ï

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏ

ÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏ

Ï

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

Ï

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏ

ÏÏ

ÏÏÏÏÏÏÏ Ï

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏ

ÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏÏÏÏÏ


ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏ

ÏÏÏ

ÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏ

ÏÏÏ

Ï

ÏÏ

Ï

ÏÏ

ÏÏ

ÏÏÏÏÏ


ÏÏÏ ÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏ

ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏ

ÏÏÏÏÏÏ

ÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏ

ÏÏÏÏÏÏÏÏÏÏ ÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏÏ

ÏÏÏÏ


The list of Wärtsilä Network companies is available atwww.wartsila.com web site.

For Inte

rnal

Use O

nly

TABLE OF CONTENTS ManualWärtsilä 26

xx– 1

0.0. General 0.0 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0.1. Introduction 0.0 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0.2. Terminology 0.0 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0. Main Data 1.0 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.1. Basic information 1.0 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.2. Output 1.0 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.3. Derating conditions 1.0 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.4. Operating Data 1.0 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1. Fuel System 1.1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1. General 1.1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1.1. HFO engines running on distillatefuels 1.1 – 3

1.1.2. Fuel 1.1 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.1. Residual fuel oil quality 1.1 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.2. Crude oil quality 1.1 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.3. Distillate fuel oil quality 1.1 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.4. Fuel oil quality before engine 1.1 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.5. Fuel conditioning 1.1 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.6. Avoiding difficulties during operation

on HFO 1.1 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.7. Comments on fuel characteristics 1.1 – 15. . . . . . . . . . . . . . . . . . . . . . .

1.1.3. Internal fuel system 1.1 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.4. Draining of fuel system 1.1 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2. Lubricating Oil System 1.2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1. Lubricants 1.2 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1.1. Requirements 1.2 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1.2. Influences on the lubricating oil

condition 1.2 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1.3. Testing of main lubricating oil 1.2 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1.4. Condemning limits main lubricating oil 1.2 – 7. . . . . . . . . . . . . . . . . . . 1.2.1.5. Comments on lubricating oil

characteristics 1.2 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1.6. Recommendations for refreshing

lubricating oil 1.2 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2. Internal lubricating oil system 1.2 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2.1. Oil flow through engine 1.2 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3. Components of internal system 1.2 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.3.1. Lubricating oil pump 1.2 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.2. Lubricating oil module 1.2 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.3. Centrifugal filter 1.2 – 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.4. Lubricating oil sampling valve 1.2 – 43. . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.4. Crankcase breathing system 1.2 – 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3. Starting Air System 1.3 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1. General 1.3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2. Start stop system 1.3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3. Compressed air starter motor 1.3 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3.1. General 1.3 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3.2. Description of compressed air starter

motor 1.3 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly

TABLE OF CONTENTSManualWärtsilä 26

xx– 2

1.3.4. Operating instructions 1.3 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.4.1. Commissioning and operation 1.3 – 10. . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.5. Maintenance 1.3 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.5.1. Complete overhaul 1.3 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.5.2. Storage 1.3 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.6. Trouble shooting 1.3 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4. Cooling Water System 1.4 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1. General 1.4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2. Cooling water 1.4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.2.1. General 1.4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2.2. Requirements 1.4 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2.3. Qualities of cooling water additives 1.4 – 4. . . . . . . . . . . . . . . . . . . . . . 1.4.2.4. Cooling water control 1.4 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.3. Internal cooling water system 1.4 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.3.1. General 1.4 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.3.2. Description HT cooling water system 1.4 – 7. . . . . . . . . . . . . . . . . . . . 1.4.3.3. Description LT cooling water system 1.4 – 11. . . . . . . . . . . . . . . . . . . . . 1.4.3.4. Cooling water pump 1.4 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.3.5. Flexible pipe connections 1.4 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.4. Maintenance cooling water system 1.4 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.4.1. General 1.4 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.4.2. Cleaning 1.4 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.4.3. Cooling water venting 1.4 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5. Charge Air and Exhaust Gas System 1.5 – 1. . . . . . . . . . . . . . . . . . . . . . . 1.5.1. General 1.5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.2. Quality of suction air filtration 1.5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.3. Internal system 1.5 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4. Charge air system 1.5 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.4.1. General 1.5 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4.2. Charge air cooler 1.5 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4.3. Condensate draining 1.5 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4.4. Maintenance 1.5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.5. Exhaust gas system 1.5 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.1. Exhaust gas manifold 1.5 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.2. Multiduct 1.5 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.3. Compensators 1.5 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.4. Insulation box 1.5 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.5. Maintenance 1.5 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.6. Operations 1.5 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.6. Turbocharger 1.5 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.1. Maintenance 1.5 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.2. Turbocharger cleaning devices 1.5 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.3. Compressor side cleaning 1.5 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.4. Turbine side cleaning 1.5 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6. Control System 1.6 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.1. General 1.6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2. Speed control system 1.6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2.1. Actuator 1.6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2.2. Booster 1.6 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 3

1.6.3. Fuel control mechanism 1.6 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.1. Load indication HP fuel pump 1.6 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.2. Checking linkage between actuator

and common fuel control shaft 1.6 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.3. Checking linkage between fuel rack

and common fuel control shaft 1.6 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.4. Stop mechanism 1.6 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.5. Checking actuator stop position 1.6 – 10. . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.6. Removing the actuator 1.6 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3.7. Mounting of the actuator 1.6 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.4. Governing system maintenance and trouble shooting 1.6 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7. Automation System 1.7– 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.1. General 1.7– 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2. Functional description 1.7– 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.2.1. General 1.7– 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2.2. Speed measuring 1.7– 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2.3. Safety system 1.7– 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.2.4. Monitoring and alarm sensors 1.7– 6. . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.3. Data acquisition 1.7– 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.4. WEnCoM–functions 1.7– 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.4.1. Background 1.7– 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.4.2. Main bearings 1.7– 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.4.3. Exhaust gas valves 1.7– 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.5. Instrumentation 1.7– 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.5.1. Local Display Unit 1.7– 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.5.2. Backup instruments 1.7– 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.5.3. Controls 1.7– 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.6. Functional testing 1.7– 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.6.1. Testing of overspeed trip 1.7– 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.7. Hardware 1.7– 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7.1. General 1.7– 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7.2. Main Control Unit 1.7– 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7.3. Distribution Unit 1.7– 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7.4. Sensors 1.7– 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7.5. Solenoid valves 1.7– 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.7.6. Relay Module 1.7– 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.8. Software 1.7– 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.8.1. VRX Operating system shell 1.7– 39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.7.9. Maintenance of electrical contacts 1.7– 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7.10. List of abbreviations 1.7– 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3. Operation 2.3 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1. General 2.3 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2. Start 2.3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2.1. Preheating 2.3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.2. Preparations before the start 2.3 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.3. Local start 2.3 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.4. Remote or automatic start 2.3 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.5. Start after a normal stop 2.3 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.6. Start after overhaul 2.3 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.7. Emergency start 2.3 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 4

2.3.3. Operation 2.3 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.1. Restrictions 2.3 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.2. Loading performance 2.3 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.3. Maintenance points during operations 2.3 – 14. . . . . . . . . . . . . . . . . . . . 2.3.3.4. Operating range 2.3 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.5. Measurement of cylinder pressure 2.3 – 17. . . . . . . . . . . . . . . . . . . . . . . 2.3.3.6. Running–in 2.3 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.7. Operating problems 2.3 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.8. Emergency operation 2.3 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4. Engine stop 2.3 – 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4. Maintenance 2.4 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1. Maintenance Schedule 2.4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1.1. Safety aspects and rules for inspectionand maintenance 2.4 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1.2. Maintenance schedule 2.4 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2. Maintenance Tools 2.4 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2.1. Miscellaneous tools 2.4 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.2. Fuel system 2.4 – 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.3. Lubricating oil system 2.4 – 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.4. Exhaust gas and charge air system 2.4 – 32. . . . . . . . . . . . . . . . . . . . . 2.4.2.5. Engine block with main bearings 2.4 – 33. . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.6. Crankshaft, connecting rod, piston

and liner 2.4 – 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.7. Cylinder head with valves 2.4 – 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.8. Camshaft and valve drive mechanism 2.4 – 58. . . . . . . . . . . . . . . . . . . 2.4.2.9. Injection system 2.4 – 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3. Background information of hydraulictools and torque spanners 2.4 – 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.1. Pneumatic driven hydraulic pump unit 2.4 – 72. . . . . . . . . . . . . . . . . . . 2.4.3.2. Hydraulic jack 2.4 – 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.3. Hydraulic extractor 2.4 – 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.4. H.P. hose 2.4 – 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.5. H.P. quick–release coupling 2.4 – 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.6. Hand–operated hydraulic pump 2.4 – 80. . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.7. Safety instructions for hydraulic tools 2.4 – 81. . . . . . . . . . . . . . . . . . . . 2.4.3.8. Loosening of hydraulically

tightened connection 2.4 – 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.9. Tightening of hydraulically

tightened connection 2.4 – 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.10. Use of torque spanner 2.4 – 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.4. Tightening torque and jack pressure 2.4 – 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.1. Lubricating oil system components 2.4 – 89. . . . . . . . . . . . . . . . . . . . . . 2.4.4.2. Cooling water system components 2.4 – 90. . . . . . . . . . . . . . . . . . . . . . 2.4.4.3. Control system components 2.4 – 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.4. Engine block with bearings 2.4 – 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.5. Crankshaft, connecting rod, piston 2.4 – 93. . . . . . . . . . . . . . . . . . . . . . 2.4.4.6. Cylinder head with valves 2.4 – 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.7. Camshaft and valve drive 2.4 – 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.8. Injection system components 2.4 – 104. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.9. General table of tightening torques

for not specified bolt connections 2.4 – 108. . . . . . . . . . . . . . . . . . . . . . . . 2.4.5. Adjustments and Tolerances 2.4 – 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.5.1. Adjustments 2.4 – 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 5

2.4.5.2. Tolerances 2.4 – 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.6. Dimensions and masses 2.4 – 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5. Engine Block with Bearings 2.5 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1. Engine block 2.5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2. Main bearings 2.5 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2.1. Removing of main bearing 2.5 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2.2. Inspection of main bearings and

journals 2.5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2.3. Main bearing assembling 2.5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3. Crankshaft axial locating bearing 2.5 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3.1. Removing of the ’0’–bearing 2.5 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3.2. Inspection of ‘0’ bearing, axial thrust

rings and thrust collars on crankshaft. 2.5 – 17. . . . . . . . . . . . . . . . . . . 2.5.3.3. ’0’–bearing assembling 2.5 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.4. Camshaft bearings 2.5 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.4.1. Inspection of camshaft bearing bush 2.5 – 18. . . . . . . . . . . . . . . . . . . . . 2.5.4.2. Removing camshaft bearing bushes

and axial bearing bushes 2.5 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.4.3. Mounting camshaft bearing bush 2.5 – 21. . . . . . . . . . . . . . . . . . . . . . . . 2.5.4.4. Mounting camshaft axial bearing bush 2.5 – 21. . . . . . . . . . . . . . . . . . .

2.5.5. Replacing cylinder head studs 2.5 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.6. Crankcase safety valves 2.5 – 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6. Crankshaft, Connecting Rod, Piston and Liner 2.6 – 1. . . . . . . . . . . . . 2.6.1. Crankshaft 2.6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1.1. Crankshaft deflections 2.6 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1.2. Measurement axial clearance thrust

bearing 2.6 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2. Driving unit 2.6 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2.1. Removing big end bearing shells without removing driving unit 2.6 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2.2. Removing driving unit 2.6 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2.3. Disassembling driving unit 2.6 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2.4. Inspection and maintenance of piston

and connecting rod 2.6 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2.5. Assembling connecting rod and piston 2.6 – 18. . . . . . . . . . . . . . . . . . . 2.6.2.6. Mounting connecting rod with piston

into cylinder liner 2.6 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2.7. Mounting driving unit 2.6 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3. Vibration damper crankshaft 2.6 – 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3.1. Maintenance 2.6 – 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3.2. Liquid sampling 2.6 – 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.4. Turning gear 2.6 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7. Cylinder Head with Valves 2.7 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1. Cylinder head 2.7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1.1. Maintenance of cylinder head 2.7 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1.2. Removing the cylinder head 2.7 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1.3. Mounting cylinder head 2.7 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2. Adjusting valve clearance 2.7 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3. Valves and valve seats 2.7 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.3.1. Removing of valves 2.7 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 6

2.7.3.2. Check and reconditioning of valve discand valve seat 2.7 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.3.3. Valve seats 2.7 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3.4. Valve guide 2.7 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3.5. Assembling of valves 2.7 – 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.4. Valve rotators 2.7 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.4.1. Inlet valve rotator 2.7 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.4.2. Exhaust valve rotator 2.7 – 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.5. Injector sleeve 2.7 – 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.5.1. Maintenance 2.7 – 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.5.2. Extracting injector sleeve 2.7 – 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.5.3. Mounting injector sleeve 2.7 – 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.6. Indicator cock and Safety valve 2.7 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8. Camshaft and Valve Drive 2.8 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1. Camshaft driving gear 2.8 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.1.1. Crankshaft gear wheel 2.8 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1.2. Camshaft gear wheel 2.8 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.2. Camshaft 2.8 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2.1. Maintenance 2.8 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2.2. Removing camshaft section and

journal 2.8 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2.3. Mounting camshaft section and

journal 2.8 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.3. Valve drive mechanism 2.8 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.3.1. Removing valve drive mechanism 2.8 – 15. . . . . . . . . . . . . . . . . . . . . . . 2.8.3.2. Inspection of valve lifting gear 2.8 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.3.3. Mounting valve drive mechanism 2.8 – 17. . . . . . . . . . . . . . . . . . . . . . . .

2.8.4. Actuator drive 2.8 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9. Injection System 2.9 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1. High Pressure (HP) fuel pump 2.9 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.1.1. Removing HP fuel pump 2.9 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1.2. HP fuel pump disassembling 2.9 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1.3. HP fuel pump maintenance and

inspection 2.9 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1.4. Assembling the HP fuel pump 2.9 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1.5. HP fuel pump adjustment 2.9 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1.6. HP fuel pump mounting 2.9 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.2. Fuel pump bracket 2.9 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.1. Removing fuel pump bracket 2.9 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.2. Mounting fuel pump bracket 2.9 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.3. Renewal sealing set push rod 2.9 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.4. Inspection of fuel pump push rod 2.9 – 17. . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.5. Inspection of fuel pump tappet 2.9 – 18. . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.3. Fuel injector 2.9 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.3.1. Fuel injector maintenance 2.9 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.3.2. Fuel injector removing 2.9 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.3.3. Fuel injector overhaul 2.9 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.3.4. Fuel injector mounting 2.9 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.4. HP fuel pipe 2.9 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4.1. Removing HP fuel pipe 2.9 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4.2. Mounting HP fuel pipe 2.9 – 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 7

2.9.5. Testing of fuel injectors 2.9 – 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1. Annex A 3.1 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2. Annex B 3.2 – 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 8

For Inte

rnal

Use O

nly

LIST OF FIGURES ManualWärtsilä 26

xx– 9

Fig. 0.0 – 1 Engine definitions 0.0 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 0.0 – 2 Example of reading the flywheel 0.0 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 0.0 – 3 Designation of main bearings / camshaft bearings 0.0 – 6. . . . . . . . . . . . . . . . . Fig. 1.1 – 1 Viscosity conversion diagram 1.1 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 – 2 Viscosity temperature diagram 1.1 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 – 3 Nomogram for deriving CCAI 1.1 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 – 4 Draining the engine fuel system 1.1 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 – 5 Draining the engine fuel system 1.1 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 1 Engine wet sump 1.2 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 2 General overview oil flow through engine 1.2 – 13. . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 3 Oil flow main bearing 1.2 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 4 Oil flow connecting rod 1.2 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 5 Gudgeon pin 1.2 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 6 Oil flow piston 1.2 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 7 Oil flow gear drive 1.2 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 8 Oil flow to turbocharger 1.2 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 9 Oil flow through camshaft 1.2 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 10 Oil flow HP fuel pump drive and valve drive 1.2 – 19. . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 11 Oil flow cylinder head 1.2 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 12 Lubricating oil for actuator drive 1.2 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 13 Lubricating oil pump 1.2 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 14 Derrick for free end side mounted pumps 1.2 – 22. . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 15 Lubricating oil pump, cross section 1.2 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 16 Pressure control and safety valve 1.2 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 17 Lubricating oil module 1.2 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 18 Lubricating oil cooler 1.2 – 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 19 Extracting tool for cooler stack 1.2 – 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 20 Thermostatic valve 1.2 – 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 21 Automatic back–flushing filter 1.2 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 22 Automatic back–flushing filter (Filtration phase) 1.2 – 33. . . . . . . . . . . . . . . . . . . Fig. 1.2 – 23 Automatic back–flushing filter (Back–flushing phase) 1.2 – 34. . . . . . . . . . . . . . Fig. 1.2 – 24 Automatic back–flushing filter (Overflow valves) 1.2 – 35. . . . . . . . . . . . . . . . . . Fig. 1.2 – 25 Automatic back–flushing filter (Maintenance) 1.2 – 36. . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 26 Centrifugal filter on engine 1.2 – 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 27 Centrifugal filter 1.2 – 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 28 Location of lubricating oil sampling valve 1.2 – 43. . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 – 29 Crankcase breather and vent pipe 1.2 – 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 – 1 Start system diagram ( principle working ) 1.3 – 3. . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 – 2 Pneumatic stop system 1.3 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 – 3 Compressed air starter motor disengaged 1.3 – 6. . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 – 4 Engaging process compressed air starter motor 1.3 – 7. . . . . . . . . . . . . . . . . . Fig. 1.3 – 5 Compressed air starter motor engaged 1.3 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 – 6 Stop process compressed air starter motor 1.3 – 9. . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 1 General flow HT cooling water system 1.4 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 2 Interconnection into cylinder head 1.4 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 3 Location of cooling water thermostatic valves 1.4 – 9. . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 4 General flow LT cooling water system 1.4 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 5 Cooling water pump 1.4 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 6 Lifting tool for pumps 1.4 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 7 Pump shaft 1.4 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 – 8 Cooling water venting locations 1.4 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 1 Charge air cooler 1.5 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly

LIST OF FIGURESManualWärtsilä 26

xx– 10

Fig. 1.5 – 2 Cooler stack 1.5 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 3 Condensate drain points 1.5 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 4 Removal charge air cooler stack 1.5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 5 Exhaust gas manifold configuration 1.5 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 6 Multiduct 1.5 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 7 Sealing multiduct / cylinder head / cylinder block 1.5 – 15. . . . . . . . . . . . . . . . . . Fig. 1.5 – 8 Gas flow through compensators 1.5 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 9 Insulation box 1.5 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 10 Compressor cleaning device 1.5 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 – 11 Turbine cleaning device 1.5 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 – 1 Fuel control mechanism 1.6 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 – 2 Fuel pump rack position transmitter 1.6 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 – 3 Linkage actuator / common control shaft 1.6 – 7. . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 – 4 Pre–clearance levers to HP fuel pump 1.6 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 – 5 Stop device 1.6 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 – 6 Stop mechanism 1.6 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 1 WECS automation system 1.7– 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 2 Sensor connection in the WECS 1.7– 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 3 Data handling procedure 1.7– 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 4 Temperature sensors of the main bearing 1.7– 13. . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 5 The main page 1.7– 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 6 The key buttons on the panel 1.7– 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 7 Testing of pressure switches 1.7– 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 8 MCU frame 1.7– 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 9 Layout of mother Board 1.7– 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 10 DPS50 DC/DC Converter 1.7– 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 11 Block diagram of the DC/DC Converter 1.7– 25. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 12 Layout of the Processor Board 1.7– 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 13 Block diagram of the Processor Board 1.7– 26. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 14 Memory Unit Layout 1.7– 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 15 LAN Board Layout 1.7– 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 16 Block Diagram of the LAN Board 1.7– 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 17 Layout of the Interface Board 1.7– 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 18 Block Diagram of the Interface Board 1.7– 28. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 19 SMU and DCU 1.7– 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 20 SMU Board layout 1.7– 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 21 SMU Board block diagram 1.7– 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 22 DCU layout 1.7– 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 23 DCU Board block diagram 1.7– 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 24 Engine speed sensors 1.7– 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 25 ABB turbocharger speed sensor 1.7– 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 26 EGT turbocharger speed sensor 1.7– 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 27 Layout of the Relay Module 1.7– 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 28 Software structure of the WECS 1.7– 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.7 – 30 Lubricating of contacts 1.7– 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 1 Local control panel 2.3 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 2 Start solenoid valve 2.3 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 3 Gradual load increase 2.3 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 4 Maximum sudden power increase 2.3 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 5 Operating range 2.3 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 6 Running–in diagram 2.3 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 – 7 Local stop 2.3 – 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 11

Fig. 2.3 – 8 Manual stop 2.3 – 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 1 Diagram pneumatically driven hydraulic pump unit 2.4 – 73. . . . . . . . . . . . . . . . Fig. 2.4 – 2 Pneumatic driven hydraulic pump unit 2.4 – 75. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 3 Cross section hydraulic jack 2.4 – 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 4 Hydraulic extractor 2.4 – 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 5 Graphic relation pressure / force 2.4 – 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 6 H.P. hose 2.4 – 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 7 H.P. quick–release coupling 2.4 – 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 8 Dust caps H.P. quick–release coupling 2.4 – 79. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 9 Hand operated hydraulic pump 2.4 – 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 10 Torque spanner – multiplier 2.4 – 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 11 Torque spanner – extension 2.4 – 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 12 Lubricating oil pump 2.4 – 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 13 Cooling water pump 2.4 – 90. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 14 Actuator 2.4 – 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 15 Main bearing 2.4 – 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 16 Vibration damper with PTO–shaft 2.4 – 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 17 Vibration damper without PTO–shaft 2.4 – 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 18 Crankshaft gear 2.4 – 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 19 Flywheel 2.4 – 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 20 Big end bearing 2.4 – 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 21 Multiduct connection 2.4 – 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 22 Tappet casing 2.4 – 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 23 Cylinder head 2.4 – 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 24 Rocker arm mechanism 2.4 – 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 25 Intermediate gear shaft 2.4 – 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 26 Camshaft / camshaft gearwheel 2.4 – 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 27 Actuator drive 2.4 – 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 28 Fuel injector 2.4 – 104. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 29 Fuel injector, HP fuel line 2.4 – 105. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 30 Fuel injector 2.4 – 106. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 31 HP fuel pump drive and tappet housing 2.4 – 107. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 32 Gear wheel train 2.4 – 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 33 Valve stem and valve burn–off area 2.4 – 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 34 Inlet valve and valve seat in cylinder head 2.4 – 117. . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 35 Exhaust valve and valve seat in cylinder head 2.4 – 117. . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 36 Driving gear 2.4 – 118. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 37 Valve drive mechanism 2.4 – 119. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 38 Actuator drive 2.4 – 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 39 Nozzle 2.4 – 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 40 fuel pump adjustment 2.4 – 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 41 Engine components 2.4 – 122. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 – 42 Main parts 2.4 – 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 1 Engine block 2.5 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 2 Position bearing temperature sensor 2.5 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 3 Positioning jack on side stud 2.5 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 4 Lifting tool for main bearing cap 2.5 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 5 Lifting tool for main bearing cap 2.5 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 6 Bearing shell driver 2.5 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 7 Inserting main bearing shell 2.5 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 8 Driving main bearing shell into position 2.5 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 9 Apply new O–ring with silicon grease 2.5 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 12

Fig. 2.5 – 10 Measuring stud elongation 2.5 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 11 Crankshaft axial locating bearing 2.5 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 12 Camshaft assembly with bearing bushes 2.5 – 18. . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 13 Extracting camshaft bearing bush 2.5 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 14 Extracting camshaft axial bearing bush 2.5 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 15 Holding bearing bushes during mounting 2.5 – 22. . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 16 Replacing cylinder head stud 2.5 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 – 17 Crankcase safety valve 2.5 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 1 Taking crankshaft deflection readings 2.6 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 2 Measuring crankshaft axial clearance 2.6 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 3 Connecting rod 2.6 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 4 Piston 2.6 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 5 Driving unit 2.6 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 6 Piston support for big end bearing inspection 2.6 – 8. . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 7 Removing anti bore polishing ring 2.6 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 8 Hydraulic tool for connecting rod studs 2.6 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 9 Lowering big end bearing cap 2.6 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 10 Lifting driving unit 2.6 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 11 Protecting crank pin journal 2.6 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 12 Extracting driving unit 2.6 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 13 Support driving unit 2.6 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 14 Removing gudgeon pin 2.6 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 15 Clockwise rotating 2.6 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 16 Counter clockwise rotating 2.6 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 17 Application piston ring pliers 2.6 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 18 Cylinder liner diameter control 2.6 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 19 Cylinder liner, mounting / manipulator 2.6 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 20 Lowering driving unit 2.6 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 21 Support ring cylinder liner 2.6 – 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 22 Securing cylinder liner 2.6 – 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 23 Measuring stud elongation 2.6 – 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 24 Liquid sampling 2.6 – 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 – 25 Turning gear 2.6 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 1 Cross section cylinder head 2.7 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 2 Tilting frame cylinder head 2.7 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 3 Disconnecting pipes from cylinder head 2.7 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 4 Cylinder head with 4 jacks 2.7 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 5 Lifting cylinder head 2.7 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 6 Securing cylinder liner 2.7 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 7 Cylinder liner cover 2.7 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 8 Cylinder head build–on 2.7 – 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 9 Stud elongation 2.7 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 10 Cylinder head with 2 jacks 2.7 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 11 Valve clearance adjustment 2.7 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 12 Valves and valve seats 2.7 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 13 Valve spring removing 2.7 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 14 Designation of valves 2.7 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 15 Blueing test 2.7 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 16 Removing valve seats 2.7 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 17 Mounting valve seats 2.7 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 18 Extracting valve stem guide 2.7 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 19 Valve stem guide 2.7 – 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 13

Fig. 2.7 – 20 Inlet valve rotator 2.7 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 21 Removing/mounting of valve spring washer 2.7 – 26. . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 22 Exhaust valve rotator 2.7 – 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 23 Removing/mounting ring bottom drive section 2.7 – 28. . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 24 Grinding of seal cylinder head with injector 2.7 – 29. . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 25 Extracting injector sleeve 2.7 – 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 26 Mounting new injector sleeve 2.7 – 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 – 27 Indicator cock / safety valve 2.7 – 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 1 Gearwheel drive camshaft 2.8 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 2 Camshaft 2.8 – 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 3 Crankshaft gear wheel 2.8 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 4 Removing camshaft gear wheel 2.8 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 5 Camshaft gear wheel 2.8 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 6 End journal camshaft gear wheel 2.8 – 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 7 Tappet assembly inlet / exhaust 2.8 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 8 Camshaft section and journal 2.8 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 9 Separating camshaft section from journal 2.8 – 10. . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 10 Tool for camshaft section 2.8 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 11 Sliding out camshaft journal 2.8 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 12 Tappet assembly and valve lifting gear 2.8 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 13 Valve lifting gear 2.8 – 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 14 Valve lifting gear 2.8 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 – 15 Actuator drive 2.8 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 1 HP fuel pump 2.9 – 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 2 Fuel rack connection to common fuel control rod 2.9 – 3. . . . . . . . . . . . . . . . . . Fig. 2.9 – 3 Disassembling HP fuel pump 2.9 – 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 4 HP fuel pump 2.9 – 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 5 Removing barrel 2.9 – 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 6 HP fuel pump adjustment 2.9 – 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 7 Fuel pump bracket 2.9 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 8 Fuel pump bracket 2.9 – 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 9 Fuel pump bracket 2.9 – 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 10 Lifting fuel pump bracket 2.9 – 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 11 Fuel pump bracket 2.9 – 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 12 Mounting push rod seal set 2.9 – 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 13 Depth gauge for push rod 2.9 – 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 14 Assembling tool fuel pump bracket 2.9 – 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 15 Cylinder head with injector 2.9 – 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 16 Fuel injector in cylinder head 2.9 – 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 17 Extracting fuel injector 2.9 – 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 18 Fuel injector 2.9 – 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 19 Tools for loosening / tightening sleeve nut 2.9 – 23. . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 20 Separating injector tip from sleeve nut 2.9 – 23. . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 21 HP fuel pipe 2.9 – 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 22 Testing device fuel injectors 2.9 – 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 – 23 Fuel injector 2.9 – 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

For Inte

rnal

Use O

nly


xx– 14

For Inte

rnal

Use O

nly

General ManualWärtsilä 26

0.0 – 1

0.0. General

For Inte

rnal

Use O

nly

GeneralManualWärtsilä 26

0.0 – 2

0.0.1. Introduction

�� !�� "#��#� $�� "#��#� !��%��

"#��#� $��

��&��

'��

(��

)��

'�� "#��#�$��*��

-��

�� /

�; <��

�; <��

�; <��

For Inte

rnal

Use O

nly


0.0 – 3

0.0.2. Terminology

�� /

Operating side�=��

Non–operating side�=��

Driving end�(��

Free end��

Designation of cylinders�-��

Clockwise rotating��

Counter–clockwise rotating��

A–bank and B–bank�!��

Inlet and exhaust valves�!��

RELATED TOISO 1204

Fig. 0.0 – 1 Engine definitions

For Inte

rnal

Use O

nly


0.0 – 4

Top dead centre (TDC)�� -$� ��

�� -$��/

TDC at scavenging�� (�� -$� �� -$��

TDC at firing�� !��-$��-$��-$��

Bottom dead centre (BDC)��

For Inte

rnal

Use O

nly


0.0 – 5

Marks on the flywheel�� >��-$��?��-$�� "�� -$�� -$��-$��!��?�@�� C?E� �� >��-$��>��-$�

1

Fig. 0.0 – 2 Example of reading the flywheelFor I

ntern

al Use

Only


0.0 – 6

Designation of bearings

Main bearings�� G�� @�� G��?��G��H�� @@�� @�

Camshaft bearing$� ��

Intermediate gear wheel bearingsJ�� @@� �� @�

7 6 5 4 3 2 1 0

Fig. 0.0 – 3 Designation of main bearings / camshaft bearings

–o–o–o–o–o–

For Inte

rnal

Use O

nly

Main Data ManualWärtsilä 26

1.0 – 1

1.0. Main Data

For Inte

rnal

Use O

nly

Main DataManualWärtsilä 26

1.0 – 2

1.0.1. Basic information

K��

(��

(��

$�� HM@

!�� OH@

G� �� M

-��

<�� ?QXQHQMQOQ>

K��

(��

(��

$�� HM@

!�� OH@

G� �� M

-��

<�� ?Q>QOQMQHQX

�� "#��#� HM� �� X;��

For Inte

rnal

Use O

nly


1.0 – 3

1.0.2. Output

Engine output according to engine rating plate

Output 100% kW 2025

Engine speed rpm 1000

Suction air temperature oC 45

Charge air coolant temperature oC 38

Engine output according to ISO substitute reference conditions

Output 100% kW 2025

Engine speed rpm 1000

ISO 3046–1:1995(E) Substitute reference conditions

Ambient air pressure mbar 1000

Site altitude above sea level m 0

Suction air temperature oC 45

Charge air coolant temperature oC 38

Total exhaust gas back pressure mbar 30

The full output of the engine is available at the ISO substitutereference conditions. No compensation (uprating) is allowed foroperating conditions better than the ISO substitute referenceconditions. For derating data see section 1.0.3.

Fuel limiter is set at 100 % and no overload is allowed.

Note!

Note!

For Inte

rnal

Use O

nly


1.0 – 4

1.0.3. Derating conditions

-��/�<��!%��?�@�H�-��!%�O@XMQ?/?ZZ>C(E��/��

�; @�O>[� �� $� �� !%��

�; @�X@[��$�� ?>��$��; @�O@[��$��

�!%��; ?�OO[��K��C?@� ��E��

��!%��; @�X[��\��?E��; @�>[��?@[��

��?�$��?@[��

Data mentioned in Operating Data (section 1.0.4.) must stay at thenominal values

]�� ?�@�X�

^�� /

�; �� ; ��/

�; �� &��; �� ; �� Q ��

�; ��C��E�� ; ��; �� ; ��$$*��C_�`j@E�; ��

Never change fuel rack settings to equalize the exhaust gas temperature.

Relative pressure loss = ��

��‰

?E

Note!

Note!

1

2

For Inte

rnal

Use O

nly


1.0 – 5

1.0.4. Operating Data

Operating Data Conditions

Max. Nom. Min.

Fuel condition before injection pumps:

– Pressure bar 7 – 6

– Viscosity (HFO) cSt – 16–24 –

– Viscosity (LFO) 1) cSt – – 2

– Temperature (HFO) oC 130 – –

– Temperature (LFO) oC 50 – –

Lube oil condition:

– Temperature before engine oC – 63 –

– Pressure before engine bar – 4.5 –

HT cooling water condition:

– Temperature before engine oC – 73 –

– Temperature after engine oC – 93 –

– Pressure before engine bar 5 3.4–4.4 2) –

LT cooling water condition:

– Temperature before engine oC 38 – –

– Temperature after engine oC – – 44

– Pressure before engine bar 5 3.4–4.4 2) –

HT and LT cooling water static pressure:

– At inlet cooling water pump bar 0.8 – 0.3

Charge air temperature in air receiver oC – 50–55 –

Starting air pressure (min. pres. at 20 oC) bar 33 30 15

Firing pressure bar 190 – –

1)�� H��!��

2) Q��


For Inte

rnal

Use O

nly


1.0 – 6

For Inte

rnal

Use O

nly

Fuel System ManualWärtsilä 26

1.1 – 1

1.1. Fuel System

For Inte

rnal

Use O

nly

Fuel SystemManualWärtsilä 26

1.1 – 2 �

1.1.1. General

!�� (��

^�� ;�� <��

(�� !��

For Inte

rnal

Use O

nly


1.1 – 3

1.1.1.1. HFO engines running on distillatefuels

��<�� <�� H>@� �� C��E�� (��!%�`H?j/�?ZZM��<Q-'*��-'J��-'$��!��?�?�H�O�

(�� ^<%� ��

For Inte

rnal

Use O

nly


1.1 – 4 �

1.1.2. Fuel

1.1.2.1. Residual fuel oil quality

��!%�`H?j/?ZMM�C(E��!%Q<Q]'*?@�Q�]'q>>��y^<%�Hz��]'^�>>��]'q�>>�*�� y^<%� ?z� �� J��

The residual fuels are further in this manual indicated as Heavy FuelOil (HFO).

Bunker quality�� /

Property Unit LimitHFO 1

LimitHFO 2

Test methodreference

Viscosity at: 100°C cSt max. 55 55 ISO 3104Viscosity at: 50°C cSt max. 730 730 ISO 3104Viscosity at: 100°F Redwood No.1 sec max. 7200 7200 ISO 3104Density at: 15°C kg/m3 max. 991 991 ISO 3675 or

kg/m3 max. 10101) 10101) ISO 12185CCAI XE max. 8502) 8702) ISO 8217Water % volume max. 1.0 1.0 ISO 3733Sulphur % mass max. 2.0 5.0 ISO 8754Ash % mass max. 0.05 0.20 ISO 6245Vanadium mg/kg max. 100 6003) ISO 14597Sodium XE mg/kg max. 50 1003) ISO 10478Aluminium + Silicon mg/kg max. 30 80 ISO 10478Conradson Carbon residue % mass max. 15 22 ISO 10730Asphaltenes�XE % mass max. 8 14 ASTM D 3279Flash point (PMCC) °C min. 60 60 ISO 2719Pour point °C max. 30 30 ISO 3016Total sediment, potential % mass max. 0.10 0.10 ISO 10307–2

Note!

For Inte

rnal

Use O

nly


1.1 – 5

?E�'�� ?@?@��& O��?>°C,��

HE�!��$$*��jj@��`X@��$�� `X@��Q��Q��Z@@�$$*��'�� `>@��`j@�� OE�!�� !��

�� %�� *�� XE�*�� !%� �� !%��

=�� {��

�� y^<%� Hz� �� /

�; �J!�'*�?@@/�?ZZM��]'^>>��]'q�>>

�; �$�'*$�?ZZ@��$��^>>��q>>

�; ��!%�`H?j/�?ZZMC(E��!%Q<Q]'^�>>��]'q�>>

For fuel oil quality before engine see section 1.1.2.4.Note! For Inte

rnal

Use O

nly


1.1 – 6 �

1.1.2.2. Crude oil quality

Bunker quality�� /

Property Unit Limit Test method refer-ence

Viscosity at: 100°C cSt max. 55 ISO 3104Viscosity at: 50°C cSt max. 730 ISO 3104Viscosity at: 100°F Redwood No. 1 sec. max. 7200 ISO 3104Density at: 15°C kg/m3 max. 991 ISO 3675 or 12185CCAI max. 870 ISO 8217Sulphur % mass max. 5.0 ISO 8754Ash % mass max. 0.05 ISO 6245Vanadium mg/kg max. 300 ISO 14597Sodium mg/kg max. 50 ISO 10478Aluminium + Silicon mg/kg max. 30 ISO 10478Conradson Carbon residue % mass max. 22 ISO 10730Asphaltenes % mass max. 14 ASTM D 3279Reid vapour pres. at 37.8°C kPa max. 65 ASTM D 323Pour point °C max. 30 ISO 3016Total sediment, potential % mass max. 0.10 ISO 10307–2

=�� {��

For fuel oil quality before engine see section 1.1.2.4.Note! For Inte

rnal

Use O

nly


1.1 – 7

1.1.2.3. Distillate fuel oil quality

Distillate fuels��!%�`H?j/?ZZM�C(E��!%Q<Q-'|��-'*��-'J��-'$�

�� /

�; �� Q?>}$� ��

�; ��

�; ��!��

�; ��$��

The distillate fuels are further in this manual indicated as Light FuelOil (LFO).

Note!

For Inte

rnal

Use O

nly


1.1 – 8 �

Bunker quality�� !%�`H?j/�?ZZMC(E��!%Q<Q-'*��-'J��-'$/

Property Unit DMA DMB DMC1) Test meth. ref.

Viscosity at 40°C cSt max 6.0 11.0 14.0 ISO 3104

Density at 15°C kg/m3 max 890 900 920 ISO 3675 or 12185

Cetane number [–] min. 40 35 – ISO 5165 or 4264

Water % volume max – 0.3 0.3 ISO 3733

Sulphur % mass max 1.5 2.0 2.0 ISO 8574

Ash % mass max 0.01 0.01 0.05 ISO 6245

Vanadium mg/kg max – – 100 ISO 14597

Aluminium + Silicon mg/kg max – – 25 ISO 10478

Carbon residue (10% voldist. bottoms, micro method)

% mass max 0.3 – – ISO 10370

Carbon residue (micromethod)

% mass max – 0.3 2.5 ISO 10370

Flash point (PMCC) 2) °C min. 60 60 60 ISO 2719

Pour point :Summer / Winter °C max 0 /–6 6 / 0 6 / 0 ISO 3016

Sediment % mass max – 0.07 – ISO 3735

Total sediment potential % mass max – – 0.10 ISO 10307–1

1)��!%Q<Q-'$�� 2)�*�� !%� �� !%��

=�� {��

!� �� >@��$��

For fuel oil quality before engine see section 1.1.2.4.

For fuel oils out of the specifications as stated in this paragraph,contact Wärtsilä Corporation.

Note!Note!

For Inte

rnal

Use O

nly


1.1 – 9

1.1.2.4. Fuel oil quality before engine

Requirement before engine*�� /

Property Unit Value

Fuel condition before injection pumps:For pressure, temperature (LFO / HFO) and viscosity(LFO / HFO) see section 1.0.4.

The HFO must be purified in an efficient centrifugesystem. Furthermore, the fuel should pass through anautomatic filter before entering the engine.

Automatic backflush filter; fineness 90% / abs. [µm] 10 / 25

Safety filter; fineness 90% / abs. [µm] 25 / 37

Water / volume ?E % max. 0.3

Sodium ?E mg/kg max. 30

Aluminium + Silicon ?E mg/kg max. 15

Quantity of clean leak fuel (at 100% load) % HE ca. 0.4

Fuel flow / fuel consumption ratio (at 100% load) min. 4 : 1

?E�*�� !%� �� !%��

HE�[��!��<��%��$��

For Inte

rnal

Use O

nly

[mm2/s]


1.1 – 10 �

1.1.2.5. Fuel conditioning

"�� <�� ?�?� ;� ?� �� ~ H&��~�!��

Fig. 1.1 – 1 Viscosity conversion diagram

Conversion from various viscosity units to [mm2/s] can be made in thediagram, fig. 1.1 – 1 . The diagram should be used only for conversion ofviscosities at the same temperature. The same temperature should thenbe used when entering the viscosity / temperature point into the diagramof fig. 1.1 – 2 .

For Inte

rnal

Use O

nly


1.1 – 11

Fuel oil viscosity and temperatureK�� {�� $�� ?�?�;�H�� /�; ��Q��

<��C�!%�]'��E��?@@�$��<��C�!%�-'��E��X@�$��O>� H&��?@@�$��^��(��=��

Residual fuel

Distillate fuel

Minimum storagetemperature

Approx. pumping limit

RM–55 (Max. 55mm2/s at 100}C)

RM–45 (Max. 45mm2/s at 100}C)

RM–35 (Max. 35mm2/s at 100}C)

RM–25 (Max. 25mm2/s at 100}C)

RM–15 (Max. 15mm2/s at 100}C)

RM–10 (Max. 10mm2/s at 100}C)

Centrifugingtemperature

Viscosity range

before HP fuelpumps

Max. temperaturebefore HP fuel pumps

DMC (Max. 14 mm2/s at 40}C)

DMB (Max. 11 mm2/s at 40}C)

DMA (Max. 6,0 mm2/s at 40}C)

DMX (Max. 5,5 mm2/s at 40}C)

H

C

D

E

F

A

G

B

[mm2/s]

[}C]–10 0 10 50403020 60 70 80 10090 110 120 130

16

50

40

30

20

60

80100

5000

2000

1000

400300

200

600

25

14

12

10

3

4

5

6

7

89

residual fuels

Fig. 1.1 – 2 Viscosity temperature diagram

For Inte

rnal

Use O

nly


1.1 – 12 �

�; �� C��{��E� �� ?@@@� H&� ��

�; �� <��

�; �� <�� <�� X@ H&� �� >@�$� �� ?X� H&� ��<��Zj�$�� "��

�; �� ^K�� >@��$��

=<%��?O@��$��^<%�

Example:�� !�� "�#

�; " �!�� $$��%

�; &��'��'��$�� (�%

�; �� )� �� *�� +�%�& ��,��,� ��-� ��'�� '�� %

�; �� )��)� �� /$�� 0�%

�; (� ��)� �� '�� )� �� )�� ' �� *� ��,� �1� ��2� ��3��$��,�� 4��,�5�%

For Inte

rnal

Use O

nly


1.1 – 13

Purification^��C�� -'$E ��

]�� ?�?�;�H��

!�� H�$�� @�ZZ?��& ��?>�$�

J��G��

Recommended centrifuge flow rate

Viscosity at 100�C mm2/s – 10 15 25 35 45 55

Viscosity at 50�C mm2/s 12 40 80 180 380 500 730

Centrifuge flow % of rated capacity 100 60 40 30 25 20 15

!�� Q�� *�� Q�� <�� ?@�[�� ?H� 2/s�� For I

ntern

al Use

Only


1.1 – 14 �

1.1.2.6. Avoiding difficulties during operation on HFO

��^<%�� /

*�� =��

<�� ^<%��<�� z<��&�� z��K��

$�� <��

=� �� H�[��z��z��?>�[��&��`�[�

*�� C�� E�� !�� *� ��

!� �� ?�?�H�j�

1

2

3

4

5

6

For Inte

rnal

Use O

nly


1.1 – 15

1.1.2.7. Comments on fuel characteristics

�� >>�

"��@�ZZ?��& ��?>�$�� $�� ?�@?@��& ��?>�$�� ?�@?@��& ��?>�$� ��

High density fuels with low viscosity may have low ignitionquality.

^�� Q��

^�� Q��

^�� C��E�

!�� CG�E�� C�E��!�� G��O@��

^��z��z� ��

^�� C�� E�*�� &�� K��

^�� ?�[��"��

Note!

1

2

3

4

5

6

7

8

9

For Inte

rnal

Use O

nly


1.1 – 16 �

]�� ^<%� �� z��z��^<%��

�� !%Q<Q-'$� �� -�� $��$��G� ��

=�� z-��z�� -�� J�� $$*��

H&��>@��$ ��& O��?>��$

Fig. 1.1 – 3 Nomogram for deriving CCAI

10

For Inte

rnal

Use O

nly


1.1 – 17

What do the CCAI values mean?!��$$*��C$��$��*�� E� �� jj@� ��`X@�� $�� `X@��Z@@�

G�� $$*��`>@��$$*��`>@��`j@� �� C�� {{��E�

$$*��`j@��

Although low ignition quality produces long ignition delay,advancing the ignition timing makes things only worse; fuel isinjected at a lower compression temperature and this willproduce even longer ignition delay.

*�� !��<�� z��z�� {{��

Note!

11

For Inte

rnal

Use O

nly


1.1 – 18 �

1.1.3. Internal fuel system

General�� =��K��^��K��J��^��J��

�; ��=��K��^K�� Q��^K�� H�Z��z�� z�

�; �� ^�� K�� ^�� K�� C^KE� �� ^��K�� H�Z��z�� z�

��y��<��!�� z�� *��*�Q�� &K�� '��

For maintenance background information , safety aspects, tools,intervals, tolerances, inspection, tightening torque and proceduressee chapter 2.4

Note!

For Inte

rnal

Use O

nly


1.1 – 19

1.1.4. Draining of fuel system

*��

�� ^<%��

6

7

Fig. 1.1 – 4 Draining the engine fuel system

$��

-�� CME��CjE��!��?�?�;�X��

1

2

For Inte

rnal

Use O

nly


1.1 – 20 �

%��CZE��CÈ��?�?�;�>��

8 9

Fig. 1.1 – 5 Draining the engine fuel system


3

For Inte

rnal

Use O

nly

Lubricating Oil System ManualWärtsilä 26

1.2 – 1

1.2. Lubricating Oil System

For Inte

rnal

Use O

nly

Lubricating Oil SystemManualWärtsilä 26

1.2 – 2

1.2.1. Lubricants

=�� *�� {��

)�� $��

%�� C��E�� ^��

!� �� %��

�� ;��"#��#�$��

For Inte

rnal

Use O

nly


1.2 – 3

1.2.1.1. Requirements

1.2.1.1.1. Main lubricating oil

'�� /

"��#��$�� %�!*(�X@"��#��&�'�("�)�� %�'��Z> ��$��#�(!*)�� : ��

Category Fuel standardISO 8217: 1996(E)

Lube oil BN [mg KOH/g]Fuel standardISO 8217: 1996(E) Required Recommended

A B C D

DMX, DMADMBDMC, RMA10 – RMK55Crude oil (CRO)

10 – 3015 –3030 –5530

10 – 25 15 – 22 50 – 55 30

Remarks$��*��J/�� JG��JG�O@��$��$/�� JG�� H�@�[� �� JG�� C��E��JGX@��=��JG�O@�� !$]��$��-/��=��JG�O@��

Additives�� C��{��E�

Foaming characteristics<�� *!�'�-�`ZHQZH�� /!�� /��?@@&@� �

Base oils%��Q��

Approved lubricating oils<��"#��#�

=��

For Inte

rnal

Use O

nly


1.2 – 4

Engine lubricating oil system requirements

Lubricating oil, supplied to the engine, must be conditioned:– centrifugal separated on water and dirt – filtered– controlled to the correct temperature.

Water content max. % vol 0.3

Fineness automatic back–flushingfilter:fine filtersafety filter

30 µm Absolute mesh size100 µm Absolute mesh size

The suction height of the main lubricatingoil pump (including pressure losses in thepipes and suction filter): max. m 4

Before any operation the lubricating oilshould be at least at preheated condition: min. °C 40

1.2.1.1.2. Other lubricants

Lubricating oil for turning gear!��Q��X@@Q>@@��!�&X@°$��!%��XM@��<��"#��#�

Actuator��H@"QX@� ��!��;��

Oil for hydraulic tools��X>� H&� �� X@� �$�� /

�; �!% ��^'�; -�G�>?>H> ��^=;K�; -�G�>?>`> ��@�; -�G�>?j>Z ��?�; *!�'�-�MM> ��

For Inte

rnal

Use O

nly


1.2 – 5

1.2.1.2. Influences on the lubricating oilcondition

"�� z�� z� �� z�� z�/

�; -��;��

�; *�� ;��;�� C��$%HE��

�; !�� ;��; *��

��&�� ; *��$$*��_�`>@��; <��

��; K��

�� K�� ;��

�; <��; ^��C_�O[�E��JG��

1.2.1.3. Testing of main lubricating oil

�� ^�� -�� H>@��%��

For Inte

rnal

Use O

nly


1.2 – 6

Recommendations for sampling�; !� ��

��; (��

� �� ; -��

�� ; J��

��

�; -��

�; -�� ; !��

��Z@[��

Information required for oil analysisG� ��

%��

-��

-��

%��

^��

]��

(��

K��

��

-��

��

*�� ;��

Unacceptable sampling*�� /

�; !� ��; *��&� ��; K��; -��

!� ��

1

2

3

4

5

6

7

8

9

10

11

12

13For Inte

rnal

Use O

nly


1.2 – 7

1.2.1.4. Condemning limits main lubricating oil

Condemning limits for used main lubrication oil system"�� $� ��

Condemning limits for used lubricating oil

Property Unit Limit Test method

Viscosity cSt at 40 }C max. 25% decreasemax. 45% increase

ASTM D 445

Viscosity cSt at 100 }C max. 20% decreasemax. 25% decrease

ASTM D 445

Water vol–% max. 0.30 ASTM D 95 orASTM D 1744

Base Number mg KOH/g min. 20 for HFO operationmax. 50% depletionfor LFO operation

ASTM D 2896

Insolubles w–% in n–Pentane max. 2.0 ASTM D 893b

Flash Point, PMCCFlash Point, COC

}C}C

min. 170min. 190

ASTM D 93ASTM D 92

For Inte

rnal

Use O

nly


1.2 – 8

1.2.1.5. Comments on lubricating oilcharacteristics

$�� -�� `@;Z@°$�� '�� `>;Z>°$� �� K�� !�� <�� H@[� �� <�� X;>�� HX��H@[��

Defects on “self–cleaning“ separators can, under certaincircumstances, quickly increase the water content of the oil

<��*��?>@�$��

"��=��

$��JG�� *��JG��

�� ?�>[��;K��

]��

!�� &��

Note!

1

2

3

4

5

6

For Inte

rnal

Use O

nly


1.2 – 9

'�� *�� *�� *��

�� C�� E�� (�� C�� E� ��

-��&��

7

8

9

For Inte

rnal

Use O

nly


1.2 – 10

1.2.1.6. Recommendations for refreshinglubricating oil

Utmost cleanliness should be observed during lubricating oiltreatment. Dirt, metal particles, rags etc. may cause serious bearingdamage. After disconnecting pipes or components from the systemcover all openings with gaskets and or tape. Avoid dirt and waterentering the lubricating oil during transport and storage.

11

Fig. 1.2 – 1 Engine wet sump

-�� C?E�<�� ?�H�O�H��J��

$��

$�� Q�� ?�H�O�H�O�

!��

��

$��?H�@@@��

Note!

1

2

3

4

5

For Inte

rnal

Use O

nly


1.2 – 11

1.2.2. Internal lubricating oil system

�� '�� J��;��/

�; =��

�; K��

�; =��

�; $��CE

�; !� ��

�; $��

��y��=��%��!�� z�� *��*�Q�� &K�� '��

For maintenance background information , safety aspects, tools,intervals, tolerances, inspection, tightening torque and proceduressee chapter 2.4

Note!

For Inte

rnal

Use O

nly


1.2 – 12

1.2.2.1. Oil flow through engine

�� C?E�� CHE��Q��Q�� CH�?E�� COE�� Q��*�� CXE�� !��?�H�;�H��

�� C>E�� /

�; ��

�; ��

�; ��

�; �� C��E�

��CME��/

�; �� CjE

�; �� CÈ

�; ��Q��

�; ��

�; ��/��

�; ��CZE

�; ��C??E

For Inte

rnal

Use O

nly


1.2 – 13

12345

6

7

8

9

2.1

10

11

Fig. 1.2 – 2 General overview oil flow through engine

For Inte

rnal

Use O

nly


1.2 – 14

1.2.2.1.1. Oil flow main bearings, connecting rodand pistons

Oil flow main bearing=�� C>E�� {��C?HE�� C?OE��?�H�;�O��C?XE�� {��

13

12

5

14

15

Fig. 1.2 – 3 Oil flow main bearing

For Inte

rnal

Use O

nly


1.2 – 15

Oil flow connecting rod��z��z�C?>E��

��{�� C?ME�� ?�H� ;� X� �� C?jE�

17

16

Fig. 1.2 – 4 Oil flow connecting rod

Oil flow piston�� !��?�H�;�>��

Fig. 1.2 – 5 Gudgeon pin

For Inte

rnal

Use O

nly


1.2 – 16

%�� X�� CH@E�� ?�H�;�M��*��C?ZE��

<��C?È��

*��CH?E�� {��-��

-�� CHHE�� *��*��

22

21

19

18

20

Fig. 1.2 – 6 Oil flow piston

For Inte

rnal

Use O

nly


1.2 – 17

1.2.2.1.2. Oil flow gear drive

K�� ?�H�;�j��

J��X��

Fig. 1.2 – 7 Oil flow gear driveFor Inte

rnal

Use O

nly


1.2 – 18

1.2.2.1.3. Oil flow turbocharger

�� CHOE��

*� �� CH>E� �� !��?�H�;�`��

23

25

Fig. 1.2 – 8 Oil flow to turbocharger

For Inte

rnal

Use O

nly


1.2 – 19

1.2.2.1.4. Oil flow engine top side

=��CHME�� CHjE�� ?�H�;�Z��

(�� z�� z� CHÈ��?�H�;�Z��?�H�;�?@��

27

28 26

Fig. 1.2 – 9 Oil flow through camshaft

<�� ^K�� CHZE��Q��CO@E�� CO?E��?�H�;�?@��COHE��?�H�;�??��

28

29 30

31

30

Fig. 1.2 – 10 Oil flow HP fuel pump drive and valve drive

For Inte

rnal

Use O

nly


1.2 – 20

K��{{��COOE��?�H�;�??�� COXE��CO>E��COME��COjE��COÈ��COZE�

33

35

34

32

37

36

38

39

Fig. 1.2 – 11 Oil flow cylinder head

1.2.2.1.5. Oil flow actuator drive

K�� CX@E��CX?E��?�H�;�?H��

41

40

Fig. 1.2 – 12 Lubricating oil for actuator drive

For Inte

rnal

Use O

nly


1.2 – 21

1.2.3. Components of internal system

1.2.3.1. Lubricating oil pump

�� C?E�� -��

�� CHE� ��Q�� Q��

��COE�� ?�H�O�?�?�

3

2

1

4

Fig. 1.2 – 13 Lubricating oil pump

For Inte

rnal

Use O

nly


1.2 – 22

Removing pump from engine

]� ��

��ZM?H��ZOZ��?�H�;�?X�� "�� CME��

9612ZT939

6

Fig. 1.2 – 14 Derrick for free end side mounted pumps

]� ��CXE��?�H�;�?O��

=�� ZM?H��ZOZ��?�H�;�?X��

Dismantling pump]� ��&��C?E��?�H�;�?>��

]� ��CHE�� COE��CXE�J��C>E��

]� ��

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


1.2 – 23

1

5

3

4

6

7

2

1

810

9

Fig. 1.2 – 15 Lubricating oil pump, cross section

Pump inspection and assembling$��

$��

��

��

$��CZE��

]��%��CÈ��C?@E�

��

K��

K�� C>E��CXE�

Mind the correct position of clamping rings.

<��COE��H@�G ��<��H�X�

Note!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


1.2 – 24

$��

Mounting pump on engine$��

]��%��

]��%��CME��CjE��%��

K��

<�� H�X�

*�� H�X�>�

'��

<��

$�� C��E�

K��

]�� %��

11

1

2

3

4

5

6

7

8

9

10

11

For Inte

rnal

Use O

nly


1.2 – 25

1.2.3.1.1. Pressure control unit

��?�H�;�?M�� C?ME��C?È��C?jE�� *��C?>E��

release to engine sump15 16

oil pressure from pump

17

�x’

18

Fig. 1.2 – 16 Pressure control and safety valve

Maintenance'�� |��?�H�;�?M�

]� ��C?ME��C?>E�

$�� ]��

$��

]��%Q��<��

'�� |�� ?�H�;�?M�

1

2

3

4

5

6For Inte

rnal

Use O

nly


1.2 – 26

1.2.3.2. Lubricating oil module

�� C?E�� CHE�� Q��COE��$��CXE�� !��?�H�;�?j��

1 234

56

7

21

2526

Fig. 1.2 – 17 Lubricating oil module

For Inte

rnal

Use O

nly


1.2 – 27

1.2.3.2.1. Lubricating oil cooler

Removing the cooler stack]� ��C>��ME��?�H�;�?j��

*��

]� ��CjE��=��?�H�;�?j��

]� ��

"��

]� ��CH>E��?�H�;�?j��

=��

]� ��CÈ��CZE��?�H�;�?`��

10

13

9111214

151617

8

18 20

Fig. 1.2 – 18 Lubricating oil cooler

1

2

3

4

5

6

7

8

For Inte

rnal

Use O

nly


1.2 – 28

]� ��C?@��??E�� C?HE�

'��C?OE��ZM?H��`jH��?�H�;�?Z��

K��C?XE�� C�� E�� %Q��C?>E��!��?�H�;�?`��

K��C?È��ZM?H��`jH��

'��C?ZE��ZM?H��`jH��?�H�;�?Z��

)��

19

Fig. 1.2 – 19 Extracting tool for cooler stack

The cooler stack is of the tubular finn type.Cooler stack tubes can not be exchanged.

<�� ?�>�X�X�?�

<��?�>�X�X�H�

Mounting the lubricating oil cooler stack

$��%Q�� $��CH@E��!��?�H�;�?`��

'��C?ZE��ZM?H��`jH��?�H�;�?Z��

K�� %Q��C?ME��!��?�H�;�?`��

]��%Q��C?ME��

Note!

9

10

11

12

13

14

1

2

3

4

For Inte

rnal

Use O

nly


1.2 – 29

K��

]� ��C?ZE� ��C?OE�� ZM?H��`jH�!��?�H�;�?`��

K��ZM?H��`jH��%Q��C?>E��

=��%��C?>E��

K��C?È��ZM?H��`jH��

]��%Q��C?jE��

<��C?HE��C??��?HE�

<��CZE��CÈ�

]��%Q��CHME��

K��

<��CH>E��?�H�;�?j��

<��C>��ME��=�� !��?�H�;�?j��

<�� %Q��

The free distance between cover (9) and telltale hole (20) givesway to oil or water to the outside in case of leaking O-rings. Seefig. 1.2 – 18 .

<��CH?E�� !��?�H�;�?j��

!��Q��

!�� =�� $��=��

Note!

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20For Inte

rnal

Use O

nly


1.2 – 30

1.2.3.2.2. Thermostatic valves

�� CHE�� !��?�H�;�H@��

Thermostatic valves

<��?�H�;�H@�� C��E��*��CHHE��CHOE��"�� CHXE��CHOE�

222423

Fig. 1.2 – 20 Thermostatic valveFor Inte

rnal

Use O

nly


1.2 – 31

Operation$�� *�� M°$��

Maintenance�� ]��

Elements exposed to a temperature of more than 10°C above thenominal working range will be damaged and should be renewed.

Trouble shooting�� H�O�O�j�?��

Warning!

For Inte

rnal

Use O

nly


1.2 – 32

1.2.3.2.3. Automatic back–flushing filter

General�� Q��C?E��?�H�;�H?�� CHE�� Q�� G�� C?E� �� Q��COE��Q�� C?HE��?�H�;�Hj��

3

12

Fig. 1.2 – 21 Automatic back–flushing filterFor I

ntern

al Use

Only


1.2 – 33

1135

36

3712

38 41

Fig. 1.2 – 22 Automatic back–flushing filter (Filtration phase)

Filtration phase��C??E��CO>E�� CX?E��*��COME��-��COjE�� COME�

��COÈ��C?HE�For I

ntern

al Use

Only


1.2 – 34

3511

39404136 4248

47 49

43 5043 34

Fig. 1.2 – 23 Automatic back–flushing filter (Back–flushing phase)

Back–flushing phase��CO>E��C??E��CO>E�� COZE��CX@E�� CX?E�

��COME�� CX?E��CXHE�

��COME��Q�� COME��Q�� COXE��?�H�;�HO��

��Q��Q��C�� COMEE��

�� CXOE��CXÈ�

For Inte

rnal

Use O

nly


1.2 – 35

3644 38

Fig. 1.2 – 24 Automatic back–flushing filter (Overflow valves)

Functioning of the overflow valves!��COME�C��E�� CXXE� �� H� �� COÈ�C��E�

^�� C�� E��

��

The filter may only be operated in this emergency condition for ashort time (opened overflow valves and differential pressurewarning). Prolonged operation in this mode can result in damage toengine components.

�� Q��

Note!

For Inte

rnal

Use O

nly


1.2 – 36

45

46

35

3940

4136

38

Fig. 1.2 – 25 Automatic back–flushing filter (Maintenance)

Maintenance(��

�� Q��

�� Q�� /

��

$��

$��COME��

Should a higher differential pressure occur beforehand, all the filtercandles (36) and the protective filter (38) must be checked and, ifnecessary, cleaned. See also section ”filter candle inspection and cleaning”.

Note!

1

2

3

For Inte

rnal

Use O

nly


1.2 – 37

A highly contaminated protective filter (38) is a sign of prolongedoperation with defective or clogged filter candles (36) and thusopened overflow valves (44), see fig.1.2 – 24 . It is necessary to check these components.

$�� CO>E�� COZE��CX@E�� CX?E�

To check this the cover (45) must be removed. Now check the easeof movement with a suitable spanner on the hexagon of the wormgear unit (46), see fig. 1.2 – 25 . If movement is sluggish, refer to section ”Sources of faults and theirremedy”.

�� COME��H��

Longer use is also possible if the filter candles (36) are checkedcarefully.

]�� CXjE�� ?�H� ;� HO� � ��

��

Warning!

Note!

Note!

4

5

6

For Inte

rnal

Use O

nly


1.2 – 38

Filter candle inspection and cleaning

-��

]� ��CXÈ��?�H�;�HO��

K�� CX?E��CX@E��

Make sure that the exposed gear (40) is not damaged.

]� ��CXZE�

��COME��

K��COME��J��H@@@� �� HX��

*�� COME��

It must be ensured that the filter candles are cleaned at a pressureof max. 60 bar and at a minimum distance of the cleaning nozzle of20 cm. Otherwise, damage to the mesh is possible.

J��COME��

Defective filter candles (36) must not be used again.

Before installation of the entire filter element, the ease of motion ofthe flushing facility must be checked. The flushing arm (41) must notgrind against the bottom filter plate (50)

G�� J��CXOE��CX@E��COZE�

]�Q��

Note!

Note!

Note!

Note!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


1.2 – 39

1.2.3.2.4. Trouble shooting automatic back–flushing filter

Sources of faults and their remedy

Cause of fault: ∆p risesReasons

and remedy

1. – Viscosity too high – Wait for normal operating conditions

2. – High volume of dirt – Check by–pass treatment unit forfunctioning

3. – Filter candles clogged – Clean candles

4. – Flushing volume too low – Check flow control device in outlet andsludge discharge line for clogging

5. – Shaft end does not turn – Turbine jammed– Remove parts jammed between turbineand wall– Gear unit defective– Check for ease of movement

(see section ”Maintenance”)Replace gear unit if necessary

– Flushing arm (41) jammed, Remove any foreign matter– Operating pressure < 2 bar– Run for prolonged period at higher pres-sure 5–6 bar and thus eliminate the block-age– Oil quantity too low / Increase oil quantity

For Inte

rnal

Use O

nly


1.2 – 40

1.2.3.3. Centrifugal filter

�� C?E�� Q��CHE��COE��?�H�;�HM��

��Cz%GzE�<�� C?E��{�� Cz!(]��$(z� ��E�� COE� �� Q�� CHE� �� C?HE� �� !�� ?�H�;�Hj��

1

2

3

Fig. 1.2 – 26 Centrifugal filter on engine

For Inte

rnal

Use O

nly


1.2 – 41

Operation�� CXE�� C>E� �� CME� �� CjE�� CÈ��CHE�� Q��CME�� CjE�� CÈ��CZE��

14

12

9 8

6

7

4

1

15

16

13

17

11

2

10

5

9

Fig. 1.2 – 27 Centrifugal filter

For Inte

rnal

Use O

nly


1.2 – 42

Centrifugal filter cleaning$��

��C?E��{��?�H�;�HM��

"��

]� �� C?OE�� C?XEE��?�H�;�Hj��

=��C?>E�� C?ME

]� �� C>E��

The rotor assembly should be removed with care in order not todamage the lower bearing, Pelton wheel and jet pipes.

^�� C?jE��]� ��

$�� CXE�(��

For easy removal of dirt in the rotor unit use a paper insert. For the part number of the insert see the parts catalogue. If the filter has reached the maximum dirt deposit layer thickness of25mm within the recommended cleaning interval (weekly), it isnecessary to clean the filter more frequently.

$��C?@E��

� (�� C?XE�� (�� %�� ]��

<�� )��%Q��

��C?jE��H@�G C��?&O��E�

]�� CME�� K��

$��C>E��

]��C?ME��C?>E�

!��C?XE��CME��<�� C?OE��C�� MQ`�G E

%��C?E��?�H�;�HM��

$��

Note!

Note!

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

For Inte

rnal

Use O

nly


1.2 – 43

1.2.3.4. Lubricating oil sampling valve

<��?�H�;�H`�� C?E�� ?�H�?�O�

1

Fig. 1.2 – 28 Location of lubricating oil sampling valve

For Inte

rnal

Use O

nly


1.2 – 44

1.2.4. Crankcase breathing system

��;��&��

�� C?E�� {��CHE��?�H�;�HZ��*��COE�

�� {�� $�� {��

*��$�� CXE��?�H�;�HZ��

3

2

4

1

Fig. 1.2 – 29 Crankcase breather and vent pipe

For Inte

rnal

Use O

nly


1.2 – 45

�� CXE� �� z�� z� �� $��*�� /

�; ��

�; ��%Q��

�; ��

Excessive smoke from crankcase breather might indicate that a hotspot is vaporizing lubricating oil and may lead to a crankcaseexplosion.


Note!

For Inte

rnal

Use O

nly


1.2 – 46

For Inte

rnal

Use O

nly

Starting Air System ManualWärtsilä 26

1.3 – 1

1.3. Starting Air System

For Inte

rnal

Use O

nly

Starting Air SystemManualWärtsilä 26

1.3 – 2

1.3.1. General

��

�� CE��

G��

�� *��

�� ;�� "�� /

�; ��

�; ��

�; ��

For Inte

rnal

Use O

nly


1.3 – 3

1.3.2. Start stop system

Engine start process�� CE�C� ��O@�� ?>��E��?�O�;�?��

%��/

�; !��C@?E��; *� ��

��=��; ��<��

��^�� q��

�; �� q��; *�� C@?E��;��{��

��<��{�� ^��

Starting Air

’K’

’F’ ’H’

’L’

Fig. 1.3 – 1 Start system diagram ( principle working )

��y��!��&!��*��!�� z�� *��*Q�� &K�� '��

Emergency engine start�� <�� H�O�H�j�

Be aware that all safety devices are overruled if the engine is startedby using the emergency start push button.

Warning!

For Inte

rnal

Use O

nly


1.3 – 4

Engine stop"�� CjE� �� CO@� ��E� �� C>E� ��^K�� ?�M�;�>��?�O�;�H��

*��CXE�� <�� ?�M�

4

7

Fig. 1.3 – 2 Pneumatic stop system

For Inte

rnal

Use O

nly


1.3 – 5

1.3.3. Compressed air starter motor

1.3.3.1. General

�� C��E�� *��

��

*��

*��O@��

*��

For Inte

rnal

Use O

nly


1.3 – 6

1.3.3.2. Description of compressed air startermotor

Control circuit*�� C?E��CHE��COE��CXE��?�O�;�O��

J�� CXE�� C>E��CME��CjE��K��CjE��CÈ� �� CZE� �� *�� C?E��CHE��C?@E�

Fig. 1.3 – 3 Compressed air starter motor disengagedFor Inte

rnal

Use O

nly


1.3 – 7

Pre–engagement*��C?@E��C?HE��;��C?OE��C?XE��?�O�;�X��*� �� C?>E��

J�� C?ME�� C?jE�� C?È��C?ZE��CH@E��!� ��C?@E��C??E��C?ZE��CHHE�

-�� C?>E��CH@E��C?È��CHOE��

23

22

Fig. 1.3 – 4 Engaging process compressed air starter motorFor I

ntern

al Use

Only


1.3 – 8

Start"��CH@E��C??E��CH>E��CHME��?�O�;�>��K��CHME�� CHjE�!�� C?E��C?XE�� CO@E��?�O�;�>��

30

Fig. 1.3 – 5 Compressed air starter motor engaged

For Inte

rnal

Use O

nly


1.3 – 9

Stop%�� CXE� �� *��CjE��CME��C>E�� ?�O�;�M��*��CjE��{��CÈ��CZE�� C?@E�$��&��C?OE��C?XE��K��CHME�� CHjE��-��CHÈ��CHZE�� C?>E�� C?XE��;��C?OE�� C?HE��C?@E��CH>E��C??E�� C?ZE� �� CH@E� �� CHOE�

23

25

26 27

Fig. 1.3 – 6 Stop process compressed air starter motor

For Inte

rnal

Use O

nly


1.3 – 10

1.3.4. Operating instructions

1.3.4.1. Commissioning and operation

�; $��

�; ��

�; K�� J��

�; ��

�; $��

For Inte

rnal

Use O

nly


1.3 – 11

1.3.5. Maintenance

1.3.5.1. Complete overhaul

<�� "#��#�$��"#��#�!��%��

1.3.5.2. Storage

"��

For Inte

rnal

Use O

nly


1.3 – 12

1.3.6. Trouble shooting<�� ?�O�;�O��?�O�;�M�

Action

Chapter / section

6. On pressing push–button, starterdoes not respond and no air flowseems to exist in control circuit.

a) Empty air vessel(s). Re–fill vessel(s).

b) Supply valve(s) closed. Open supply valve(s).

c) Control circuit blocked. Disconnect and clean .

7. On pressing push–button, starterdoes not respond, although airflows through control circuit.

a) Leaking control duct. Repair or replace.

b) Insufficient air pressure. Increase pressure in vessel.

c) Piston (7) and valve (8) sticking in closedposition.

Remove and check both; smoothen guidesor change parts.

d) Push–button stuck. Remove and clean same.

e) Excessive length of main air pipework. Approach push–button to starter or install asolenoid valve near the latter.

8. Pinion revolves and advances, butdoes not engage the ring gear.

a) Ring gear and/or pinion burrs or dam-age.

Clean gear ring and remove burrs

b) Lack of clearance between pinion andring gear ring.

Check for distortion of gear ring and pinion.

9. Pinion revolves but does not ad-vance.

a) Push–rod (11) inoperative. Disassemble, check, smoothen guide dia–meter; clean or replace if corrosion is vis-ible.

b) Insufficient air pressure. Increase pressure in air vessel.

c) Splined shaft (19) sticking. Disassemble, clean, check spring (22) andreassemble.

d) Excessive length of control pipe. Approach push–button to the starter or in-stall a solenoid valve near the latter.

For Inte

rnal

Use O

nly


1.3 – 13

Action

Chapter / section

10. Pinion advances but does not re-volve.

a) Pneumatic motor inoperative. Disassemble, inspect rotors for foreignmatters between teeth and for possiblewear of gears, spindles and bearings.Clean and reassemble. Replace worn parts.

b) Check valve (13) stuck or blocked. Disassemble, clean and reassemble.

11. Pinion engages gear ring, but willnot turn the engine.

a) Main valve (26) blocked. Disassemble, clean and reassemble or re-place main valve.

b) Rotors worn or blocked. Disassemble, clean and reassemble or re-place rotors.

c) Insufficient air pressure. Increase pressure in air vessel.

d) Main air pipework restricted or of insuffi-cient bore.

Check all pipework and replace it if necess-ary.

12. Starter starts working after openingthe flow valve of the feed line, al-though push–button (or solenoidvalve ) is not actuated.

a) Incorrect connection of control pipes. Connect control pipes as per installation in-structions.

b) Main valve (26) blocked and open. Disassemble, clean, and replace joint ifneeded.

13. Lack of starter power.

a) Main pipework choked or its bore is lessthan stipulated for the starter.

Check entire pipework for correct bore andreplace if incorrect.

b) Insufficient air pressure. Increase pressure in air vessel.

c) Badly worn rotors. Disassemble, replace rotors and reassemble.

For Inte

rnal

Use O

nly


1.3 – 14

Action

Chapter / section

14. After starting the engine, piniontries to re–engage and hits the ringgear which results in damage toboth.

a) Incorrect bore of main pipework. Check entire pipework for correct bore andreplace if incorrect.

b) Starting period unnecessarily long. Check and adjust timer (if fitted) or pressstarter push–button for shorter period.

c) Idling of main valve (26). Disassemble, clean and reassemble.

15. Starter motor will not stop.

a) Main valve (26) blocked. Disassemble, clean and reassemble.

b) Piston (7) and leak valve (8) defective. Disassemble, clean and reassemble, Re-place if needed.

c) Check valve (13) keeps open or does notseat properly.

Disassemble, check for correct closing ofthe ball and that plug presses the valveagainst its seat.

d) Seal ring badly fitted. This is a frequent fault after changing themotor bearings. Check for correct position.

e) Incorrect adjustment of controls. Adjust timer (if fitted), or operate push–but-ton for shorter periods.

f) Splined shaft (19) sticking. Disassemble, clean, check spring (22) andreassemble.

–o–o–o–o–o–For Inte

rnal

Use O

nly

Cooling Water System ManualWärtsilä 26

1.4 – 1

1.4. Cooling Water System

For Inte

rnal

Use O

nly

Cooling Water SystemManualWärtsilä 26

1.4 – 2

1.4.1. General

�� C�� E�� <�� *��

1.4.2. Cooling water

1.4.2.1. General

$��'��Q��'��;�� "�� /

�; -� ��{��

�; ]��

�; -�� C�� E�

�; !��

�; !��

$��

(�� G%�� /

�; ]��

�; -��

�; !��

The better the water quality the less additive has to be supplied.'��;�� <�� ?�X�H�H�

Note!

For Inte

rnal

Use O

nly


1.4 – 3

1.4.2.2. Requirements

'��;�� <�� Q��

Make–up water quality

Free of any foreign particles, air, gases and within the following specification:

Property Unit

Chloride (Cl) [mg/l] max. 80

Sulphate content (S) [mg/l] max. 150

pH [–] min. 6.5

Hardness [°�dH] max. 10

Engine cooling water system

Coolingwater supply

– cooling water loss through evaporation should be compensated by make–up water.

– cooling water loss through leakages or otherwise should be compensated by adding fully treated water.

Coolingwater re–use

Cooling water to be drained may be re–used providedthat it is collected in a clean tank.

Property Unit

Temperatures and pressure !��

Preheating: – Temperature of HT cooling

water system before starting. [°C] min. 60

Re–use of cooling water provided that the quality is beyond anydoubt is highly recommended instead of new. Used cooling watercontains very little oxygen, is environmentally more friendly andneeds less correction.Not re–usable cooling water should be drained and disposed of inan ecologically safe way.

Note!

For Inte

rnal

Use O

nly


1.4 – 4

1.4.2.3. Qualities of cooling water additives

General)��

!��

Approved cooling water additives<�� "#��#�$��

Recommended$��G��Q�� Q G��

�� {��Q ��

Limited suitable (see restrictions when mentioned):$��G��C��E Q �� C�^��E

�� Q G��

�� {��Q ��

!�� Q ^�� Q $��

�� Q G��

'�� Q ^�� Q $��

%�� Q '�� C��E��{��C��{��E�

Not advised$�� K��J��C��E��

�� Q��!��Q��?�@�O�

For Inte

rnal

Use O

nly


1.4 – 5

1.4.2.4. Cooling water control

$�� '��

With most additives correct dosing is very important. Under dosing ofadditives causes spot corrosion while overdoses may causedeposits.

]�� Q��

<��

]��

Note!

1

2

For Inte

rnal

Use O

nly


1.4 – 6

1.4.3. Internal cooling water system

1.4.3.1. General

(��^�� =��

�; ��^��^��C��E��

�; ��=��=��C��E��

'�� J��;��/

�; ^��=��

�; ^��=��

�; $��^��=��

�; =��

�; $��

�; $� ��

��y��$��"��!�� z�� *��*Q�� &K�� '��

For maintenance background information, safety aspects, tools,intervals, tolerances, inspection, tightening torque and proceduressee chapter 2.4.

Note! For Inte

rnal

Use O

nly


1.4 – 7

1.4.3.2. Description HT cooling water system

*��C?E��^�� CHE�� C?ME�� COE�� CXE��

5

4

10

4

21

8 9 1516

3

Fig. 1.4 – 1 General flow HT cooling water system

For Inte

rnal

Use O

nly


1.4 – 8

Flow from cylinder liner to cylinder head�� CXE�� *�� G��

*�� *��C??E�� ?�X�;�H��

12

5

4

11

Fig. 1.4 – 2 Interconnection into cylinder head

Cylinder head�� *�� $�� C?HE�� *�� C>E��?�X�;�?��

For Inte

rnal

Use O

nly


1.4 – 9

HT cooling water charge air cooler

�� C>E��^��CÈ��C��E��!�� ?�>��<�� CZE��C?@E�� COE��C?>E��C?E�� ?�X�;�?��

Thermostatic valves

]�� ^��=�� ^�� =�� J�� !�� C?E� �� !��?�X�;�O��

From engine

To cooler By–pass

From engine

To coolerBy–pass

1

2

3 4

52

73 4

57

HT

LT

Fig. 1.4 – 3 Location of cooling water thermostatic valves

For Inte

rnal

Use O

nly


1.4 – 10

Operation$�� *�� M°$��

Trouble shooting�� H�O�O�j�?��

1.4.3.2.1. Maintenance thermostatic valves

$��

Removal / mounting of thermostatic valves-��

]� �� CHE�� COE��?�X�;�O�

$�� $��

Be careful not to mix the thermostatic valves of different liquidsystems due to the fact that each system has its own working range.

]��

]��CXE��C>E��CjE��?�X�;�O�

<��

Elements exposed to a temperature of more than 10°C above thenominal working range will be damaged and should be renewed.

Note!

Warning!

1

2

3

4

5

6For Inte

rnal

Use O

nly


1.4 – 11

1.4.3.3. Description LT cooling water system

*��C?E��=�� CHE�� C?HE�� COE�� CXE��C>E�� CME� ��=�� C��E��C��?�>�E

*��CjE�� CÈ�� CZE�� C��?�H�E��C?@E�� COE��C??E��C?E�� !��?�X�;�X�

1 2

10

5

4

310

9876 12 11

Fig. 1.4 – 4 General flow LT cooling water system

For Inte

rnal

Use O

nly


1.4 – 12

1.4.3.4. Cooling water pump

$�� ^��=�� ^��=�� '�� &��*�� C??E��C?ZE�!��?�X�;�>��

567

12

1

18

13

2 3 4 9 911 17 1615

25262423

’X’

10

8A8B

10

14 1–+

27

19

Fig. 1.4 – 5 Cooling water pump

For Inte

rnal

Use O

nly


1.4 – 13

1.4.3.4.1. Renewal of seals

<��

Removal seals-��;��

]� �� C?E�

�� C>E��CHE��]� ��COE�� CXE��]� �� C?OE��?�X�;�>��

]� �� C`*E�

]� ��CME��CjE�

]� ��;��C`JE�� C?@E�

Mounting seals$��

��

$�� C?HE��

$��Q��C??E��

<��%;��CZE��CjE��C?@E��

!�� *��

<��CME�

K��;�� C`JE��CjE��)��

K�� C`*E��

K��CHjE��

K�� C-��'�� -��E��G��Q�� COE��CXE��

K�� C?OE�

1

2

3

4

5

6

1

2

3

4

5

6

7

8

9

10

11

For Inte

rnal

Use O

nly


1.4 – 14

q�� COE�� !��H�X�X�

]�Q��"��

]�� C?E��H@�G ��<��H�X�X�

1.4.3.4.2. Maintenance cooling water pump

Removal pump from engine-��;��

]� ��

�� |��?�X�;�>��

q�� C?XE�

��ZM?H��ZOZ�� ?�X�;�M��

9612ZT939

14HT pump

LT pump

Fig. 1.4 – 6 Lifting tool for pumps

12

13

14

1

2

3

4

5

For Inte

rnal

Use O

nly


1.4 – 15

Removal gear wheel and pump shaft]� ��?�X�O�X�?�

�� C?È��C?>E��]� ��C?ME�� C?jE�� ]� �� C?OE��?�X�;�>��

*�� C?OE��

J��C?ZE��=�� CH@E��?�X�;�j��

^��CH?E�� C?OE�

^��CHHE�� C?OE�

]� ��CHOE��CHXE��!��?�X�;�>��

21 13

221920

Fig. 1.4 – 7 Pump shaft

Pump inspection and assembling$��

$��

��

]�� C�� %;��E�

^��CHHE��`@°$�� C?OE�<��C?ZE��CH@E�� C?OE�!��CH@E��C?ZE�

^��CH?E��`@°$�� C?OE��?�X�;�j��

1

2

3

4

5

6

7

1

2

3

4

5

6

For Inte

rnal

Use O

nly


1.4 – 16

'��CHXE��CHOE��?�X�;�>��

'��;�� CH?E��?�X�;�j��

$��

*� �� ?�X�O�X�?�� ;'��/��H��?O�

K�� C-��'�� -��E��G��Q�� COE��CXE��

K�� C?È�� C?OE�

��C?>E��C?È�� C?OE��?�X�;�>��^��!��H�X�X�

]�Q��"��

<��%;��CH>E��CHME��

)��ZM?H��ZOZ��

<��C?XE��?�X�;�M��X@�G �� H�X�X�

]�� C?E��?�X�;�>��H@�G ��<��H�X�X�

$�� !��H�X�>��H�X�;�OH��

K��

7

8

9

10

11

12

13

14

15

16

17

18

19

20For Inte

rnal

Use O

nly


1.4 – 17

1.4.3.5. Flexible pipe connections

!� �� z ��;��;��z�� z ��;��;��z��?[��

Fitting instructions]� ��

$�� (��

'��

!��-��

K��

K��

��

Torque indicated on coupling is valid for radially rigid pipes.Couplings can be used several times! No dirt under sealing lips!

Disassembling of coupling=��$�� -��

Note!

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


1.4 – 18

1.4.4. Maintenance cooling water system

1.4.4.1. General

G�� *�� G��

��{�� $��;��

�� $�� $� ��

1.4.4.2. Cleaning

�� ?�X�H�-�� -��

G�� -�� &��

For Inte

rnal

Use O

nly


1.4 – 19

1.4.4.3. Cooling water venting�� ;�� K�� $�� *�� {��

$��^�� C?E��"��CE�CHE�� ?�X�;�`��=�� Q��^��=�� ?�>��?�H�

��COE��-��

3

2

1

Fig. 1.4 – 8 Cooling water venting locations


For Inte

rnal

Use O

nly


1.4 – 20

For Inte

rnal

Use O

nly

Charge Air and Exhaust Gas System ManualWärtsilä 26

1.5 – 1

1.5. Charge Air and Exhaust Gas System

For Inte

rnal

Use O

nly

Charge Air and Exhaust Gas SystemManualWärtsilä 26

1.5 – 2

1.5.1. General

�� z��z��z��z��

!�� CE��

��

1.5.2. Quality of suction air filtration

��

Property UnitDust concentration (��_�>�µ E 3.0 [mg/ 3

n]Chlorides (Cl) 1.5 [mg/ 3

n]Hydrogen Sulphide (H2S) 375 [µg/ 3

n]Sulphur dioxide (SO2) 1.25 [mg/ 3

n]Ammonia (NH3) 94 [µg/ 3

n]

*��+� 3n��@}$��?@?O� ��

'�� HXQ��?Q��

"�� Q��

*� ��

For Inte

rnal

Use O

nly


1.5 – 3

1.5.3. Internal system

$� �� ;��/

�; *��

�; ��

�; ��^��=��

�; ��

�; $� ��

��y��$��*��(��!�� z�� *�� *� Q� �� &K�� '��

For Inte

rnal

Use O

nly


1.5 – 4

1.5.4. Charge air system

1.5.4.1. General

�� <�� <��/

�; (��

�; *��

�; �� X>°$��

�; *��

�; <�� H�O�

�� *�� ?� ��

For maintenance background information, safety aspects,intervals, tolerances, inspections, tools and torque spannerinstructions, see chapter 2.4.

Note!

For Inte

rnal

Use O

nly


1.5 – 5

1.5.4.2. Charge air cooler

��

�� H@@°$�� C?E�� !��?�>�;�?��

�� ^�� Z@;?@@°$�� =�� >@°$�

1

Fig. 1.5 – 1 Charge air coolerFor I

ntern

al Use

Only


1.5 – 6

1.5.4.2.1. Cooler stack

��C?E�� CHE��COE��

*�� CZE��!��?�>�;�H��

�� ^�� =�� CÈ��

^��CjE��CME��=��CXE��C>E�

7

6

5

4

1

3

2

8

8

8 9

Fig. 1.5 – 2 Cooler stack

For Inte

rnal

Use O

nly


1.5 – 7

1.5.4.2.2. Operation

�� {�� >�°$��"�� >�°$�� {�� {��

*�� *��

1.5.4.3. Condensate draining

$�� )��

�� /

Q�$��

$�� =�� =��J�� =��-��

(��C��E�� {{��

Q�$��

�� ^��&��=��$��C��E$��

��

For Inte

rnal

Use O

nly


1.5 – 8

Condensate drain points have the function to inform the operator onthe presence of water in the charge air receiver.Condensate drain points are not designed to drain large quantitiesof water and should always be open.

condensate drain points

Fig. 1.5 – 3 Condensate drain points

Note!

For Inte

rnal

Use O

nly


1.5 – 9

1.5.4.4. Maintenance

$��H�X��

Removal of charge air cooler stack-��^��=��Q��

]� �� CjE��;��

-��

]� ��

]� ��

1 2

3

4

5 6

7

4

Fig. 1.5 – 4 Removal charge air cooler stack

]� ��

]� ��C>E��

'�� ZM?H��`>X��C?E�� CHE��?�>�;�X��

1

2

3

4

5

6

7

8

For Inte

rnal

Use O

nly


1.5 – 10

<��COE��CXE�� CjE�

]� �� CME�

]� ��CME��

]� �� CjE�

K�� CjE��CME��COE��

=��

Mounting cooler stack$��

$��

'��ZM?H��`>X��?�>�;�X�

*��

=��

<��%Q��

!��-��Q��%Q��

'��

]� ��ZM?H��`>X�

<��

]��C>E��

]��^��=�� {��

]�� CME��

9

10

11

12

13

14

1

2

3

4

5

6

7

8

9

10

11

12

13For Inte

rnal

Use O

nly


1.5 – 11

1.5.4.4.1. Cleaning

General$�� $�� !��

$��

-��

!��

*��

Cleaning water side]� �� "�� ]��%;��

Cleaning air side]� �� ]�� -��

When using chemicals take the necessary precaution and follow theinstructions provided by the manufacturer of the chemicals.

Hydraulic cleaning^�� {{�� <��{{�� O� �� *�� *�� H� ��

When using a high pressure water cleaning device take care not todamage the fins. Damaged fins will result in an decreased capacityof the cooler stack.

Note!

Note!

For Inte

rnal

Use O

nly


1.5 – 12

1.5.4.4.2. Repairs

Leaking tubes�� *��

=�� )��?@�� <�� ?@� ��

^��

Leaking seal*��%;�� ]� ��'��

For Inte

rnal

Use O

nly


1.5 – 13

1.5.5. Exhaust gas system

1.5.5.1. Exhaust gas manifold

�� CHE�� COE��J�� C?E� �� ?�>�;�>��

�� *� ��

��

1

3

223

Fig. 1.5 – 5 Exhaust gas manifold configuration

For Inte

rnal

Use O

nly


1.5 – 14

1.5.5.2. Multiduct

�� ^�� C>E� ��C?E��?�>�;�M��C?E�� ^��CHE��COE��%�� CXE��^��*��

1

2

35

4

Fig. 1.5 – 6 Multiduct

For Inte

rnal

Use O

nly


1.5 – 15

Multiduct connection(�� C?E��M��CHE��COE��CXE��CZE��?�>�;�j��

1

2 3

4

5

6

7

8

7

7

9

Fig. 1.5 – 7 Sealing multiduct / cylinder head / cylinder block

�� C>E��

�� ^�� CME�� CjE��

�� CÈ� �� H�X�X�� ZMHH��H?>��ZM?H��OOH�

For Inte

rnal

Use O

nly


1.5 – 16

1.5.5.3. Compensators

$� �� '�� !��?�>�;�`��

Gas flow

1

Fig. 1.5 – 8 Gas flow through compensators

When reinstalling a compensator check if flanges of the exhaustmanifolds are in line and parallel. Maximum deviation 1mm.

1.5.5.3.1. ’V’ Clamp installation instructions

(��

K��

<�� C?E��!��?�>�;�`��

(��Q��Q��

%��Q��H@�G �� G�� ZQ?H�G �

Note!

1

2

3

4

5

For Inte

rnal

Use O

nly


1.5 – 17

1.5.5.4. Insulation box

�� C?E�� CHE��?�>�;�Z��

1

2

Fig. 1.5 – 9 Insulation box

The heat insulating box is not designed to carry weight.

The heat insulating material, as part of the panels, is at the insidecladded with stainless steel sheeting. This sheeting should not bepainted as part of the heat insulation exist in the reflection of heatradiation.

Warning! For Inte

rnal

Use O

nly


1.5 – 18


"�� /

�; ��

�; �� !��C=��E�

�; ��

1.5.5.6. Operations

$��

�� ?�@�H�

$��

$��

1

2

3

4

For Inte

rnal

Use O

nly


1.5 – 19

1.5.6. Turbocharger

��Q��

��

�� Q��


'�� "#��#�$��

)��

1.5.6.2. Turbocharger cleaning devices

�� {{��]��!�� H�X�?�

�� /

�; (��

�; <��

�; =��

�; J��

For Inte

rnal

Use O

nly


1.5 – 20

1.5.6.3. Compressor side cleaning

�� )��-�� Q��

�� C?E��-��CHE�� COE�

1

234

5

Fig. 1.5 – 10 Compressor cleaning device

For Inte

rnal

Use O

nly


1.5 – 21

Cleaning procedure"�� >j@%��]��

=��CXE�� C?E��?�>�;�?@��

<��

]��CXE�

J��C>E��CHE��COE��

�� X�;�?@�� ?@� ��

%�� >� ��

1.5.6.4. Turbine side cleaning

-��HX��H>@��

Regular cleaning of the turbine during operation prevents or retardsexcessive formation of deposits.

)��{{�� <�� {{�� {{��

*��{{��

Note!

1

2

3

4

5

6

For Inte

rnal

Use O

nly


1.5 – 22

�� {�� C?E��(��

12

3

Fig. 1.5 – 11 Turbine cleaning deviceFor Inte

rnal

Use O

nly


1.5 – 23

Cleaning procedure turbine side��/

�; $�� ; "��O�>��M��; "��H>��& ��

J��

�� G��

K�� X@@�$��X>@�$�� ?>� ��

$��C?E��O�>��!��?�>�;�??��

%��CHE��{{��COE�

��O@��

$��{{�� CHE�

]��H��O��

*��

$�� ?@� ��

Never stop the engine within 20 minutes after completion of thecleaning process to dry the exhaust gas system.


Note!

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


1.5 – 24

For Inte

rnal

Use O

nly

Control System ManualWärtsilä 26

1.6 – 1

1.6. Control System

For Inte

rnal

Use O

nly

Control SystemManualWärtsilä 26

1.6 – 2

1.6.1. General

�� /�"#��#�(��$��!�� Q�"($!�H@@@C!��$��?�j�*�� !�� E�

�� /

�; ��

�; �� ; ��; ��; ��; �� ; ��

�; ��

�; ��

�; �� C�� E�

$�� *��

For maintenance background information, safety aspects,intervals, tolerances, inspections, and torque spanner instructions,see chapter 2.4.

Note!

For Inte

rnal

Use O

nly


1.6 – 3

1.6.2. Speed control system

1.6.2.1. Actuator

'�� H�X�?�H��

"�� -�� '�� $��

$��Q��

'�� -�� %�� >@[��

"�� /

�; ��

�; ��

�; ��

�; ��

�; *��

�; ��

�; ��

�; ��

<�� ;��

For Inte

rnal

Use O

nly


1.6 – 4

1.6.2.2. Booster

��

��{�� ;��;��

��

"��

"��

$��

For Inte

rnal

Use O

nly


1.6 – 5

1.6.3. Fuel control mechanism

�� C?E�� CHE��COE��?�M�;�?��

]�� CXE��^K�� {��

Special attention should be paid to the function of the fuel linkagemechanism as a defect to this mechanism may result in a disastrousover speeding of the engine, unstable engine operation or an engineunable to take load.

1 2 3

4

Fig. 1.6 – 1 Fuel control mechanism

Warning!

For Inte

rnal

Use O

nly


1.6 – 6

1.6.3.1. Load indication HP fuel pump

]�� CME��^K�� C>E�� "($!�H@@@�� !��?�M�;�H��

5

6

Fig. 1.6 – 2 Fuel pump rack position transmitter

For Inte

rnal

Use O

nly


1.6 – 7

1.6.3.2. Checking linkage between actuator and common fuel control shaft

K��^K�� CHH E�� CME�� CXE��?�M�;�O��^K�� !��?�M�O�O�

$��C?E��CME��C>E��Z@�}�

$��COE��>��CjE�C��@;?@E�

��C>E��

K��^K�� @� �� CME�

$��COE��@��@�>��CjE�

1

2

3

4

5

6

7

Eind linkZ16.02

Fig. 1.6 – 3 Linkage actuator / common control shaft

1

2

3

4

5

6

For Inte

rnal

Use O

nly


1.6 – 8

1.6.3.3. Checking linkage between fuel rack and common fuel control shaft

*��CjE��CÈ��Q��>� ��?�M�;�X��

85 mm

7

Fig. 1.6 – 4 Pre–clearance levers to HP fuel pump

K��

]��^K�� "��CÈ��^K��

The maximum deviation between fuel rack positions is � 0.5 mm.

$�� !��?�M�O�H�

!��

Note!

1

2

3

4

5For Inte

rnal

Use O

nly


1.6 – 9

1.6.3.4. Stop mechanism

1.6.3.4.1. Manual stop

'��CME�� *��J��$��CjE��?�M�;�M��

1.6.3.4.2. Local stop

K��CHE�� H�O�;�?��CjE��?�M�;�>�� C>E� ��^K�� CjE��

1.6.3.4.3. Remote stop

K�� CjE�C��E��

1.6.3.4.4. Checking stop mechanism

$�� C�� E��CÈ��!��?�M�;�M��

K��CME��*��?�M�;�M��

K�� C�� E�

K��CHE�� H�O�;�?�� {��

$�� z{��z��

$��|��|�� ?��?�>� ��!��?�M�;�M��

03 air filter and water separator04 air receiver05 stop cylinder07 solenoid10 non–return valve302 control air

Fig. 1.6 – 5 Stop device

1

2

3

4

5For I

ntern

al Use

Only


1.6 – 10

1.6.3.5. Checking actuator stop position

K��CME��J��?�M�;�M��

$��COE��@��@�>��CjE�C��@;?@E��?�M�;�O��

Eind linkZ16.16

$��^K�� K��{��

]��CjE�

7

’A’ ’B’

6

’X’

8

Eind linkZ16.03

Fig. 1.6 – 6 Stop mechanism

1.6.3.6. Removing the actuator

'�� C?E� �� COE� ��C?E��?�M�;�O��

]� ��C?E��

-��

]� ��

]� ��CHE��

The actuator should not rest on its drive shaft.Eind linkZ16.09

Note!

1

2

3

4

1

2

3

4

5

For Inte

rnal

Use O

nly


1.6 – 11

1.6.3.7. Mounting of the actuator

$��$��COE��!��?�M�;�O��

-�� =��>Z?@��

J��

<�� CHE�� !��?�M�;�O��

'��C?E�� COE�

$��^K�� ?�M�O�H�

1.6.4. Governing system maintenance and trouble shooting

'�� /

�; ��Eind linkZ16.11

�; ��

�; ��

Trouble shooting<�� /

$��

$��

$��

$��

$��

1

2

3

4

5

6

1

2

3

4

5

For Inte

rnal

Use O

nly


1.6 – 12

$��

$��]��

$��

Booster maintenance$��

��

$�� )��;��

"�� *��<��

Fuel control mechanism maintenance��

��J�� K��

q��

$�� @�>� ��^K��

$��

Stop device maintenance$��&��

$��

$��

$�� C��E��


6

7

8

1

2

3

1

2

3

4

1

2

3

4

For Inte

rnal

Use O

nly

Automation System ManualWärtsilä 26

1.7– 1

1.7. Automation System

For Inte

rnal

Use O

nly

Automation SystemManualWärtsilä 26

1.7– 2

1.7.1. General

*�� "#��#� (�� $�� !�� "($!�H@@@��"($!��

DCU

Wecs CabinetSMU

To External System

Fig. 1.7 – 1 WECS automation system

��"($!��?MQ��Q�� -��$��)��C-$)E��!��'��)��C!')E��*��-$)��!')�� '��$��)��C'$)E��]��'��C]'E�� =��-��)��C=-)E�

For Inte

rnal

Use O

nly


1.7– 3

��"($!�� /

�; Measuring of the engine and turbocharger speed

�; Engine safety system; ��; ��; ��; �� ; ��

�; Signal processing of all monitoring and alarm sensors

�; Readout of important engine parameters on a graphical display

�; Data communication with external systems (e.g. alarm and �� E�

The WECS will start–up, when the main power supply is available.However both power supply sources are required for a fail–safeoperation. Although the engine keeps running, when both powersupplies fail (without safeties). Switching on the main – andback–up power supply, both at the same time or in consecutivesequence, will initiate the shut–down of the engine.

Warning!

For Inte

rnal

Use O

nly


1.7– 4

1.7.2. Functional description

1.7.2.1. General��"($!��!�� !�� ?�j�H�O�

1.7.2.2. Speed measuring�� Q��%��Q��-$)��-$)��-$)��Q�� Q�� ]�� '�� Q�� ]�� '��C��E��Q��Q��-$)��!')��"($!��-$)��

1.7.2.3. Safety system�� "($!�� C]��'��E��

1.7.2.3.1. Starting�� "($!/

�; Start conditions are all configurable so they may vary depending on theinstallation,

�; The engine won’t start, if either local or remote reset button isn’t pressed aftershutdown.

For Inte

rnal

Use O

nly


1.7– 5

1.7.2.3.2. Stopping�� "($!��

�; The emergency stop signal isn’t blocked by the stop override signal

�; �he stop override signal is connected via the Relay Module to the MCU.

1.7.2.3.3. Start blockings*��/

�; low pre–lubricating oil level at turbo charger

�; turning gear engaged

�; stop lever in stop position

�; local/remote switch in local position (blocks the remote start)

�; local/remote switch in remote position (blocks the local start)

�; external start blocking input

�; shutdown condition active.

%��y'�� z��

�� %��'��

1.7.2.3.4. Shutdowns*�� {��"($!��

��Q��G�� '��

%��y'�� z��

Shutdown backup system!� �� "($!�� ]��'��

For Inte

rnal

Use O

nly


1.7– 6

��/

�; low lubricating oil pressure�; overspeed trip�; optional shutdown switch.*�� ]��'��

*�� Q��

��]��'��C�� E��"($!��

1.7.2.3.5. Load reduction��"($!�� "��

]�� O� ��?>� �

1.7.2.4. Monitoring and alarm sensors

��

Code Name Type

PT101 Fuel oil pressure, engine inlet A

TE101 Fuel oil temperature, inlet A

LS103A/B Fuel oil leakage, injection pipe 5) B

PT111 Fuel oil pressure, filter inlet A

PDS113 Fuel oil filter pressure difference 1) B

GT165 Fuel rack position A

SE167 Engine speed for governor A

SE168 Engine speed, after flexible coupling (separate) A

GS171 Stop lever in stop position A

ST173 Engine speed A

ST174 Engine speed, backup system A

For Inte

rnal

Use O

nly


1.7– 7

TypeNameCode

PT201 Lube oil pressure, engine inlet A

PSZ201 Lube oil pressure, inlet (backup system) B

TE201 Lube oil temperature, inlet A

LE204 Lube oil level (in case of wet sump) A

PT241 Lube oil pressure, filter inlet A

PDS243 Lube oil pressure difference 1) B

LS271 Lube oil level at turbocharger A

TE272/82 Lube oil temperature, turbocharger outlet 5) A

PT301 Start air pressure A

PT311 Control air pressure A

PT401 HT water pressure, inlet A

TE401 HT water temperature, inlet A

TE402 HT water temperature, outlet A

TSZ402 HT water temperature, outlet A

PT451 LT water pressure, inlet A

TE451 LT water temperature, CAC inlet A

TE511../13 Exhaust gas temperature, Turbo inlet 2) 5) A

TE517 Exhaust gas temperature, Turbo outlet 5) A

TE5xxA/B Exhaust gas temperature, cylinder outlet (xx= cylinder number=01,.....) 5)

A

PT601 Charge air pressure, inlet A

TE601 Charge air temperature, inlet A

TE700… Main bearing 0 temperature 4) A

SE518/28 Turbocharger speed 5) A

GS792 Turning gear engaged B

OS735 Emergency stop A

A Analogue sensorB Binary (on/off) sensor1) Calculated value (not a separate sensor)2) 1...3 pcs depending on exhaust gas system3) 2 pcs/cylinder4) (n + 2) pcs, where n = number of cylinders5) A–bank/B–bank

(��

For Inte

rnal

Use O

nly


1.7– 8

��

For Inte

rnal

Use O

nly


1.7– 9

1.7.3. Data acquisition�� "($!� �� -��)��C!')��-$)�E��%��'$)��J��]��'��?�j�;�H��

�� {�� /

�; ��

�; ��

�; ��

�; �� {��

��"($!� �� -$)&!')��*�� ?�j�;�H��

sensors/

switches

POWERSTATUS

CANFLASHRESETVAISALA

RS–485

digitallink

DCU SMU

VAISALA

sensors/

switches

CAN

digitallink

RS–232C

digitallink

Modbus

digitallink

External

Control

System

MCU

LDU

Analog

signals

mA, V, f

etc.

backup

sensors/

switches

RM11A

switches

RE

LAYM

OD

ULE

LUB

E O

IL SH

UTD

OW

NLU

BE

OIL S

HU

TDO

WN

BLO

CK

ING

OP

TIO

NA

L SH

UT

DO

WN

EC

U S

TO

P/S

HU

TD

OW

NH

AR

DW

IRE

D S

TO

PO

VE

RS

PE

ED

SH

UTD

OW

NE

ME

RG

EN

CY

STO

PE

CU

WAT

CH

DO

GS

TO

P/S

HU

TD

OW

N O

VE

RR

IDE

SH

UT

DO

WN

RE

SE

TLU

BE

OIL S

HU

TD

OW

N S

WIT

CH

FA

ILUR

EO

PT

ION

AL S

HU

TD

OW

N S

WIT

CH

FA

ILUR

EE

NE

RG

IZED

STO

P S

OLE

NO

ID FA

ILUR

E

STO

P R

ELAY

HA

RD

WIR

ED

STA

RT B

LOC

KIN

GH

AR

DW

IRE

D S

TAR

TE

CU

STA

RT

FUE

L LIMITE

RS

LOW

TU

RN

ING

FAILU

RE

ALA

RM

SP

EE

D S

WITC

H 1

SP

EE

D S

WITC

H 2 U

1U

2U

3U

4U

5BA

CK

UP

Modbus

or

Fig. 1.7 – 2 Sensor connection in the WECS

��"($!��?�j�;�O�� &%��!')�J��

For Inte

rnal

Use O

nly


1.7– 10

<��{�� -$)�J��

��-$)�� *��-$)�� $*G��'$)��'$)��'��'$)��-$)��'$)�� C��'��=-)��E�� -�� '$)��'��

SMU Board

– Measuring

– Filtering

– Linearization

– Error check

serial

I/O

DCU Board

Measurement

MCU

I/O

Database

WEnCoM LDU

Math Scale

CAN

Measurement

Database

Safety

Hour

Math

serial

Modbus master

Modbus

– validity check

– alarm check

– power reduct. check

– shutdown check

LDU

Fig. 1.7 – 3 Data handling procedure

DCU/SMU��"($!�� -$)&!')��-$)�� !')��K$J��$*G�� %��-��)�� /

�; XQH@� *��

�; ��

�; ��

�; K�Q?@@�

�; �� q��!��

�; ��

�; ��

�; ��C ��H��E�

For Inte

rnal

Use O

nly


1.7– 11

(�� (��C@QjE��?H��-$��?>��-$��C`QZE��>��-$�

��CÈ��-$)&!')��!�� <�� CHE��-$)&!')�

For Inte

rnal

Use O

nly


1.7– 12

1.7.4. WEnCoM–functions

1.7.4.1. Background

��"(�$�'��"#��#�-��`@�� $]�Q�� "��

��"(�$�'��/�� "($!� �� "($!�� "($!�

�� '$)��-��{�� "(�$�'Q��

1.7.4.2. Main bearings�� ?�j� ;� X� �� *�� ?�^{�

For Inte

rnal

Use O

nly


1.7– 13

Fig. 1.7 – 4 Temperature sensors of the main bearing

It is recommended to have trend diagrams of the main bearingtemperatures in the external system.

1.7.4.3. Exhaust gas valves�� *�� *� ��

Note!

For Inte

rnal

Use O

nly


1.7– 14

1.7.5. Instrumentation�� "($!��/

�; =��

�; =��

�; =��&��

�; =��&��

�; =��-��)��

�; J��

�; J��

�; J��^��

1.7.5.1. Local Display Unit��=��-��)��C=-)E�� '$)��'��

Fig. 1.7 – 5 The main page

For Inte

rnal

Use O

nly


1.7– 15

THE MAIN PAGE-��

$�� /; ��C��E; ��

(�� /; �� C��E; ��

C��E; ��

C��E; ��&��

C��E

THE HISTORY PAGE��

��

��Q��/; *��*�� ; J��!��; !��!��; (��( ��; =��=��; '��'��; G��G��C�� E

THE SYSTEM PAGE�� "($!��%��

!�� /; !��; (�� ; (��; $��; "�� ; %��

For Inte

rnal

Use O

nly


1.7– 16

�� /; =�� ; *��C�� E; J��

THE KEY BUTTONS��'*�G�� )��^�!�%]��

��,�� -.��/*��0*102��

)��0�.��

UP

ENTER

DOWN

F1 F2 F3 F4 F5 F6 F7 F8

HISTORY

SHIFT

HELP

MAIN

Fig. 1.7 – 6 The key buttons on the panel

��,��, ��/

; ,�/�!��; ,�/�(�� ; ,/�(�� ; ,�/�$�� C��"HM��E; ,3/�'�� ; ,/�$�� ; , /�<��

!� �� "�� )��-.��/*��

For Inte

rnal

Use O

nly


1.7– 17

*�� /��41 1-4��402"��0��)��4��,1�-.��4��,1��/*��

MODBUS ACTIVE INDICATION��'%-J)!��'%-J)!��'%-J)!��

1.7.5.2. Backup instruments��=-)�� /�� ^��

1.7.5.3. Controls��&��

Local/Remote��

Start��

Stop��

Shutdown reset*�� *�� *��

For Inte

rnal

Use O

nly


1.7– 18

1.7.6. Functional testing��

1.7.6.1. Testing of overspeed trip�� %��C!�?jOE��-$)&!')��C!�?jXE��]��'��%��

�� -$)&!')�� ]��'�� -$)&!')��?>�[�� ]��'��?`[��

�� %��

��

�� ]�� '��

If the WECS does not receive both signals from the speed sensorsST173 and ST174 the safety and alarm system is NOT fully activated.Running of the engine, however, is still possible but this could leadto serious engine damage. The absents of both signals can be seenduring engine start–up. On the ”Main page” of the WECS–screen,first the signal ”Start fail or rpm missing” and after a while ”Startblocked” appears. An alarm ”SS174 Engine speed” will be activatedwhen one ore both signals fail.

1.7.6.1.1. Testing of overspeed trip by running theengine

�� M@��

��

$��

�� -$)&!')�

Warning!

5

6

For Inte

rnal

Use O

nly


1.7– 19

"��]��'��-$)&!')�C!�?jOE��

Do not forget to connect the speed sensor after testing!

1.7.6.1.2. Testing of overspeed trip by using a signalgenerator

$�� !��?�j�;�HX�� ?H��

��

$��

��

The Relay module is delivered with the “Record Relay ModuleTuning document” where are indicated all the test frequecies andthe Relay Module’s set points.

�� /

��

��

��

�� Z@@�� ?@@@�� XM��

Note!

Note!

7

8

9

For Inte

rnal

Use O

nly


1.7– 20

Frequency corresponding

to speed

900 rpm (nominal speed) 345 Hz

1035 rpm (15% overspeed limit, DCU/SMU) 396 Hz

1062 rpm (18% overspeed limit, RM) 407 Hz

Frequency corresponding

to speed

1000 rpm (nominal speed) 383 Hz

1050 rpm (15% overspeed limit, DCU/SMU) 440 Hz

1180 rpm (18% overspeed limit, RM) 452 Hz

1.7.6.1.3. Testing of pressure switches (back–up)��

Fig. 1.7 – 7 Testing of pressure switches

��?�j�;�j��Q�� Q��*��

For Inte

rnal

Use O

nly


1.7– 21

Do not forget to open the shut–off valve after testing!Note!

For Inte

rnal

Use O

nly


1.7– 22

1.7.7. Hardware

1.7.7.1. General�� "($!� �� {�� (�� '��K$J�� &%�� -�KQ��

1.7.7.2. Main Control Unit��'$)�� '$)��<�� '��J��K��J�� -$&-$�$�� '� ��)�� =*GJ��J��

Fig. 1.7 – 8 MCU frame

For Inte

rnal

Use O

nly


1.7– 23

1.7.7.2.1. Frame�� '$)�� '$)�� J��

1.7.7.2.2. Motherboard��-'J>@�'��J�� ]��?�j�;�Z��

Fig. 1.7 – 9 Layout of mother Board

Install the MCU boards to the slots, which are dedicated to them. Ifa board is in a wrong slot and power is turned ON, the boardbecomes permanently damaged.

Caution!

For Inte

rnal

Use O

nly


1.7– 24

1.7.7.2.3. DC/DC Converter��-K!>@�-$&-$�$�� '$)��J��

��-$&-$�$��?�j�;�??�

Fig. 1.7 – 10 DPS50 DC/DC Converter

�� '$)�� '$)�� ?H��>��Q>��?`��

LED indicators��=(-��-$&-$�$��?�j�;�?@��

�; J�� &�$��(]]%]

�; J*��(]��<)==

�; $^*]��G�

�; *$�%G�C�� *$��E�

For Inte

rnal

Use O

nly


1.7– 25

Fig. 1.7 – 11 Block diagram of the DC/DC Converter

1.7.7.2.4. Processor Board�� K�� J�� '$)� �� '$)�J�� K��J��?�j�;�?O�

Fig. 1.7 – 12 Layout of the Processor Board

For Inte

rnal

Use O

nly


1.7– 26

Fig. 1.7 – 13 Block diagram of the Processor Board

1.7.7.2.5. Memory Unit

��-''>@�'� ��)�� K$�$��

Fig. 1.7 – 14 Memory Unit Layout

LED indicators��K$�$��*��J��=(-�� !�*�)!Q=(-��'� ��)��

For Inte

rnal

Use O

nly


1.7– 27

1.7.7.2.6. LAN Board��=*G�J��'$)�� '$)��$*G��]!QX`>��'%-J)!�

Fig. 1.7 – 15 LAN Board Layout

Fig. 1.7 – 16 Block Diagram of the LAN Board

The LAN Board front panel LED’s

�; ��=(-�� ?@��C�� E�

�; ��=(-��%<<��=(-��%G��'$)�

For Inte

rnal

Use O

nly


1.7– 28

1.7.7.2.7. Interface Board

��-'�>@�� '$)��`Q��&��"($!��J��

Fig. 1.7 – 17 Layout of the Interface Board

Fig. 1.7 – 18 Block Diagram of the Interface Board

For Inte

rnal

Use O

nly


1.7– 29

1.7.7.3. Distribution Unit��-��)��!��'��)��C!')E��!')�J��-��$��)��C-$)E��!')�J��$��J��

Fig. 1.7 – 19 SMU and DCU

�� !')� �� -$)�� !')� �� !]*'� � �� !')� �� {�� !')��]!QX`>��Q��!')��

*�-$)�� !')�J��-$)�J��!')��-$)�J�� K$�$��$*G��

For Inte

rnal

Use O

nly


1.7– 30

1.7.7.3.1. SMU board��!')�J��/

�; XQH@� *��

�; ��

�; ��

�; K�Q?@@

�; �� q��!��

�; ��

�; ��

�; ��C ��H��E

Fig. 1.7 – 20 SMU Board layout

��!')�J��`Q��`@$>?<$�$K)��?X�j�'^{��!')�J�� *-�� ?MQ�� &��*&-��

��!')�J�� HX��!')��!')� J�� "($!� ��

For Inte

rnal

Use O

nly


1.7– 31

Fig. 1.7 – 21 SMU Board block diagram

1.7.7.3.2. DCU Board��-$)�� Q��?MQ��-$)�J��!')�� !')�� !')� �� -$)��

Fig. 1.7 – 22 DCU layout

�� -$)��$*G��HQ��]!QX`>��]!QHOH$�� $K)��

For Inte

rnal

Use O

nly


1.7– 32

�� HQ�� ]!QX`>� �� !')�J��K$�$��!]*'��<=*!^� � ��

��-$)�J��C�>��?H�E�� j�� !')�� -$)� �� !')��

Fig. 1.7 – 23 DCU Board block diagram

%��-$)��$*GQ��*�K$�$�� -$)� �� -$)<=*!^Q � ��

LED’s on the DCU

LED COLOR LED Indication

POWER Green Continuously ON while the unit is receivingpower

CAN Yellow Blinks during CAN transmission

STATUS Green Blinking indicates software operation

FLASH Yellow Continuously ON when FLASH voltage is con-nected (normally during configuration or soft-ware loading)

RESET Red Indicates system reset at start–up, duringmanual reset or in insufficient power supplyconditions

For Inte

rnal

Use O

nly


1.7– 33

1.7.7.4. Sensors

1.7.7.4.1. Speed sensors

Engine speed sensor�� KGKQ�� ?@�Q�O@��-$��C�� ?>��-$��"($!E�� @��-$��?>��-$�C��E�

��Q ��Q��'?`��?�>� �� Q��(��J!X��

�� !�� )�� ?�>��H�@�Q�H�>� ��

Do not run or turn the engine while the sensor is being mounted.

Fig. 1.7 – 24 Engine speed sensors

ABB TPS turbocharger speed sensor�� "($!�

�� '?H� �� ?�H>� �� Q��

Caution!

For Inte

rnal

Use O

nly


1.7– 34

�� -��?>�G �

Do not run or turn the engine while the sensor is being mounted.

Fig. 1.7 – 25 ABB turbocharger speed sensor

EGT turbocharger speed sensor�� (�� *JJ��$��

�� >&`z�)G<��OQX�

EGT turbocharger speed sensor

Turbocharger type Pulses

Napier 155 2

Napier 295 2

Napier 297 G–wheel 9

Napier 297 GS–whell 13

Napier 355 2

Napier 457 6

Napier 557 6

The engine must not run while the sensor is being mounted.

Caution!

Caution!

For Inte

rnal

Use O

nly


1.7– 35

Fig. 1.7 – 26 EGT turbocharger speed sensor

1.7.7.5. Solenoid valves��OQ�� (��!��{�� HX��-$��Q?>�[��?@�[��??�"��C��Q��E��

1.7.7.6. Relay Module��]��'�� '$)�� '�� ]��'��]��'��

)��"($!��]��'�� $�� ]�� '�� ]�� '�� /

�; �� C��E

�; ��C��E

�; ��C��E

�; �'$)��&��

�; ��

�; ��C��E

�; ��

For Inte

rnal

Use O

nly


1.7– 36

�; �'$)��

�; ��&��

�; ��

�; ��

�; ��

�; �'$)��

�; ��

�; ��

�; ��

�; ��

Fig. 1.7 – 27 Layout of the Relay Module

Trimmers��]��'�� ]'��

Indication LEDs��]��'��=(-��*��=(-��{��=(-��

For Inte

rnal

Use O

nly


1.7– 37

LED’s on the Relay Module

LED Color LED indication

Lube oil shut-down

Red Lube oil pressure switch has caused ashutdown and local hardwired reset buttonhas not yet been pressed

Lube oil shut-down blocking

Yellow Lube oil shutdown is blocked during start ofan engine

Optional shut-down

Red Optional shutdown switch has caused ashutdown; i.e. it has been closed. Localhardwired reset button has not yet beenpressed

MCU stop/shut-down

Red MCU stop signal is active and is causing astop of an engine

Local stop Red Hardwired (normally local) stop button isbeing pressed or it has been released lessthan 60 s ago

Overspeedshutdown

Red Overspeed has caused a shutdown andlocal hardwired reset button has not yetbeen pressed. The speed is measured withbackup speed pick–up

Emergencystop

Red Emergency stop button is pressed downand causes a shutdown

MCU watchdog Red MCU watchdog signal is missing andcauses a shutdown

Stop/shutdownoverride

Red Stop/shutdown override signal from theMCU is active

Shutdown reset Yellow Shutdown reset button is being pressed

Stop relay Red Stop relay is active

Sart blocking Yellow Hardwired start blocking signal from theexternal system is active

Local start Green Hardwired (normally local) start button isbeing pressed

MCU start Green ECU start signal is active

Fuel limiter Yellow Fuel limiter signal from the ECU is active

Slow turning Yellow Slow turning signal from the ECU is active

Relay Modulefailure

Red Failure signal of the Relay Module is ac-tive. Also either one of the failure indicationLED’s should be ON or one of the voltageLED’s should be OFF

Speed switch 1 Green Speed of the engine is over speed limit 1

Speed switch 2 Green Speed of the engine is over speed limit 2

Speed pulse Green Indication of the backup speed signal

For Inte

rnal

Use O

nly


1.7– 38

Failure LED’s on the Relay Module


Lube oil shutdownswitch failure

Yellow Lube oil shutdown switch circuit isopen

Optional shutdownswitch failure

Yellow Optional shutdown switch circuit isopen

Stop solenoid failure Yellow Energized stop solenoid circuit isopen

Emergency stop fail-ure

Yellow Emergency stop circuit is open

Short circuit Yellow

Power supply LED’s on the Relay Module


U1 Green U1 voltage (U6 and not stop relatedfunctions of the RM) is ON

U2 Green U2 voltage (MCU and test instru-ments) is ON

U3 Green U3 voltage (DCU chain 1) is ON

U4 Green U4 voltage (DCU chain 2) is ON

U5 Green U5 voltage (LDU) is ON

Backup Green Backup voltage (stop related functionsof the RM) is ON

12 VDC Green 12 V power supply to MCU is ON

For Inte

rnal

Use O

nly


1.7– 39

1.7.8. Software

1.7.8.1. VRX Operating system shell

�]|�C��]��Q�� (��E�� ]*'Q��Q��

�� ]|�� ]|�� -��]|��

%�� ]|� �� *�� ]|��

�� ]|��(�� C'$)��-$)�E�

Fig. 1.7 – 28 Software structure of the WECS

For Inte

rnal

Use O

nly


1.7– 40

1.7.9. Maintenance of electrical contacts

�� "($!��

��

$�� ^��

Prior to use read the product information.

Action 1 Preliminary actions!��?�!��!��H�!��"($!��

If Check there is no tension in CAN–bus

Action 2 Cleaning of the DCUs and SMUs!��O�=��C@?E�C!��<��?�j�;�HZ�E�!��X�$��

Do not use any detergent liquid.

Action 3 Lubricating of electrical contacts!��>�=��K�� C@HE�!��M�$�� C@OE�

If electrolube grease is missing use CRC for electric circuit.

Note!

Warning!

Caution!

Note!

For Inte

rnal

Use O

nly


1.7– 41

!��j�K��K��

!��`�$��

!��Z��-$)��C@XE�

Fig. 1.7 – 30 Lubricating of contacts

For Inte

rnal

Use O

nly


1.7– 42

1.7.10. List of abbreviations

� ��$��5��

6�� $��7��7��$��5��

�� 2�$��8��9��$��7��

!�1 !��1��

:�� !��$�#�&�7��;��&��89��

:9� :��9��&

� �<$�7��

� � �<$�7��

� * �� *��

�� 88$�&��9��

�2� �#��$��2�&��&$��#��<��

�21 �$�<�&��2$#�1�:�

�14 ��$��1��4��&

�6 � ��7��$�� $��7��5��

��

��- ��:��&��-��

��. ��$��.$��$7�

��4 ��9��$��7�4#��8

�.� ��7��$��.$��8��#

�2 * �#�$8��2$�&�8� ��8��#

�- 21 ��$��-��5��$�� #��<��

2��5��61�$��8��

�10 �$�$�1��8��$��0=��98��

00.2�� 0��$��#�0�$�$:��.��7�$88$:��2�$&��#��8��#

0�� 0��8��&��9$#

0�� 0��$7��>��

0.2�� 0�$�$:��.��7�$88$:��2�$&��#��8��#

04� 0��4�$��<$�7�

, 1 ,�� $��1$:��$�&�!#��4��

$��$��>��$�&��

,,1 ,$��,��1�$��>��8$��

,� 4� 0��$��#��$�$:��0.2��8�8��#

,42 ,��4�$��2$�7�

?*� ?��&

�1 ��7<�1�89��$��

�/ �$�&�$��

For Inte

rnal

Use O

nly


1.7– 43

�� &��8��9��&��8��8$��:��>�

.<��9�

�� &��>��$��*�8:��>�$�4�-

��00.2�� 4��$��#��&��&��>��$��

00.2��$�<��-�:�$�&

�6� ��9��6��9��

� * ��$�� $�*��

��- ��$��9$#�-��

�0� ��7<��08��7��&�

�� :��$��7��

�2- ��2�9�$��$:��-��

�1 ��1�89��$��

�4! ��$��4�7��>��$��!��

�: ��7$�:��(��8��:��)

�! ��7$�!#��(��8��:#��)

��- �$��-��

��!-4 ��&��$��8$��:��>��&��

�4! ��4�7��>��$��!��

�4? ��$7�

�1 �$��$��1��8��$�

�1!, ��$��8��!��,$��

�112 ��$��1�8��1��2�9$��

*@��@ *��&

*� *��8$��#��&

*�� *��$&8��8

*�� *��$�$9��9�

*� *��8$��#��9��

.� .��$��89��

.�6�1 .��$��89��7��

�;�6�;��9��

.�! .��&��!�$�&

.�� .��8:��<$8:��

.�� 6A0�� .��$��89��8��#��$�&

��$��$�� $��6A$9$�

��&��#��5��98�� $��

.0 .��5��0$��<

.��!-4 ��:��9$�$��:��>�"$��$�$

.�� >��<

.��9��7�$��5$��

9986� 9$��9��8��6&�7��(&��>�)

.1� .��5��1<��8$��>>��(2��)

For Inte

rnal

Use O

nly


1.7– 44

.��;; .�$��8��89��$��

2� 2��5�&��$�$�(24��24��3)

2 � 2$�&�8� ��8��#

2� 2��$#��&��

2�4 2��$#��$��4=�$��

2.� 2�5��.��

2�� 2�$&��#��8��#

21� 2�$��1�8��

214 2�=��1��4��&

21- ��!-4�8�&��&��-

2�� 2��5�&��$�$�(24��)

4� 4��$�$�(24��24��3)

4�- 4��9��'��-��

42 � 4�$��2$�&�8� ��8��#

4/ 4�>��$��

1� 1<��8��9��

1A 1<��8��9��#9��A

1B 1<��8��9��#9��B

14 1<��8��9��#9��4

11 1<��8��9��#9��1

1�� 1�$��8��&��$�$�(24��)

-*, 1<��$&��$�&$�&

"0. "$��$�$�0�<$��&�.��

"? "�&��?�$>9<�� #

"2� 2�$��8��9��$��7��#��8

�<��C"$��$�$�2�$��8��5�D

/0�4 /E��E�0�7��4#��8

/0�� /E��E�0*7��&��8��7

�1 .��$��89��&��7

��;�6;��89$��:��9��For Inte

rnal

Use O

nly

Operation ManualWärtsilä 26

2.3 – 1

2.3. Operation

For Inte

rnal

Use O

nly

OperationManualWärtsilä 26

2.3 – 2

2.3.1. General

J��

��

*��

��*�� ?�@��

"#��#� $��

*��Q �� HXQ�� "��

For running HFO engines on distillate fuels see section 1.1.1.1.Note! For Inte

rnal

Use O

nly


2.3 – 3

2.3.2. Start

2.3.2.1. Preheating

�� Q��

!��Q�� /

�; <�� ; ^��

�� M@°$�� K�� X[��

�; =�� X@�°$�

2.3.2.2. Preparations before the start

J�� &��

J��/

�; =��; !�� ; $��; %�� ; ]��; =��; !�� ; $�� ; $��; <��; ��; <��; !�� ; �� ; *��; K�� ; !��; (��; (�� ; J��

Keep engine clear during start–up and operation.Note!

For Inte

rnal

Use O

nly


2.3 – 4

2.3.2.3. Local start

-�� !��?�@�X�

In case a stand–by pump is used for prelubrication preventcontinuous operating to avoid excessive fouling of theturbocharger.

*��Q��

J��

<��H�O�H�H�

$��

!��

80604020

0–20–40–60–80

80604020

0–20–40–60–80

A L OMode: Running

Main page

Exhaust gas temperature 483 5C

ENGINESPEED

LUBE OILPRESSURE

HT WATERTEMPERATURE

REMOTE LOCAL

ENGINEMODE

SHUTDOWNRESET

STOPSTART

2

1

Fig. 2.3 – 1 Local control panel

K��C?E��H�O�;�?�� ^K�� ?@@�� ?@��

Warning!

1

2

3

4

5

6

For Inte

rnal

Use O

nly


2.3 – 5

-��

-��/

�; �� ; �� ; �� ; �� ; ��; �� ; �� ; ��

��

2.3.2.4. Remote or automatic start

*�� C��E��

�� *��

*��

2.3.2.5. Start after a normal stop

�� /

�Q ��Q�� !��H�O�H�?�

�Q K��

�Q <��

�Q G��

�Q *��

�Q ��

�Q �� `� �� H��

7

8

For Inte

rnal

Use O

nly


2.3 – 6

2.3.2.6. Start after overhaul�� Q��

General*��

��

<��

-��

*�� ^K�� {��

K��$��

Test run*�� &��

��

If anything is suspected during the test run procedure, stop theengine immediately.

!�� H�O�H�O��

� ��Q��/

; =��(��^K��

; (��; K��; �� ; !��; <��

*��>� ��

Note!

1

2

3

4

5

1

2

3

For Inte

rnal

Use O

nly


2.3 – 7

Removing of the crank case covers immediately after engine stopis only allowed after maximal 5 minutest test running.In all other cases allow the engine to cool down 10 minutes.

%��

$�� $��

��

$��

Operating check��>� ��!��/

$��

$��

$��

$��

$�� &��'��

$��

$��

$��

$��

$��

=��

$��

$�� H�O�O�>�

Warning!

4

5

6

7

1

2

3

4

5

6

7

8

9

10

11

12

13

For Inte

rnal

Use O

nly


2.3 – 8

2.3.2.7. Emergency start

�� C?E��CHE�� ;�� COE��CHE��H�O�;�H��

q�� z])Gz��'��

Be aware that all safety devices are overruled if the engine is startedby using the emergency start push button.

2 3

1

Fig. 2.3 – 2 Start solenoid valve

Warning!

For Inte

rnal

Use O

nly


2.3 – 9

2.3.3. Operation

G��

Golden ruleSatisfactorily operation of a diesel engine depends mainly on thequality of the systems supporting the engine.

�� /

�� <((=��=%%q��=�!�(G�� -�� "#��#�$��

q��

�� /

; ��Q�� ; ��Q�� ; ��

��

��&��

1

2

3

4

5

For Inte

rnal

Use O

nly


2.3 – 10

%�� Q��

�; ��

!��

�; %�� )��

�; !��

�; <��

!�� z��z� ��

]�� /

�; ��

�; !��; �� ; ]��

=��/�� !��H�O�O�H�

-��!��H�O�O�?�H�

Unnecessary idling should be avoided as much as possible.

$��

G�� ^K��

The maximum deviation between fuel rack positions is � 0.5 mm.

Note!

Note!

6

7

8

9

10

11

12

13

For Inte

rnal

Use O

nly


2.3 – 11

2.3.3.1. Restrictions

2.3.3.1.1. Restrictions for operation at excessivesuction air temperature

�� ?�@�O�

<�� Q>��$��&��

2.3.3.1.2. Restrictions for low load and idling

-�� *��*�� <�� J��

Restrictions for idling:C�� E/

; '�� ?>� �� ?@� ��

; '�� M��

Unnecessary idling should be avoided as much as possible.

Restrictions for low load operation:%��>��H@[��/

; '�� ?@@��; *��?@@��

�� j@[��?��

2.3.3.1.3. Restrictions for a planned stop<��H@[��

Note!

For Inte

rnal

Use O

nly


2.3 – 12

2.3.3.2. Loading performance

�� &��

Maximum loading speed should only be used when absolutelynecessary.

2.3.3.2.1. Gradual load increase

�� ~F�� ~��H�O�;�O��=��

Fast loading creates larger thermal load strain and reduces life timeof the engine components considerably.

�

��

��

��

��

� ��

��

��

��

Load increase [%]

Time [s]

Fig. 2.3 – 3 Gradual load increase

Note!

Note!

For Inte

rnal

Use O

nly


2.3 – 13

2.3.3.2.2. Sudden load increase

*�� F�� H�O� ;� X� �� !%�`>H`Q>�

Engine load [%]

Load increase [%]

0

10

20

30

40

0 20 40 60 80 100

Maximum suddenpower increase

Fig. 2.3 – 4 Maximum sudden power increase

For Inte

rnal

Use O

nly


2.3 – 14

2.3.3.3. Maintenance points during operations

��

For the complete maintenance schedule see section 2.4.1.2.

%�� <�� H�O�O�X�?��

$�� -��

$��

<��$��/Q��Q�� CE�Q��

=��-��/

�; �� ; �� ; �� ; �� C�� E��

�� ; ��

-�� *��

q��^K�� C�� E��

$��$%]]%!�%G��

$��*�� *��

]��

]��

]��

Note!

1

2

3

4

5

6

7

8

9

10

11

12

For Inte

rnal

Use O

nly


2.3 – 15

2.3.3.4. Operating range

Fixed pitch propeller�� {��G�� `>[�� H�O�;�>�"�� Z>[�� /�M>��`@[��<��

0

50

100

150

200

250

300

350

300 400 500 600 700 800 900 1000Speed [rpm]

Ou

tpu

t [k

W/c

yl]

MCRMECHANICAL FUEL STOP

MIN. SPEED

RANGE FOR

CONTINUOUS OPERATION

RANGE FOR TEMPORARYOPERATION ONLY

PROPELLER LAY–OUT AREA

NOMINAL PROP. CURVE

85 % MCR

Fig. 2.3 – 5 Operating range

For Inte

rnal

Use O

nly


2.3 – 16

2.3.3.4.1. Engine log sheet (example)

�� -��

YEAR .. WEEK .. day ... ... ... ... ... ... ... Time ... ... ... ... ... ... ...Engine speed rpm ... ... ... ... ... ... ...Turbocharger speed rpm ... ... ... ... ... ... ...Fuel rack position mm ... ... ... ... ... ... ...Load kW ... ... ... ... ... ... ...Load indication governor ... ... ... ... ... ... ... HT cooling bar ... ... ... ... ... ... ...LT cooling bar ... ... ... ... ... ... ...Lubricating oil bar ... ... ... ... ... ... ...Fuel bar ... ... ... ... ... ... ...Charge air receiver bar ... ... ... ... ... ... ...Exhaust gases after turboch. m.bar ... ... ... ... ... ... ...Barometer m.bar ... ... ... ... ... ... ...Crankcase pressure m.bar ... ... ... ... ... ... ... Ambient air oC ... ... ... ... ... ... ...Air after turbocharger oC ... ... ... ... ... ... ...Air in receiver oC ... ... ... ... ... ... ...Water before air coolers oC ... ... ... ... ... ... ...Water before oil coolers oC ... ... ... ... ... ... ...Lubricating oil before coolers oC ... ... ... ... ... ... ...Lubricating oil after coolers oC ... ... ... ... ... ... ...Lubricating oil before engine oC ... ... ... ... ... ... ...HT water before the engine oC ... ... ... ... ... ... ...HT water after the engine oC ... ... ... ... ... ... ...HT water after the HT cooler oC ... ... ... ... ... ... ...

Fuel before the engine oC ... ... ... ... ... ... ...Fuel after the engine oC ... ... ... ... ... ... ... Exhaust gases cyl.1, A1 / B1 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.2, A2 / B2 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.3, A3 / B3 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.4, A4 / B4 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.5, A5 / B5 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.6, A6 / B6 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.7, A7 / B7 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.8, A8 / B8 oC ./. ./. ./. ./. ./. ./. ./. ” cyl.9, A9 / B9 oC ./. ./. ./. ./. ./. ./. ./.Exhaust gases before turboch. oC ... ... ... ... ... ... ...Exhaust gases after turboch. oC ... ... ... ... ... ... ...

For Inte

rnal

Use O

nly


2.3 – 17

2.3.3.5. Measurement of cylinder pressure

General�� -�� >Q?>��

Cylinder pressure measurement at the indicator cock is useful forindividually comparison, however, the value measured is notrepresentative for the real pressure in the combustion space.

'�� &�� ^��

��/

�Q ��

�Q -��

It is not permitted to switch off fuel injection of a cylinder tomeasure compression pressure.

Checking cylinder firing pressure$��*�� *��

Recording cylinder combustion pressures withoutsimultaneously recording engine load is practically worthless.

Note!

Note!

Note!

For Inte

rnal

Use O

nly


2.3 – 18

2.3.3.6. Running–in

�� Q�� <��Q�� ]�� ]��Q�� Cq��JG�� E�

$��C��E��H�O�H�M��

!��Q��

�; � �� @�>�� ; �� @�j>��?��; �� @�H��@�H>��; ?��` ��&��

0

10

20

30

40

50

60

70

80

90

100

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15[hours]

1

2

34

56

7 8

= Output= Engine rpm

a b c

load

/ rp

m [

%]

Fig. 2.3 – 6 Running–in diagram

]��?&H��)��G��

*��

1

2

3

4

For Inte

rnal

Use O

nly


2.3 – 19

2.3.3.7. Operating problems

<�� H�X�� !� �� %��

2.3.3.7.1. Trouble and possible reason

Action

1. Compressed air starter motor not activateda) Engine start blocked. Check start blockings.

2. Crankshaft rotates however engine does not fire

a) Too low cranking speed. Check pressure starting air.

b) Fuel pump rack blocked.

c) In case of starting on HFO, too low engine and/or fueltemperature.

d) Too low compression pressure.

e) Aspirated air temperature too low.

f) Gas in fuel supply lines. Check pressure and vent fuelsystem.

g) Actuator does not move. Check starting routine ofspeed control unit.

3. Engine fires irregularly

a) See points 2d, 2e, 2f, 4c.

b) Fuel control mechanism is set incorrectly or jams. Readjust fuel rack.

c) HP pump operates improper.d) Bad working fuel injector. Nozzle holes clogged.

e) Fuel booster pressure too low. Check working of pressureregulating valve and system.

For Inte

rnal

Use O

nly


2.3 – 20

Action

4. Engine speed not stable

a) Actuator incorrectly adjusted.

b) See point 3b.

Readjust dynamics in speedcontrol unit.

c) Too much clearances in control mechanism.

d) Water in fuel. Check separator.

e) Automatic load control mechanism malfunctioning.

f) Gassing in fuel booster line. Fuel temperature too high.

g) Actuator drive worn.

5. Knock or detonation

a) Big end bearing clearance excessive.

b) Valve springs or tappet spring broken.

c) Excessive valve clearance. Find cause of excessive wear.Readjust valve clearance.

d) Valve(s) jams.e) HP fuel pump malfunctioning.

f) Fuel rack position incorrect. Correct fuel pump rack posi-tion.

h) Piston seizure.

j) Ignition delayed. Check fuel quality.

6. Exhaust gases dark coloured

a) Engine overloaded. Check HP fuel pump rackpositions, exhaust gas tem-peratures and charged airpressure/temperature.

b) Delayed injection. Check timing.

c) See points 3b, 3c, 4.

d) Insufficient charge air pressure due to:– clogged air filter of turbocharger– dirty compressor section– clogged nozzle ring– turbine speed too low– too much clearance between rotor

and shroud ring– clogged air cooler.

e) Deteriorated injectors.f) Too fast engine loading e.g. during start up.

Clean air side air cooler.

Adjust load–limiter or followadvised load steps.

For Inte

rnal

Use O

nly


2.3 – 21

Action

7. Exhaust gases blue or greycoloured

a) Excessive lubricating oil consumption due to badsealing of piston rings.

b) Grey gases due to water leakage in the combustionchamber.

Note:Blue smoke appears when running at low load orat low ambient temperature shortly after starting.

8. Exhaust gas temperatures of one or more cylin-ders too high

a) Engine overloaded. See engine log sheets andtest bed protocol.

b) See points 3c and 3d.

c) Charge air temperature too high. Inspection charge air coolingsystem.

d) Exhaust valve leaking. Inspection/overhaul exhaustvalve.

e) Turbocharger contaminated.

f) Malfunctioning of exhaust gas temperature measuringequipment.

g) Valve clearance too large. Check valve clearance.

For Inte

rnal

Use O

nly


2.3 – 22

Action

9. Exhaust gas temperature of one cylinder belownormal

a) Malfunctioning of exhaust gas temperature measuringequipment.

b) Leaking of fuel injector or HP fuel pipe.

c) Malfunctioning of HP fuel pump. Inspection/overhaul HP fuelpump.

d) See point 3b and 3d.

10. Exhaust gas temperature deviation too high

a) Too low fuel booster feed pressure. Insufficient filling of HP fuelpumps,

Dangerous !Causes high thermal overloadin individual cylinders.

b) See points 3b and 6b when idling.

11. Lubricating oil pressure too low

a) Malfunctioning of WECS reading. Check pressure gauge / trans-mitter.

b) Lubricating oil level in tank too low.

c) Filter contaminated. Check working automaticback–flush filter

d) Lube oil temperature too high. See 13.

e) Lubricating oil seriously diluted with fuel or water.

f) Malfunctioning of lubricating oil pressure regulatingand safety valve.

Inspection/overhaul pressureregulating valve.

g) Lubricating oil suction pipe leakage.

h) Suction strainer dirty or blocked.

j) Malfunctioning of lubricating oil pump.

k) Lubricating oil pipes inside engine damaged.

12. Lubricating oil pressure too high

a) See point 11f.

For Inte

rnal

Use O

nly


2.3 – 23

Action

13. Lubricating oil temperature:

too high

a) Wrong temperature indication. Check temperature reading.

b) Disturbance of cooling water system.

c) Too high LT water temperature.

d) Oil cooler contaminated.

e) Thermostatic valve:– check working range of thermostatic valve– wrongly positioned– check of sliding part of thermostatic valve is not

jammed.

f) Insufficient heat transferred to coolant tomaintain temperature.

too low

g) Wrong temperature indication. Check temperature reading.

h) Thermostatic valve:– wrong element temp. mounted– check of sliding part of thermostatic

valve is not jammed.

14. Cooling water:

temperature too high

a) Malfunctioning of pump.

b) Water cooler contaminated.

c) Thermostatic valve:– check of working range of thermostatic valve– wrongly positioned– check of sliding part of thermostatic valve is not

jammed.

d) Incorrect valve position in the system.

difference between inlet andoutlet temperature too high

e) See point 14a.

f) Water cooler clogged or contaminated.

g) Insufficient flow of cooling water through engine, air insystem, valves leaking.

For Inte

rnal

Use O

nly


2.3 – 24

Action

15. Water in lubricating oil

a) Leaking oil cooler. Repair cooler.

b) Leakage along cylinder liner O–rings. Replace O–ring.

c) Wrongly adjusted lube oil separator. See separator instructionbook.

d) Defective cylinder liner or cylinder head. Replace liner / cylinder head.

16. Charge air cooler

a) Insufficient performance of the charge air cooler 1. Vent the water side ofcharge air cooler.2. Clean the charge air cooler.

A rising air temperature ac-companied by a fall in air pres-sure indicates that the finplates are becoming dirty. Arising air temperature with wa-ter pressure loss over thecooler indicates obstruction ofthe tube by scaling. In eithercase cleaning is required.

17. Water in charge air receiver

a) Charge air coolers leakage. Inspect cooler

b) Condensate. Increase charge air tempera-ture

18. Engine lowers speed at constant or increasedload

a) Engine overloaded. A further increase of load isprevented by a load limiter.

b) See points 2d, 4d and 4e.

19. Engine stops

a) Shortage of fuel.

b) Safety device is activated.

c) Automatic stop device is activated.

d) Malfunctioning of actuator. See actuator manual

e) Malfunctioning of actuator drive.

For Inte

rnal

Use O

nly


2.3 – 25

Action

20. Engine continuous running although stop leveris set in stop position or remote stop signal isgiven

a) Fuel control mechanism wrongly set (3b, 3c). Activate stop device manually.If engine does not stopimmediately close fuel supplyto engine.Before restarting problemmust be located andcorrected.Risk of overspeed.

b) Malfunction remote engine stop. Use stop lever on engine.

c) Engine is driven by generator, propeller or othersource.

2.3.3.8. Emergency operation

2.3.3.8.1. Operation with defective air cooler(s)

-�� "�� C��?�@�X�E�� =��

For Inte

rnal

Use O

nly


2.3 – 26

2.3.3.8.2. Operation with defective turbocharger

*� ��

K�� H@[��(�� '�� >@@�$�

2.3.3.8.3. Operation with one cylinder misfiring

*� �� "�� /�� ^K� �� "#��#�$��

(�� %�� Q�� Q� ��

Engine operation, with one cylinder misfiring, is only allowed incase restrictions, mentioned in a report concerning torsionalvibration behaviour of this particular installation, are observed!

Note!

For Inte

rnal

Use O

nly


2.3 – 27

2.3.4. Engine stop

��/�� /

; !�� ; !��; !��C��E�

Idle engine 5 – 10 minutes before a normal stop.

Local stopK��CHE��

80604020

0–20–40–60–80

80604020

0–20–40–60–80

A L OMode: Running

Main page

Exhaust gas temperature 483 5C

ENGINESPEED

LUBE OILPRESSURE

HT WATERTEMPERATURE

REMOTE LOCAL

ENGINEMODE

SHUTDOWNRESET

STOPSTART

2

1

Fig. 2.3 – 7 Local stop

Remote stopK��

Note!

For Inte

rnal

Use O

nly


2.3 – 28

Manual stop'��CME�� *��J��$��CjE��

7

’A’ ’B’

6

Fig. 2.3 – 8 Manual stop

Final stop of the engine<��


For Inte

rnal

Use O

nly

Maintenance ManualWärtsilä 26

2.4 – 1

2.4. Maintenance

For Inte

rnal

Use O

nly

1

2

3

4

5

6

7

8

9

MaintenanceManualWärtsilä 26

2.4 – 2

2.4.1. Maintenance Schedule

�� !�� "#��#�$��

�� !��Q��

2.4.1.1. Safety aspects and rules for inspectionand maintenance

General"��

�� !��

K�� '�� (��

)�� '*G)*=� �� K*]�!�$*�*=%�)(�

-��

J�� J�� *�?@� ��

%��

*�� %Q��

��%Q�� !��%Q��

G�� "($!� �� -��

For Inte

rnal

Use O

nly

1

2

3

4

1

2

3

4

5

6

1

2

3

4


2.4 – 3

RemovalJ��H�X�O��

J�� *�� (��%��

�� <��

��

Mounting'�� C�� E

�� -��

J��H�X�O��

<�� G��

J�� Q�� %Q��

��<�� {��*�� C��E�

<��

Last check��

��

-�� HX��

]��

]��

For Inte

rnal

Use O

nly


2.4 – 4

2.4.1.2. Maintenance schedule

�� /

�Q ��

�Q ��

�Q (��

�Q ��

�Q �� M@[� �� ?@@[� �� O�@@@��M�@@@��

�Q �� Q�� Q��

�Q ��

-�� &��

2.4.1.2.1. Procedure for inspection and maintenance

Inspection

�Q ��

�Q ��X�@@@��

For Inte

rnal

Use O

nly


2.4 – 5

Maintenance intervals

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

General

Check engine on leakages, fixation of piping,cables and wiring.

� � � � � � � � � �

Check engine on bolt connections. � � � � � � � � �

Check condensate drain points of charge air re-ceiver on possible water.

� � � � � � � � � �

Record performance data in engine log sheetand check for deviations.

� � � � � � � � � �

Check fluid levels. � � � � � � � � � �

Record combustion pressures. � � � � �

Engine arrangement

Check foundation bolts and chocks – first year every 2 months.

�

– at interval of � � � � �

Check reference points of epoxy resin chocks (if applicable).

� � � � �

Inspect elastic engine mounting elements(if applicable).

� � � � �

Elastic elements of flexible coupling: – inspect visually after the first 4,000 running h.

�

– inspect at interval of: � � �

– renew every 48,000 running hours �

Measure axial displacement and crankshaftdeflections of crankshaft.

� � � � �

Check alignment between engine and enginedriven machinery.

� � � � �

For Inte

rnal

Use O

nly


2.4 – 6

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Fuel System (Chapter 1.1)

Check the leak fuel quantity of the fuel system. � � � � � � � � � �

Fuel filter: – check pressure difference,

clean if necessary.� � � �

– renew filter elements. � � � � � �

Drain impurities and condensate of fuel day tank. � � � � � � � � � �

Renew O–rings of fuel supply and return lines. �

Inspect fuel pump bracket, tappet and spring: – one � �

– all �

Lubricating oil system (Chapter 1.2)

Sample / analyse lubricating oil; record analysisresults, lubricating oil service time consumptionand charge changes on basis of condemning lim-its, see section 1.2.1.1.

�

Inspect / overhaul thermostatic valves: – check function. – renew.

� �

�

Inspect / overhaul lubricating oil pump(s). �

Inspect / overhaul lubricating oil cooler. �

Lubricating oil filter – check pressure difference, clean candles

if necessary. – inspect candles, renew if necessary. – renew candles

�

� � � �

� �

� � �

Clean centrifugal filter.Renew all seals of centrifugal filter.

� � � � �

�

�

�

�

�

�

�

�

�

For Inte

rnal

Use O

nly


2.4 – 7

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Starting air system (Chapter1.3)

Drain starting air vessels and air treatmentunit(s).

� � � � � � � � � �

Inspect compressed air starter motor. � �

Inspect compressed air starter motor and renew seals �

Inspect / overhaul compressed air starter motorafter every 48,000 running hours.

�

Cooling water system (Chapter 1.4)

Control condition of HT and LT cooling water. � � � � � � � � �

Check working of cooling water venting system. � � � � �

Thermostatic valve: – check function. – renew.

� �

�

Inspect / overhaul cooling water pumps and re-new seals and bearings.

�

For Inte

rnal

Use O

nly


2.4 – 8

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Charge air and exhaust gas system (Chapter 1.5)

Turbocharger (See also rating plate on turbocharger and sub–supplier manual.)

Clean turbine by water injection, every 48 ... 200running hours.

�

Clean compressor by water injection. � � � � � �

Inspect and clean turbocharger after the first4,000 running hours

�

Inspect and overhaul turbocharger(s)Renew plain bearings.

� � �

Renew compressor wheel of turbocharger after48,000 running hours.

�

Renew turbine wheel of turbocharger after 96,000running hours.

�

Inspect and clean air filter to the turbocharger. � � � � � �

Renew air filter material (if applicable). � � �

Charge air cooler

Inspect air side and inspect the water side afterthe first 4,000 running hours.

�

Inspect air side. � �

Inspect / overhaul charge air cooler. � � �

Exhaust gas ducting

Inspect exhaust manifolds, compensators, etc. � � �

Renew compensators after 48,000 running hours. �

For Inte

rnal

Use O

nly


2.4 – 9

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Control system (Chapter 1.6)

Fuel control mechanism linkage: – check / lubricate. � � � � � � � �

– inspect / overhaul. �

Inspect filter/water seperator control air � � � � �

Refresh actuator lubricating oil charge. � � � �

Inspect / overhaul actuator �

Inspect / overhaul actuator drive �

Check if alarm & safety system is on with runningengine, daily and after every start.

� � � � � � � � � � �

Check functioning of the alarm & safety system /devices.

� � � � � � � �

Check functioning of measuring devices. � � � � � � � � � �

Calibrate measuring devices. � � �

Check functioning of the oil mist detector.( If applicable )

� � � � � � � � � �

Operation (Chapter 2.3)

Test starting process for engine in stand–by posi-tion.

� � � � � � � � �

Carry out test run. � �

Carry out running–in program. � � �

Carry out load performance test. � � � � �

For Inte

rnal

Use O

nly


2.4 – 10

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Engine block with bearings (Chapter 2.5)

Inspect crankcase visually. � � � � �

Inspect cooling water spaces. � � �

Vibration damper(s): – sample fluid after the first 12,000 hereafter

next sample interval or renewal of damperas advised by test result.

�

Inspect one main bearing and journal. � �

Renew main bearing and inspect main journals. �

Inspect one camshaft bearing and journal. �

Renew camshaft bearings and inspect journalsafter every 48,000 running hours. �

For Inte

rnal

Use O

nly


2.4 – 11

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Crankshaft, connecting rod, piston and liner (Chapter 2.6)

Inspect one:piston, (without dismantling of piston rings), con-necting rod, crankpin with bearing, cylinder liner,gudgeon pin and bearing after the first 4,000running hours.

�

Gudgeon pins and bearings : – inspect. � � �

– renew every 48,000 running hours. �

Inspect and overhaul connecting rods. � � �

Renew crankpin bearings and inspect journals. � � �

Inspect and overhaul pistons and renew pistonrings.

� � �

Renew piston every 48,000 running hours. �

Inspect and overhaul cylinder liners and renewanti bore polishing rings. � � �

Renew cylinder liner with anti bore polishing ring. �

Check operation of turning gear and start inter-lock device.

� � � � � � � �

Refresh lubricating oil of turning gear. �

Renew crankshaft sealing. �For I

ntern

al Use

Only


2.4 – 12

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Cylinder head with valves (Chapter 2.7)

Make endoscopic inspection of valves, valveseats and running surface of cylinder liners.

� �

Renew safety valves. �

Inspect/overhaul cylinder head – one after the first 4,000 running hours. �

– all at interval of: � � �

Check valve clearances: – of new and overhauled engines after the first

100 running hours.�

– at the interval of: � � � � � � �

Check function of valve rotators. � � � � �

Inlet valves: – inspect / overhaul. � �

– renew. �

Exhaust valves: – inspect / overhaul � �

– renew �

For Inte

rnal

Use O

nly


2.4 – 13

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Camshaft and valve drive mechanism (Chapter 2.8)

Inspect camshaft sections. � � � � �

Inspect camshaft driving gear ; – after the first 4,000 running hours. �

– at interval of: �

Inspect inlet/exhaust tappet: – one � �

– all at interval of: �

Check pushrod pivots. � � �

Inspect and overhaul valve lifting gear andbracket.

�

Driving gear pumps (Chapter 2.4)

Inspect driving gear built–on pumps: – after the first 4,000 running hours. �

– at interval of: � � �

For Inte

rnal

Use O

nly


2.4 – 14

Every

(running hours)

Description

D

A

I

L

Y

W

E

E

K

L

Y

S

P

E

C

I

A

L

5

0

0

1

0

0

0

2

0

0

0

4

0

0

0

8

0

0

0

1

2

0

0

0

2

4

0

0

0

3

6

0

0

0

Injection system (Chapter 2.9)

Inspect fuel injectors, renew nozzles and test. � � � � �

Renew inner parts of injector holders. �

Inspect conical sealings and cavitation on inside ofthe HP fuel pipes. � � � �

Renew HP fuel pipes. �

Check the fuel injection timing. � � �

Remove all HP fuel pumps. Inspect the plungerand spring. Renew the O–rings arround the bar-rel.

� � �

Inspect the plunger and spring at the bottom sideof one HP fuel pump.

� �

Inspect and overhaul all HP fuel pumps. Depending on results renew pump elements andtest pump or renew complete pump

�

For Inte

rnal

Use O

nly


2.4 – 15

2.4.2. Maintenance Tools

'�� !� ��

�� !��

��

��

'�� H�X�H�?��

�� H�X�H�j��

Depending on the scope of supply the following tool sets are available:

?� �� z(�� !��z

H� �� z!��!��z

O� (�� z(��!��z

X� (�� z"��!��z

>� !�� z!��!��zFor Inte

rnal

Use O

nly


2.4 – 16

?� ”Economic Set” ��8:��G1��

��ZM?H��ZZ?*��/

*�� -�� G� ��

ZM?H��Z@? ^�� H

ZM?H��O`? ^�� H

ZMHH��ZZH ^�� ?

ZM?H��ZHj =�� ?

ZM?H��Z@X �� H

ZM?H��H>> !��^K�� ?

ZM?H-�H>Z !�� ?

ZM?H��ZX@ -�� ?

ZM?H��Zj` ^�� ?

ZM?H��Z?O ^�� ?

ZM?H��Z?Z $� �� ?

ZM?H-�HM@ '�� ?j@@�G ?

ZMHH-�H?M ��?>@Q`@@�G ?

ZMHH-�H?> ��j@QO>@�G ?

ZM?H��ZO? (�� ?

ZM?H��ZOX �� ?

ZM>@��?@` *�� ?

ZM?H��?`j� !�� ?

ZM?H��H>? <�� H

ZM?H!">?@ �Q��` ?

ZMHH-�H?X ��H@Q?@@�G ?

ZM?H��OO? $�� ?

ZM?H��OOH (�� ?

ZM?H��ZMH �� ?For Inte

rnal

Use O

nly


2.4 – 17

H� ”Standard Set” ��8:��G1��

$��/z(�� z�ZM?H��ZZ?*��ZM?H��`ZO�

��ZM?H��`ZO��/

*�� -�� G� ��

ZM?H��?`> K�� ?

ZM?H��?Z> ��'` ?

ZM?H��H>@ $�� ?

ZM?H��OOX *��O&`z ?

ZM?H��XX> '�� ?

ZM?H��Z@H �� H

ZM?H��Z@O �� H

ZM?H��Z@M �� ?

ZM?H��Z?@ J�� ?

ZM?H��Z?? '�� ?

ZM?H��Z?H (�� ?

ZM?H��Z?j K�� ?

ZM?H��ZO> !�� &�� ?

ZM?H��ZO` K�� ?

ZM?H��ZX? -�� ?

ZM?H��ZXX ^�� H

ZM?H��Z>@ K�� ?

ZM?H��Z>? K�� ?

ZM?H��`jj (�� ?

ZM?H��H>M !�� H

ZM?H��`>M -� �� ?

ZM?H��ZHX =�� X

ZM?H��ZH> =�� HFor Inte

rnal

Use O

nly


2.4 – 18

O� ”Extended Set” � ��8:��G1��

$��/z!��!��z�ZM?H��ZZH*��ZM?H��`Z?�

��ZM?H��`Z?��/

*�� -�� G� ��

ZM?H��HXj -�� H

ZM?H��O`@ K�� &�� ?X@@�� ?

ZM?H��OjM $�� ?

ZM?H��Z@? ^�� H

ZM?H��Z?> �� ?

ZM?H��Z?` -�� H

ZM?H��ZHZ -�&�� = ?

ZM?H��ZOM !�� ?

ZM?H��ZXH <�� ?

ZM?H��ZXj �� ?

ZM?H��Z>O *� �� ?

ZM?H��Z>M �� ?

ZM?H��Zj@� K��= H

ZM?H��Zj> !��z%��z�� ?

ZM?H-�OjO ^�� X

For Inte

rnal

Use O

nly


2.4 – 19

X� ”Workshop Set”� ��8:��G1��3 �H��G1��!

��ZM?H��ZZ>*��ZM?H��ZZO*��ZM?H��`ZX�

��ZM?H��`ZX��/*�� -�� G� ��

ZM?H��Zj? -�&�� ?

ZM?H��ZX> �� ?

ZM?H��HOO '�� ?

ZM?H��HOX '�� ?

ZM?H��ZXM '�� ?

ZM?H��ZM? =�� ?

ZM?H��HH> K�� ?

ZM?H��XZj !�� ?

ZM?H��>Xj -�� ?

ZM?H��Ojj K�� H

ZM?H��Z>` �� ?

ZM?H��Z@Z -�� ?

ZM?H��Z>X �� ?

ZM?H��Z`? ^�� ?

ZM?H��`>@ �� ?

ZM?H��?ZX K�� ?

ZM?H��`>> !�� ?

ZM?H��>M@ ]�� ?&XQ>&?M ?

ZM?H��ZM@ -�Q�� ?

ZM?H��`>Z (�� ?

ZM?H��ZX` K�� ?

ZM?H��Z?M ^�� ?

ZM?H��ZOH (�� ?

ZM?H��ZjZ <�� MH@@G ?

ZM?H��Z`@ -�� ?

ZM?H��Z`H ^�� ?

ZM?H��>>` �� ?

ZM?H��`MX ^�� ?

ZM?H��`MO �� ?

For Inte

rnal

Use O

nly


2.4 – 20

��ZM?H��ZZMJ��/

*�� -�� G� ��

ZM?H��Z`> �� ?

ZM?H��`>O -�&�� ?

ZM?H��`>X -�&�� ?

ZM?H��`jH -�&�� ?

ZM?H��ZOZ *� �� ?

ZM?H��ZHZ -�&�� HM�= ?

ZM?H��Zj@ $�� ?

ZM?H��Z`Z -�&�� HM�= ?

ZM?H��HXj $��C��E ?

ZM?H��`>H -�&�� HM�= ?

ZM?H��ZMO -�&�� ?

ZM?H��ZHM -�&�� &�� = ?

ZM?H��HX` ^�� ?

ZM?H��`>M -� �� ?

For Inte

rnal

Use O

nly


2.4 – 21

>� 49��$�� 8:��G1��

4��8��>��<��>��7��9��$��%

*�� -�� G� ��

ZM?H��`M? K�� ?

ZM?H��`MH �� ?

ZM>@��`@? �� ^�� ?

ZM>@��`@H �� J!K�H ?

ZM>@��`@O �� J!K�O ?

ZMHH-�ZX? K��@QHH@�� ?

ZMHH-�ZXH K�� ?

ZMHH-�ZXO G�� ?

ZMHH-�ZXX $�� ?

ZMHH-�ZX> -�� ?

ZMHH-�ZXM ^�� ?

ZM?H��O>O '�� ?

ZM?H��OM> �� ?

ZM?H��ZjO ��Q�� ?

ZM?H��`M> K�� ?

ZMHH-�ZOM �� ?

ZMHH-�Hj> '��-�� ?

ZM?H��`Mj '�� ?

ZM?H��`M` (�� ?

ZM?H��`j@ ^�� ?

ZMHH-�ZMZ !�� ?

ZM?H��`jZ K�� {�� ?

ZM?H��`j? $��"($! ?

For Inte

rnal

Use O

nly


2.4 – 22

2.4.2.1. Miscellaneous tools

Description Codenumber

Weightkg

Dimensions

Hydraulic pump (air operated).

9612ZT380


Weightkg

Dimensions

Hydraulic pump (manually operated).

9622ZT992

400515

505

For Inte

rnal

Use O

nly


2.4 – 23


Weightkg

Dimensions

Hydraulic jack (3).

With:1. Knurled nut2. Tool pin.

Used for:– main bearing studs– side studs– cylinder head studs.

9612ZT901

9612ZT1199612ZT125


Weightkg

Dimensions

Hydraulic jack.

Used in combinationwith:– camshaft bearing

bush extractor– valve removing /

mounting tool.– extractor for

cylinder liner.

9612ZT913

9612ZT850

9612ZT919

9612ZT912

For Inte

rnal

Use O

nly


2.4 – 24


Weightkg

Dimensions

HP hose. 9612DT381


Weightkg

Dimensions

Distribution block HPhoses.

9612ZT918

For Inte

rnal

Use O

nly


2.4 – 25


Weightkg

Dimensions

Hydraulic hose. 9612DT373


Weightkg

Dimensions

Depth gauge.

Used for:– cylinder head stud– main bearing stud– side stud.

9612ZT941

For Inte

rnal

Use O

nly


2.4 – 26


Weightkg

Dimensions

Tool for removing /mounting studs.

Used for:– main bearing studs– cylinder head studs.

9612ZT935


Weightkg

Dimensions

Torque spanner20 – 100 Nm.

9622DT214

For Inte

rnal

Use O

nly


2.4 – 27


Weightkg

Dimensions


9622DT215


Weightkg

Dimensions


9622DT216

For Inte

rnal

Use O

nly


2.4 – 28

2.4.2.2. Fuel systemC$��H�Z�E


Weightkg

Dimensions

Lifting tool fuel pumpbracket.

9612ZT961


Weightkg

Dimensions

Tool for HP fuel pumptappet.

Used in combinationwith:– HP hose– hydraulic pump.

9612ZT960

9612DT3819622ZT992

For Inte

rnal

Use O

nly


2.4 – 29


Weightkg

Dimensions

Locking tool for HP fuelpump tappet.

9612ZT925


Weightkg

Dimensions

Tool for sealing set in HPfuel pump bracket.

9612ZT953

For Inte

rnal

Use O

nly


2.4 – 30


Weightkg

Dimensions

Depth gauge for fuelpump push rods.

9612ZT547

For Inte

rnal

Use O

nly


2.4 – 31

2.4.2.3. Lubricating oil systemC$��?�H�E


Weightkg

Dimensions

Lifting tool for enginemounted pumps.

9612ZT939


Weightkg

Dimensions

Tool for lubricating oilcooler.

9612ZT872

For Inte

rnal

Use O

nly


2.4 – 32

2.4.2.4. Exhaust gas and charge air system(Chapter 1.5.)


Weightkg

Dimensions

Tool for removal chargeair cooler.

Consisting of:1. plate2. frame3. trolley.

9612ZT854

1 2

3

For Inte

rnal

Use O

nly


2.4 – 33

2.4.2.5. Engine block with main bearingsC$��H�>�E


Weightkg

Dimensions

Tool set for side stud.

Consisting of:2. tie rod4. distance piece

Used in combinationwith:1. hydraulic jackincluding:3. knurled nut5. tool pin.

9612ZT902

9612ZT1299612ZT130

9612ZT901


Weightkg

Dimensions

Tool set for main bearingstud.


Used in combinationwith:1. hydraulic jackincluding:3. knurled nut5. tool pin.

9612ZT903

9612ZT1279612ZT128

9612ZT901

For Inte

rnal

Use O

nly


2.4 – 34


Weightkg

Dimensions

Lifting tool for main bearing cap and jacks.

Consisting of:1. girder2. top plate3. support4. lifting tool.

9612ZT906

9612ZT2619612ZT2629612ZT2639612ZT267


Weightkg

Dimensions

Bearing shell driver. 9612ZT910

For Inte

rnal

Use O

nly


2.4 – 35


Weightkg

Dimensions

Air driven rachet.

Used for:– main bearing lifting

tool.

9612ZT334

9612ZT267


Weightkg

Dimensions

Extractor for camshaftbearing bush.

Consisting of:1. disc2. support disc3. disc axial bearing

bush4. support disc for

axial bearing bush.

Used in combinationwith:5. hydraulic jack.

9612ZT850

9612ZT5459612ZT5469612ZT153

9612ZT154

9612ZT913

For Inte

rnal

Use O

nly


2.4 – 36


Weightkg

Dimensions

Tool for mountingcamshaft axial bearingbushes.

9612ZT948


Weightkg

Dimensions

Sleeve for cylinder linerfixation.

9612ZT256

For Inte

rnal

Use O

nly


2.4 – 37


Weightkg

Dimensions

Positioning pin forcamshaft bearing bush.

9612ZT194


Weightkg

Dimensions

Polishing ring.

Used for:– contact surface on

cylinder block for liner– cylinder head gas

sealing surface.

9612ZT950

For Inte

rnal

Use O

nly


2.4 – 38

2.4.2.6. Crankshaft, connecting rod, pistonand liner

C$��H�M�E


Weightkg

Dimensions

Depth gauge forconnecting rod studs.

9612ZT940


Weightkg

Dimensions

Extractor anti borepolishing ring.

9612ZT915

For Inte

rnal

Use O

nly


2.4 – 39


Weightkg

Dimensions

Tool set for big endbearing stud.

Consisting of:1. hydraulic jack2. tie rod3. knurled nut4 tool pin

9612ZT944

9612ZT4769612ZT4779612ZT125


Weightkg

Dimensions

Tool connecting rod cap. 9612ZT929

For Inte

rnal

Use O

nly


2.4 – 40


Weightkg

Dimensions

Lifting tool for connectingrod/piston/liner assembly(driving unit).

Consisting of:1. protecting sleeves2. positioning bracket3. protecting sleeves.

9612ZT911

9612ZT1149612ZT1139612ZT112


Weightkg

Dimensions

Extractor for cylinderliner.

Consisting of:1. tie rod2. ring3. nut4. bracket.

Used in combinationwith:– lifting tool.– jack.

9612ZT912

9612ZT1600350 0079612ZT1569612ZT159

9612ZT9119612ZT913

4

32

1For Inte

rnal

Use O

nly


2.4 – 41


Weightkg

Dimensions

Tap M8 for threadedholes in piston crown.

9612ZT195


Weightkg

Dimensions

pliers for locking ringgudgeon pin.

9612ZT250

For Inte

rnal

Use O

nly


2.4 – 42


Weightkg

Dimensions

Piston ring pliers. 9612ZT185


Weightkg

Dimensions

Clamp for piston rings. 9612ZT917

For Inte

rnal

Use O

nly


2.4 – 43


Weightkg

Dimensions

Tool for removing /mounting connecting rodstuds.

9612ZT936


Weightkg

Dimensions

Tilting frame forconnecting rod /piston / liner assembly(driving unit).

9612ZT954

For Inte

rnal

Use O

nly


2.4 – 44


Weightkg

Dimensions

Piston support. 9612ZT938


Weightkg

Dimensions

Lever for checking axialclearance crankshaft.

9612ZT376

For Inte

rnal

Use O

nly


2.4 – 45


Weightkg

Dimensions

Support for connectingrod/piston assembly(driving unit).

9612ZT445


Weightkg

Dimensions

Polishing ring for gassealing surface cylinderliner top.

9612ZT951

For Inte

rnal

Use O

nly


2.4 – 46


Weightkg

Dimensions

Crankshaft protectingsheet.

9612ZT970


Weightkg

Dimensions

Dummy counter weight. 9612ZT856

For Inte

rnal

Use O

nly


2.4 – 47


Weightkg

Dimensions

Spanner for samplingplug vibration damper.

9612ZT497


Weightkg

Dimensions

Multiplier,max. 6200 Nmrate 21:1.

Used for:– crankshaft vibration

damper.

9612ZT979

For Inte

rnal

Use O

nly


2.4 – 48

2.4.2.7. Cylinder head with valves

C$��H�j�E


Weightkg

Dimensions

Feeler gauge for valveclearance.

9612ZT251


Weightkg

Dimensions

Extension with spline forcylinder head – multiductconnection.

Used in combinationwith:– torque spanner.

9612ZT332

9622DT215

For Inte

rnal

Use O

nly


2.4 – 49


Weightkg

Dimensions

Tool set for cylinder head

Consisting of:1. frame2. shackle3. hydraulic jack4. tie rod and distance

piece

9612ZT942

9612ZT1979612ZT1989612ZT9019612ZT904


Weightkg

Dimensions

Tie rod and distancepiece


Used in combinationwith:– hydraulic jackincluding:– knurled nut– tool pin.

9612ZT904

9612ZT1319612ZT196

9612ZT901

2

1

3

4

9612ZT901

1

2For Inte

rnal

Use O

nly


2.4 – 50


Weightkg

Dimensions

Lifting tool for cylinderhead.

9612ZT927


Weightkg

Dimensions

Tilting frame for cylinderhead.

9612ZT958

For Inte

rnal

Use O

nly


2.4 – 51


Weightkg

Dimensions

Tool set for removing /mounting valves.

Consisting of:1. pressing plate MDO2. pressing plate HFO.

Used in combinationwith:– jack.

9612ZT919

9612ZT1459612ZT184

9612ZT913


Weightkg

Dimensions

Tool for exhaust valverotator.

Used only for:– HFO engines.

9612ZT956

For Inte

rnal

Use O

nly


2.4 – 52


Weightkg

Dimensions

Tool support ring valvespring.

9612ZT947


Weightkg

Dimensions

Extractor valve guide. 9612ZT909

For Inte

rnal

Use O

nly


2.4 – 53


Weightkg

Dimensions

Mounting tool valveguides.

9612ZT233


Weightkg

Dimensions

Extractor exhaust valveseat.

9612ZT859

For Inte

rnal

Use O

nly


2.4 – 54


Weightkg

Dimensions

Mounting tool valve seat. 9612ZT945


Weightkg

Dimensions

Tool for refacing valveseats.

9612ZT863

For Inte

rnal

Use O

nly


2.4 – 55


Weightkg

Dimensions

Extractor injector sleeve. 9612ZT932


Weightkg

Dimensions

Mounting tool injectorsleeve.

9612ZT946

For Inte

rnal

Use O

nly


2.4 – 56


Weightkg

Dimensions

Grinding tool for seat fuelinjector in cylinder head.

9612ZT962


Weightkg

Dimensions

Spanner indicator cock. 9612SW510

For Inte

rnal

Use O

nly


2.4 – 57


Weightkg

Dimensions

Cylinder liner cover(wood).

9612ZT247


Weightkg

Dimensions

Extractor cooling waterinterconnecting pipe.

9612ZT877

For Inte

rnal

Use O

nly


2.4 – 58

2.4.2.8. Camshaft and valve drive mechanismC$��H�`�E


Weightkg

Dimensions

Ratchet spanner forcamshaft section bolts.

9612ZT560


Weightkg

Dimensions

Torque wrench forcamshaft section bolts.20 – 200 Nm.

Consisting of:1. torque wrench2. bit holder3. screwdriver bit.

9612ZT558

For Inte

rnal

Use O

nly


2.4 – 59


Weightkg

Dimensions

Locking tool for tappetsinlet and exhaust.

9612ZT924


Weightkg

Dimensions

Tool for separatingcamshaft section fromjournal.

Consisting of:1. Bolt M12 / 40 mm2. Bolt M12 / 80 mm3. Retainer nut

9612ZT377

1 or 2

3

For Inte

rnal

Use O

nly


2.4 – 60


Weightkg

Dimensions

Support for camshaftjournal.

9612ZT853


Weightkg

Dimensions

Support for camshaftsection.

9612ZT985

For Inte

rnal

Use O

nly


2.4 – 61


Weightkg

Dimensions

Frame.

Used in combinationwith:– tool for intermediate

gear wheel assembly– tool for camshaft gear

wheel assembly.

9612ZT963

9612ZT989

9612ZT852


Weightkg

Dimensions

Tool for intermediategear wheel assembly.

9612ZT989

For Inte

rnal

Use O

nly


2.4 – 62


Weightkg

Dimensions

Tool for camshaft gearwheel assembly.

9612ZT852


Weightkg

Dimensions

Secure tool camshaft. 9612ZT855

For Inte

rnal

Use O

nly


2.4 – 63


Weightkg

Dimensions

Hydraulic nipplecamshaft gearwheel.

9612ZT864


Weightkg

Dimensions

Tool for separatingcamshaft end journalfrom camshaft gearwheel.

9612ZT982

For Inte

rnal

Use O

nly


2.4 – 64

2.4.2.9. Injection systemC$��H�Z�E


Weightkg

Dimensions

Socket spanner for HPfuel pipe in cylinderhead.

Used in combinationwith:– torque spanner

9612ZT255

9622DT215


Weightkg

Dimensions

Crow foot spanner HPfuel pipe.

Used in combinationwith:– torque spanner

9612ZT331

9622DT215For Inte

rnal

Use O

nly


2.4 – 65


Weightkg

Dimensions

Tool for extracting fuelinjector.

1. handle.2. .nut.3. bush.

9612ZT931

9612ZT178

000000185 014

9650ZT107


Weightkg

Dimensions

Holder for fuel injector.

Used in combinationwith:– torque spanner– multiplier– socket spanner.

9612ZT978

9622DT2169612DT2609612ZT259

1

200

140

290

2

3

For Inte

rnal

Use O

nly


2.4 – 66


Weightkg

Dimensions

Multiplier,max. 1700 Nmrate 4.5:1.

Used in combinationwith:– socket spanner– torque spanner– holder for fuel injector.

9612DT260

9612DT2599622DT2169612ZT978


Weightkg

Dimensions

Testing device fuelinjector.

9612ZT934

For Inte

rnal

Use O

nly


2.4 – 67


Weightkg

Dimensions

Tool for disassembling /assembling HP fuelpump.

9612ZT971


Weightkg

Dimensions

Socket spanner forinjector sleeve nut.

Used in combinationwith:– torque spanner– multiplier– holder for fuel injector.

9612DT259

9622DT2169612DT2609612ZT978For I

ntern

al Use

Only


2.4 – 68


Weightkg

Dimensions

Spanner for plug fuelinjector.

9612ZT187


Weightkg

Dimensions

Adjusting tool fuelinjector.

9650ZT108

For Inte

rnal

Use O

nly


2.4 – 69


Weightkg

Dimensions

Synthetic driver for HPfuel pump barrel.

9612ZT225

For Inte

rnal

Use O

nly


2.4 – 70

For Inte

rnal

Use O

nly


2.4 – 71

2.4.3. Background information of hydraulictools and torque spanners

*� �� "�� <��

<��

<�� /

”Rolled thread”�� z��z�� -�� ]��

The ”easy going” nut�� ^�� z�� z� ��<�� z��z��

Studs*�� Z@[��

�� ?@[� �� Q� ��

For Inte

rnal

Use O

nly


2.4 – 72

��

Use genuine parts�� "#��#$��

�� z��z�� !��

Use of locking fluids$��

See for specification relevant drawing / parts list (Parts Cata-logue).

The hydraulic tool set��/

�; ^��

�; *��

2.4.3.1. Pneumatic driven hydraulic pump unit

�� C��H�X�;�?�E�� /

�; *��CjE��C �� j��; *��&��C?HE��; *��C?OE��; *��CME��@��M��; *� �� C>E�� ; *��CXE�� ; *��Q��COE�C��E��

��C ��E��{��; *��C?E��C��>��E��; *�� CÈ��; *��Q��C?@E��; *��CZE��^�K��

Note!

For Inte

rnal

Use O

nly


2.4 – 73

�� C>E� �� CME�� @��?@@@��M�J��?@@@��z��z�� C>E ��^�K��

�� C>E��?@[��

*� �� CÈ��^�K�� ]�� ?@��

$��CÈ��<��^�K��

1 3 4 5 6 12

8 10

9

2

11

713

Fig. 2.4 – 1 Diagram pneumatically driven hydraulic pump unit

For Inte

rnal

Use O

nly


2.4 – 74

Operating*�� {�� '�� C?XE��-��^�K�� <��H�X�;�H��J��CZE�� C?>E�� G�� CHE�� C<��?�H�E�

$��CXE��CZE��H�X�;�?��H�X�;�H��

$��C?@E��^�K��C??E��C?>E�

$��CjE�

*��z��z�� CXE�� {�� CÈ��*��?@[��

!��CME��

$�� CÈ�� ?@�[��

*��

(�� C��>��E��"�� CXE��CZE��CXE� ��

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.4 – 75

Remark"�� "�� C?@E�K�� =��

Always check the correct connecting of hose couplings to pumpunit and jacks special when more jacks are connected at the time.An incorrectly made connection may cause the jack is notconnected and the jack in question not pressurized although themanometer indicates the correct pressure.

52

6

15 1

94

8

10

11

14

Fig. 2.4 – 2 Pneumatic driven hydraulic pump unit

Warning!

For Inte

rnal

Use O

nly


2.4 – 76

2.4.3.2. Hydraulic jack

*��H�X�;�O�� COE��C?E�� %;��CjE��CÈ�

��%Q�� C?OE�� (�� C��E�� Z� ��

*��*�� C?HE��

�� CXE��C??E��C?@E�

�� {�� For I

ntern

al Use

Only


2.4 – 77

��

4

1112

13

10

3

8

71

Fig. 2.4 – 3 Cross section hydraulic jack

2.4.3.3. Hydraulic extractor

<�� {�� H�X�;�X��

Stroke 78 mm

9622ZT992

9612ZT913

Fig. 2.4 – 4 Hydraulic extractor

barMaximum pressure

kN

Fig. 2.4 – 5 Graphic relation pressure / force

For Inte

rnal

Use O

nly


2.4 – 78

2.4.3.4. H.P. hose

�� ?>@@��

��^�K�� X��

��Q��y��z��

y��z�� ^�K��

��

y��z��

Work safely!$��Q��

(��Q��-�� Q��

*��Q��C?E�

1 1

Fig. 2.4 – 6 H.P. hose

*�5��<�&$8$7�&�<��+�� /

��5��

��5�� ?M@�

��5��

��5��

��5��

��5��

��5��

Damaged hoses or quick–release couplings should be discarded.DO NOT CARRY OUT REPAIRS!

Note!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.4 – 79

2.4.3.5. H.P. quick–release coupling

*�� Q��/?� ��H� � ��O� ��

2 1

3 3

Fig. 2.4 – 7 H.P. quick–release coupling

��^�K��Q�� Q��

��

�� <�� Q��

��CXE��C>E�

5 4

Fig. 2.4 – 8 Dust caps H.P. quick–release coupling

��CGK�E�� -��K��

For Inte

rnal

Use O

nly


2.4 – 80

2.4.3.6. Hand–operated hydraulic pump

��

?� ��

H� ��

O� ��

X� ^�K��CH�E

>� ��

M� ��

j� ��

`� ��

3

4

2

6

1

7 8

5

Fig. 2.4 – 9 Hand operated hydraulic pump

OperatingJ��

��C?E�� C*��?�H�?�?�E

$�� ^�K��

Never apply pressure to a jack which is not in use for stretchingstuds, otherwise the plunger will exceed its maximum stroke.

$��C>E��

*��{�� &��

Note!

1

2

3

4

For Inte

rnal

Use O

nly


2.4 – 81

2.4.3.7. Safety instructions for hydraulic tools

��

J�� *�� {��

J�� !��Q��-��Q��

(��

<��C��E��=��

�� K��{��{��

-��*�� *��

-�� C�� E�

*�� Q��*��

*�� %Q�� *��-��

1

2

3

4

5

6

7

8

9

For Inte

rnal

Use O

nly


2.4 – 82

*��

)�� -��

q�� (��C��j@°$E��

G�� %��

-��^��

q�� "�� )��

2.4.3.8. Loosening of hydraulically tightened connection

Loosening pressure = tightening pressure.

��

Prevent overstretching�� >[��<��

�� "��

Note!

10

11

12

13

14

15

For Inte

rnal

Use O

nly


2.4 – 83

�� @�@>� �� *��

If the nut is not free$��

$��Q��

$��

�� >[�

�� ?@[��'��?@[��

��?@[�� <��

'��

If e.g. one cylinder head nut has to be cut leave the other three nutstightened to prevent damage to cylinder head and liner.

If, due to any cause, doubt exists regarding the stress inhydraulically tensioned studs the loosening value must be found.

��>@��

$��

�� ?@[��

Note!

1

2

3

4

5

6

7For I

ntern

al Use

Only


2.4 – 84

2.4.3.9. Tightening of hydraulicallytightened connection

�� C�� E��/

First step, positioning of engine components and pre–stress�� {��Q�� ]�� G��

Second step, setting of materialsK��{�� "�� *��

Third step, obtaining the correct final stress��z�� z��{��G�� *��

For Inte

rnal

Use O

nly


2.4 – 85

Fourth step, checking the correct final stress�� z��z��K��{�� $��@�@O� ��

In case it is possible to tighten the nuts more than the prescribednumber of holes or there is still clearance between nut and contactsurface, the connection is NOT safe. In such a case all componentshave to be disconnected and examined: – on deviation in material – wrong assembling – wrong assembling procedure.

2.4.3.10. Use of torque spanner

'�� ^� ��

��

�; *�� (��

�; ��

�; ��H@[��?@@[�� X[� ��

�; $�� {��

Warning!

For Inte

rnal

Use O

nly


2.4 – 86

�; G��?@@[��-��

�; *�� "��

�; G��

�; *��"��

�; !�� C�� E�

�; *��;�� )��

�; �� =��-%�G%��)!(��](*!(�

Torque spanner in combination with multiplier��C?E�� CHE��

1

2

Fig. 2.4 – 10 Torque spanner – multiplier

Note!

For Inte

rnal

Use O

nly


2.4 – 87

Torque spanner in combination with extension"�� C?E� �� CHE��

(�� /�]��H@@�G �=��>@@�� =��jM�H� �

1 2

76.2500

Torque spanner reading: – extension used in line= 200 x = 173.5 Nm.

500500 + 76.2

– extension used in right–angle= 200 Nm.

Fig. 2.4 – 11 Torque spanner – extension

10 Nm = 1 Kgm

Note!

Note!

For Inte

rnal

Use O

nly


2.4 – 88

For Inte

rnal

Use O

nly


2.4 – 89

2.4.4. Tightening torque and jack pressure

2.4.4.1. Lubricating oil system componentsC$��?�H�E

Pos. Connection TorqueNm

1. Lubricating oil pump 80

2. Gearwheel on shaft 65�5

CLOCKWISE ENGINE COUNTER–CLOKWISE ENGINE

2

2

11

Fig. 2.4 – 12 Lubricating oil pump

For Inte

rnal

Use O

nly


2.4 – 90

2.4.4.2. Cooling water system componentsC$��?�X�E


1. Cooling water pump 195

2. Gear wheel on shaft 17

3. Suction house 43

4. Impeller on shaft 15

3

4

2

1

Fig. 2.4 – 13 Cooling water pump

For Inte

rnal

Use O

nly


2.4 – 91

2.4.4.3. Control system componentsC$��?�M�E


1. Actuator drive housing 175

2. Gear wheel on shaft 10

3. Adapter 80

3

1

2

Fig. 2.4 – 14 Actuator

For Inte

rnal

Use O

nly


2.4 – 92

2.4.4.4. Engine block with bearingsC$��H�>�E

Pos. Connection Torque /Jack

pressure

Elongation studmm

1. Main bearing stud , mounting 200 Nm

2. Main bearing cap, tightening tool nr.9612ZT903

first stepsecond stepthird step

Elongation

200 bar900 bar900 bar

Measure size ’X’

Measure size ’Y’’Y’–’X’ = 1.4–1.7

3+4 Side stud, mounting 0 Nm 180� back

3. Side stud (long), tightening tool nr.9612ZT902


Elongation




4. Side stud (short), tightening tool nr.9612ZT902


Elongation




The process of stud stretching is mentioned in chapter 2.5.2.3.

4

3

1

’Y’–’X’ ’X’’Y’

2

Fig. 2.4 – 15 Main bearing

Note! For Inte

rnal

Use O

nly


2.4 – 93

2.4.4.5. Crankshaft, connecting rod, pistonC$��H�M�E


1. Vibration damper 3100

2. Gear wheel with PTO–shaft 195

3. Extension piece 195

A–A

A

A

3

2

1

Fig. 2.4 – 16 Vibration damper with PTO–shaftFor Inte

rnal

Use O

nly


2.4 – 94


1. Vibration damper 2400

2. Gear wheel without PTO–shaft 195

3. Extension piece 195

A–AA

A

1

23

Fig. 2.4 – 17 Vibration damper without PTO–shaft

For Inte

rnal

Use O

nly


2.4 – 95


1. Split gear wheel on crankshaft 270

2. Split gear wheel on crankshaft 540

2

1

Fig. 2.4 – 18 Crankshaft gear

For Inte

rnal

Use O

nly


2.4 – 96


1. Flywheel 2400

2. Toothed ring 80

1

2

Fig. 2.4 – 19 Flywheel

For Inte

rnal

Use O

nly


2.4 – 97


pressure

Elongation studmm

1. Big end stud, mounting 100 Nm

2. Big end bearing cap, tightening tool nr.9612ZT944


Elongation



Measure size ’Y’’Y’–’X’= 0.6 – 0.8

1

’Y’–’X’’X’’Y’

2

Fig. 2.4 – 20 Big end bearing

For Inte

rnal

Use O

nly


2.4 – 98

2.4.4.6. Cylinder head with valvesC$��H�j�E


1. Multiduct to cylinder head 195

2. Multiduct to exhaust gas manifold 195

3. Multiduct to engine block: 80

3

2

1

Fig. 2.4 – 21 Multiduct connection


1. Tappet casing 46

1

Fig. 2.4 – 22 Tappet casing

For Inte

rnal

Use O

nly


2.4 – 99


pressure

Stud elongationmm

1. Cylinder head stud, mounting 300 Nm

1. Cylinder head, tightening tool nr.9612ZT904


Elongation



Measure size ’Y’’Y’–’X’ = 0.78 –

0.95

1

’Y’–

’X’

’X’

’Y’

Fig. 2.4 – 23 Cylinder head

For Inte

rnal

Use O

nly


2.4 – 100


1. Rocker arm bracket 390

2. Locking nut 120

3. Locking nut 220

1

2

3

Fig. 2.4 – 24 Rocker arm mechanismFor Inte

rnal

Use O

nly


2.4 – 101

2.4.4.7. Camshaft and valve driveC$��H�`�E


1. Intermediate gear wheel shaft cover 46

2. Gear wheel 560

12

Fig. 2.4 – 25 Intermediate gear shaftFor Inte

rnal

Use O

nly


2.4 – 102


1. Camshaft section to journal:first stepsecond step (final setting)

40135

2. Thrust ring to journal 80

3. Journal to camshaft gear wheel 195

1 3

2

Fig. 2.4 – 26 Camshaft / camshaft gearwheel

For Inte

rnal

Use O

nly


2.4 – 103


1. Drive shaft nut 100

2. Locking bolt 10

Make adjustments only with required tools.

1

1

2

2

Fig. 2.4 – 27 Actuator drive

Note!

For Inte

rnal

Use O

nly


2.4 – 104

2.4.4.8. Injection system componentsC$��H�Z�E


1. Fuel injector nut 45

2. Stud 10

1

2

Fig. 2.4 – 28 Fuel injectorFor Inte

rnal

Use O

nly


2.4 – 105


1. Connecting pipe 120

2. HP fuel line union 140

3. Lock nut 60

View A – A

AA

1

2

3

Fig. 2.4 – 29 Fuel injector, HP fuel line

For Inte

rnal

Use O

nly


2.4 – 106


1. Nozzle (Use loctite Molykote G–rapid plus orNever–Seez Regular grade NS 42 B on thread)

750..800

2. Pressure adjustement screw 50..70

3. Guiding screw 10..14

4. Plug 10..22

2

1

3

4

Fig. 2.4 – 30 Fuel injector

For Inte

rnal

Use O

nly


2.4 – 107


1. HP fuel pump 140

2. Fuel pump support 46

3. Barrel 90

4. Cover for barrel 53

2

1

3

4

Fig. 2.4 – 31 HP fuel pump drive and tappet housing

For Inte

rnal

Use O

nly


2.4 – 108

2.4.4.9. General table of tightening torquesfor not specified bolt connections

"��

)��

<�� /;�-�G�?O;�z�-��]��HHO@z;�-�G�;�Z?H�;�ZO?�;�ZOO�;�MZ?H�;�jZ`X�

Norm bolt connections

ThreadDim. Pitch

Bolt class TorqueNm

8.8 2,8

M4 0,7 10.9 4,1

12.9 4,8

8.8 5,5

M5 0,8 10.9 8,1

12.9 9,5

8.8 9,5

M6 1,0 10.9 14,0

12.9 16,5

8.8 23,0

M8 1,25 10.9 34,0

12.9 40,0

8.8 46,0

M10 1,5 10.9 68,0

12.9 79,0

8.8 79,0

M12 1,75 10.9 117,0

For Inte

rnal

Use O

nly


2.4 – 109

Norm bolt connections

TorqueNm

Bolt classPitch

ThreadDim.

12.9 135,0

8.8 125,0

M14 2,0 10.9 185,0

12.9 215,0

8.8 195,0

M16 2,0 10.9 280,0

12.9 330,0

8.8 280,0

M18 2,5 10.9 390,0

12.9 460,0

8.8 390,0

M20 2,5 10.9 560,0

12.9 650,0

8.8 530,0

M22 2,5 10.9 750,0

12.9 880,0

8.8 670,0

M24 3,0 10.9 960,0

12.9 1120,0

8.8 1350,0

M30 3,5 10.9 1900,0

12.9 2250,0

For Inte

rnal

Use O

nly


2.4 – 110

For Inte

rnal

Use O

nly


2.4 – 111

2.4.5. Adjustments and Tolerances

2.4.5.1. Adjustments

Timing, clearances and settings

Valve clearances cold engine:– Inlet valve 0.75 mm– Exhaust valve 0.75 mm

Fuel delivery commencement See test recordsOpening pressure fuel injector needle 450 bar

Nominal speed900 rpm

Overspeed stop1035 + 10 rpm

For Inte

rnal

Use O

nly


2.4 – 112

2.4.5.2. Tolerances

Part, measuring point

Bearings

The engine bearings consist of a steel shell onto which a very tiny bonding of al-most pure Aluminium. On this bonding is a running layer of Aluminium alloy. It concerns bearings for: – crankshaft – connecting rod big end – camshaft

A bearing is suitable for use as long as:– the shell thickness is expected to stay within the given tolerances, until the

next inspection, (see this chapter). – the inside diameter is within the given tolerances, until the next inspection,

(see this chapter).– the bearing shell is free of damage.– the bearing shell is free of corrosion.– the wear pattern is equal.– the running layer is not overloaded. An overloaded bearing shell can be

recognized by locally melted or smeared lining.

Restriction for refitting of bearings.Refitting is only allowed one time if the number of running hours is not morethan 5000 hrs. even if the bearing is within the mentioned criteria.

New bearings are treated with a corrosion protection that has to be removed be-fore mounting.Where bearings show heavy wear grooves in the running layer, the quality of thelubricating oil cleaning process should be observed more carefully.

For determination of wear, engine components and measuringequipment should for some hours first be acclimated at roomtemperature ( 20 �C).

Note!

For Inte

rnal

Use O

nly


2.4 – 113

Part, measuring point Designmeasurements

Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Lubricating oil pump (chapter 1.2.)

Backlash driving gear wheel (1)lubricating oil pump gear wheel (2) 0.50–0.80 0.85

Cooling water pump (chapter 1.4.)

Backlash driving gear wheel (1)H.T. cooling water pump gear wheel (3) 0.55–0.90 0.95

Backlash driving gear wheel (1)L.T. cooling water pump gear wheel (4) 0.50–0.80 0.90

2

3

1

4

Fig. 2.4 – 32 Gear wheel train

For Inte

rnal

Use O

nly


2.4 – 114


Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Main bearing (chapter 2.5.)

Crankshaft journal diameter 280.000 279.968

Crankshaft journal parallelism 0.025 –––

Crankshaft journal straightness 0.015 –––

Main bearing housing bore 295.032 295.000

Main bearing shell thickness 7.395 7.375 7.360

Assembled main bearing bore 280.329 280.258

Main bearing clearance (also ”0”–bearing) 0.258–0.361 0.390

Crankshaft thrust bearing ring thickness 11.000 10.950

Crankshaft thrust bearing axial clearance 0.15 – 0.45 0.80

Camshaft bearing (chapter 2.5.)

Camshaft journal diameter 180.000 179.975

Camshaft bearing housing bore 200.029 200.000

Camshaft bearing bush thickness 9.930 9.915

Assembled camshaft bearing bore 180.224 180.167

Camshaft bearing clearance 0.167–0.249 0.280

Camshaft diameter (”0”–bearing) 210.000 209.971

Camshaft ”0”–bearing housing bore 240.029 240.000

Camshaft ”0”–bearing bush thickness 14.908 14.879

Assembled camshaft ”0”–bearing bore 210.285 210.205

Camshaft ”0”–bearing clearance 0.205–0.314 0.350

Camshaft thrust bearing collar thickness 7.90 7.85

Camshaft thrust bearing axial clearance 0.15 – 0.45 0.70

Big end bearing (chapter 2.6.)

Crank pin diameter 235.000 234.971

Crank pin parallelism 0.020 –––

Crank pin straightness 0.015 –––

Big end bore 247.029 247.000

Big end bore circularity 0.015 –––

Big end bearing shell thickness 5.925 5.905 5.890

Assembled bearing bore 235.233 235.165

Big end bearing clearance 0.165–0.262 0.290

For Inte

rnal

Use O

nly


2.4 – 115

Part, measuring point

Crankshaft deflection criteria (chapter 2.6.)

While measuring the crankshaft deflections the commissioning report is consideredas a reference. Use the “Crankshaft alignment” measurement record supplied byWärtsilä where to fill in all the measurement�

Gauge position

L 1)

L engine 115 mm

V engine 155 mm

(1) The reference surfacefor L is the counterweight /cranckweb mounting face.

Cold

engine 1)

Hot

engine 2)

DescriptionAcceptable

[mm]

Acceptable

[mm]

Realignment

recommended

[mm]

Max difference between two opposite re-adings 3) on the same crank 4). 0,050 0,050 0,080

Max difference between the same read-ings on two adjacent cranks 4). 0,035 0,035 0,055

Max difference between two opposite re-adings 3) on the end crank if coupled tothe installation (vertical direction).

0,12 0,12 0,16

Max difference between to opposite read-ings 3) on the end crank and it’s adjacentcrank when coupled to the installation(vertical direction).

0,085 0,085 0,110

(1) At ambient temperature.(2) At normal operation temperature,which means within 40 minutes after en-gine running for more than 6 hours at 60% load at least.(3) The opposite reading to C is F, themean value between A and E.(4) Except for a coupled end crank(s).

L

+–

operating side non–operating side

For Inte

rnal

Use O

nly


2.4 – 116


Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Piston (chapter 2.6.)

Gudgeon pin diameter 120.000 119.985 119.980

Small end bore 134.975 134.950 134.985

Small end bearing bush thickness 7.465 7.445

Assembled small end bearing bore 120.150 120.085

Gudgeon pin bearing clearance 0.085–0.165 0.200

Axial clearance small end bearing –piston 0.400–0.700 0.800

Gudgeon pin bore in piston 120.070 120.045

Clearance gudgeon pin – piston 0.045–0.085 0.090

Piston– Compression ring 1 gap– Compression ring 2 gap– Oil scraper ring gap

0.600–0.9002.400–2.7000.800–1.150

0,5000,3500,200

Piston ring height: 6.987 6.965

Piston ring groove height:– Groove 1– Groove 2– Groove 3

7.1307.1207.110

7.0907.0807.070

7.5007.3507.150

Piston ring height clearance:– Compression ring 1– Compression ring 2– Oil scraper ring

0.103–0.1650.093–0.1550.083–0.145

0.5000.3500.200

Cylinder liner diameter 260.052 260.000 260.600

Cylinder liner cylindricity at TDC 0.020 ––– 0.100

Piston diameter at bottom in cross direc-tion of engine 259.875 259.850 259.750

Corresponding clearance piston–liner 0.150–0.177 0.900For I

ntern

al Use

Only


2.4 – 117

Cylinder head with valves (chapter 2.7.)

Valve guide inner diameter 20.16 20.13 20.25

Valve stem diameter: I+IIIII

20.00020.000

19.97919.979

19.97019.900

Valve burn–off area: Z Y

0.08.2

0.07.8

1.07.0

Clearance valve stem / valve guide: I+IIIII

0.130–0.1810.130–0.181

0.3000.350

115 55 55

I II III

Y

Z

Fig. 2.4 – 33 Valve stem and valve burn–off area

∅ 79

∅ 95

29°53’±5’30°+3’

–1’

Nom. ∅ 95+0–0.2

Max. ∅ 97.0–0.4+0

–0.2+0

Recess ∅ 105+0.03+0

Fig. 2.4 – 34 Inlet valve and valve seat in cylinder head

29°53’±5’∅ 71∅ 86

30°+3’–1’

Nom. ∅ 86+0–0.2

Max. ∅ 88.0–0.4+0

+0+0.2

Recess ∅ 79.4+0.03+0

Recess ∅ 97+0.03+0

Fig. 2.4 – 35 Exhaust valve and valve seat in cylinder head

For Inte

rnal

Use O

nly


2.4 – 118


Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Driving gear (chapter 2.8.)

Backlash crankshaft gear wheel (1)intermediate gear wheel (large) (2) 0.10–0.45 0.50

Backlash intermediate gear wheel (3)camshaft gear wheel (4) 0.10–0.30 0.40

Backlash gear wheel actuator drive (5)gear wheel actuator drive unit (6) 0.30–0.40 0.50

Backlash toothed ring flywheel (8)pinion starting unit (7) 0.70–1.00

Backlash toothed ring flywheel (8)turning gear gear wheel (9) 0.60–1.30

Axial clearance intermediate gear wheel 0.30–1.50 1.60

2

5

3

1

4

6

7

8

9

Fig. 2.4 – 36 Driving gear

For Inte

rnal

Use O

nly


2.4 – 119


Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Valve drive mechanism (chapter 2.8.)

Tappet roller casing inner diameter (1) 70.030 70.000

Tappet roller (2) 69.940 69.910

Clearance tappet roller / casing 0.060–0.120 0.15

Pin bore in tappet roller 28.021 28.000

Pin diameter (3) 28.000 27.987

Clearance pin / tappet roller 0.000–0.034 0.05

Bearing bush inner diameter (4) 28.050 28.030

Clearance pin / bearing bush 0.030–0.063 0.08

Bearing bush outer diameter (4) 35.950 35.925

Roller inner diameter (5) 36.016 36.000

Clearance bearing bush / roller 0.050–0.089 0.10

Rocker arm shaft diameter (6) 65.000 64.981

Shaft bore in rocker arm (7) 65.075 65.030

Clearance shaft / rocker arm 0.030–0.094 0.11

Bridge piece pin diameter (8) 23.000 22.987

Pin bore in bridge piece (9) 23.065 23.024

Clearance pin / bridge piece 0.024–0.078 0.10

Axial clearance roller / tappet 0.200–0.400 0.50

12

345 86 7

9

Fig. 2.4 – 37 Valve drive mechanism

For Inte

rnal

Use O

nly


2.4 – 120


Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Actuator (chapter 2.8.)

Backlash driving gear * 0.12–0.18 0.25

� !��z�z��{��


For Inte

rnal

Use O

nly


2.4 – 121


Nominalclearance

[mm]

No – Go

[mm]Max.[mm]

Min.[mm]

[mm] [mm]

Injection system (chapter 2.9.)

Nozzle needle lift ’A’ 0.6 0.5 0.8

Distance ’B’ fuel pump push rod 1.1 0.9 1.2

’A’

Fig. 2.4 – 39 Nozzle

J

Fig. 2.4 – 40 fuel pump adjustment

For Inte

rnal

Use O

nly


2.4 – 122

2.4.6. Dimensions and masses

Cylinder head280 kg

Piston+pin70 kg

Connecting rod83 kg

Cylinder liner125 kg

Assembly278 kg

Valve Inlet 2 kg Exhaust 2 kg

Valve spring2 kg

Fuel injector7 kg

HP fuel pump25 kg

Camshaft part32 kg

Main bearing shell4 kg

Compressed air starter motor30 kg

Crankshaft gearwheel85 kg

Camshaft gearwheel58 kg

Intermediate gearwheel assy85 kg ( 31 + 54 kg)

Fig. 2.4 – 41 Engine components

For Inte

rnal

Use O

nly


2.4 – 123

Turbocharger 6L26335 kg

Turbocharger 8+9L26 and V–engines775 kg

Charge air cooler 6L26In–line engine

Charge air cooler 8+9L26In–line engine

Charge air cooler insert V–engineLube oil cooler insert

Dimensions and masses of cooler inserts; lubricating oil and charge air

En-gine

Dimensions [mm] Masses cooler inserts [kg]gine

A B (B) C (C) D E G H J oil1 oil2 oil3 chargeair

6L26 8L26 9L26

121311851185

1001 (774)1007 (830)1007 (830)

756 (756)830 (906)830 (906)

970955955

490535535

55510101010

ø330ø330ø330

975 975 975

75 85 – 75 85 120 84 120 –

470 570 570

12V2616V2618V26

118511851185

830 830 830

978 (1007)978 (1007)978 (1007)

625625625

605605605

1900 1900 1900

ø370ø370ø370

130013001300

145 – –145 165 –145 165 –

680 725 725

1) 2) 3) Lubricating oil cooler insert with standard1 / higher2 / highest3 capacity

Fig. 2.4 – 42 Main parts

For Inte

rnal

Use O

nly


2.4 – 124


For Inte

rnal

Use O

nly

Engine Block with Bearings ManualWärtsilä 26

2.5 – 1

2.5. Engine Block with Bearings

For Inte

rnal

Use O

nly

Engine Block with BearingsManualWärtsilä 26

2.5 – 2

2.5.1. Engine block

�� C?E�� CHE��{��COE��

�� CXE��

�� *��

1

2

3

3

4

Operating side Non–operating side

Fig. 2.5 – 1 Engine block

For maintenance background information, safety aspects,intervals, tolerances, and hydraulic tightening procedures, seechapter 2.4.

Note!

For Inte

rnal

Use O

nly


2.5 – 3

2.5.2. Main bearings

'�� @��

J�� Q �� *��

In order to avoid bearing and crankshaft damages the bearing capshave to be mounted always in the same position. It is essential tofollow the sequence described in this chapter of the manual .

2.5.2.1. Removing of main bearing

Never remove two main bearings mounted side by side.

Removing side studs]� ��

��

]� ��

]� �� CZE�� C?@E��C??E��C?HE�� C�� E��!��H�>�;�H��

Note!

Warning!

1

2

3For Inte

rnal

Use O

nly


2.5 – 4

11

9

10

12

Fig. 2.5 – 2 Position bearing temperature sensor

��ZM?H��?HZ��H�>�;�O��

K��ZM?H��?O@��ZM?H��Z@?��ZM?H��??Z��H�>�;�O��

When two jacks are available the side studs may simultaneously beloosened.

$��^�K��ZM?H-�O`?�� ZMHH��ZZH��

�� *�� M��

$�� H�X�X�X��$�� >[��

=��ZM?H��?H>��>��M��

!��{��

Note!

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.5 – 5

9612ZT901

9612DT3819612DT381

9622ZT992

9612ZT129

9612ZT119

9612ZT125

9612ZT130

Fig. 2.5 – 3 Positioning jack on side stud

-��

]� ��

]��

Removing main bearing cap nuts<�� ZM?H��Z@M��ZM?H��HM?

��H�>�;�X��

K��ZM?H��HMj��ZM?H��HMO��

K��ZM?H��HMH��ZM?H��HMO�

11

12

13

14

15

16

For Inte

rnal

Use O

nly


2.5 – 6

K�� ZM?H��Z@O�� ZM?H��Z@?�� ZM?H��?H`� �� Q��ZM?H��?Hj� �� ZM?H��HMH��C?XE��ZM?H��OOX�

9612ZT9019612ZT128

9612ZT127

9612ZT381

9612ZT26114 9612ZT263

9612ZT119

9612ZT267

9612ZT262

9622ZT992

Fig. 2.5 – 4 Lifting tool for main bearing cap

��

!��

]�� C?XE��

��

]��

��ZM?H��??Z��ZM?H��?H>�

$�� ^�K�� ZM?H-�O`?� �� ZMHH��ZZH��

*�� M��

K��!��H�X�X�X�

��>��M��

17

18

19

20

21

22

23

24

25

26

27

For Inte

rnal

Use O

nly


2.5 – 7

!��{�� ^�K��

]� ��

]� ��

9612ZT263

Fig. 2.5 – 5 Lifting tool for main bearing cap

Lowering main bearing cap]� �� ZM?H��HMH� �� ZM?H��HMO��

H�>�;�>��

(�� ^��

]� ��

=��

If it is not possible to lower the main bearing cap loosen the sidestuds of the adjacent main bearing caps.

Note!

28

29

30

31

32

33

34

For Inte

rnal

Use O

nly


2.5 – 8

Removing of bearing shells]� ��

��

�� ZM?H��Z?@��H�>�;�M�/

�; J��

�; ��ZM?H��Z?@��

�; $��

�; *��

9612ZT910

Fig. 2.5 – 6 Bearing shell driver

35

36

For Inte

rnal

Use O

nly


2.5 – 9

2.5.2.2. Inspection of main bearings andjournals

$��

'�� -� ��

No scraping of bearing shells, caps and housings is permitted.

2.5.2.3. Main bearing assembling

Bearing shell mounting$��

G��

%��*��

K�� K�� )�� !��H�>�;�j��

Push by hand

Push by hand

Fig. 2.5 – 7 Inserting main bearing shell

Note!

1

2

1

2

3

For Inte

rnal

Use O

nly


2.5 – 10

�� /

�; ��ZM?H��Z?@��H�>�;�`��

�; J��

�; ]� ��

9612ZT910

Fig. 2.5 – 8 Driving main bearing shell into position

Lifting bearing capK��

��

=��

)�� ZM?H��Z@M��ZM?H��HMj��ZM?H��HMO�� H�>�;�X��

"�� ZM?H��?H>�

=��

4

5

6

7

8

9

For Inte

rnal

Use O

nly


2.5 – 11

Mounting side studs

Side studs are different in length depending on the position of theengine feet. Consequently a difference in elongation and so in nutshifting exists. Consult section 2.4.4.

$�� C?jE� �� %;��C?ME��K��%;��H�>�;�Z��

17

16

Fig. 2.5 – 9 Apply new O–ring with silicon grease

*�� '��

Side studs may not touch main bearing cap studs.

%��

<��

Note!

Note!

10

11

12

13

For Inte

rnal

Use O

nly


2.5 – 12

Side stud at operating side��9

�; ��ZM?H��Z@H��H�>�;�O��

�; K��ZM?H��Z@?��$��^�K��

�; K��?@@��

�; $��@�@>� ��$��

�; !�� {��

�; ]� ��

�; K�� ZM?H��ZX?�� |��!��H�>�;�?@��

Side stud at non operating side1st step

�; ]��?X��

Main bearing cap studs<�� H�>�H�?��?X

��HX��*�� ZM?H��?H>�

1st step

�; ��H@@��

�; <��

�; $��@�@>� ��

�; !��{��

�; -�� ZM?H��Z@M��H�>�;�X��

�; K�� ZM?H��ZX?�� |��!��H�>�;�?@��

14

15

16

17For Inte

rnal

Use O

nly


2.5 – 13

2nd step

�; <��

�; ��H�X�X�X�

�; <��

�; !�� {��

3rd step

�; ��

�; $�� @�@>� � ��

�; !�� {��

�; -�� H�>�;�X��

�; K�� ZM?H��ZX?� �� '��

�; ��;��|�� H�X�X�X�

’Y’–’X’

’X’ ’Y’

Fig. 2.5 – 10 Measuring stud elongation

In case the stud elongation is outside limits the connection is NOTsafe. In such a case all components have to be disconnected andexamined on deviation in material or wrong assembling.

Warning!

18

19

For Inte

rnal

Use O

nly


2.5 – 14

Side stud at operating side2nd step

�; ��ZM?H��Z@H��H�>�;�O��

�; K��ZM?H��Z@?��$�� ^�K��

�; K��

�; !�� {��

3rd step

�; K�� !��

�; $�� @�@>� � ��

�; !�� {��

�; -��

�; K�� ZM?H��ZX?��

Side stud at non operating side2nd and 3rd step

�; ]��H@��H?��

�; ��;��|�� H�X�X�X�

In case side studs of the adjacent main bearings are loosened thesehave to be tightened according procedure mentioned above.

]�Q��

<��

��

]�� Q��

$��

Note!

20

21

22

23

24

25

26

27

For Inte

rnal

Use O

nly


2.5 – 15

2.5.3. Crankshaft axial locating bearing

�� @�Q�� C{��Q��E��@�Q��COE��

��@��CXE�

��C?E�� CHE�

’0’–bearing

Main bearing no. 1

1

2

3

4

4

Operating side Non–operating side

Fig. 2.5 – 11 Crankshaft axial locating bearing

For maintenance background information, safety aspects,intervals, tolerances, inspections, and hydraulic tighteningprocedures, see chapter 2.4.

Note!

For Inte

rnal

Use O

nly


2.5 – 16

2.5.3.1. Removing of the ’0’–bearing

Never remove main bearing number 1 if the ’0’–bearing is removed.Never move the crankshaft in axial direction by exerting a force onthe counter weights

J�� @�Q��

Measuring the axial clearanceK��Q��

'�� ZM?H��OjM��H�M�?�H�

'��

K��{��

'��

G�� H�X�>�H��

Removing the ’0’–bearing<�� z]� �� z� �� H�>�H�?�

��?��OX��

]� ��@�Q��CHE�� !��H�>�;�??��

<�� z]� �� z� �� H�>�H�?��OM�

!��

Warning!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.5 – 17

2.5.3.2. Inspection of ‘0’ bearing, axial thrustrings and thrust collars on crankshaft.

$��

'�� ]��

'�� H�X�>�H��

2.5.3.3. ’0’–bearing assembling

$�� G��

<��z'�� z��H�>�H�O��H��O��X�

!��

<��

<��z'�� z��H�>�H�O��>��Z�

K�� ZM?H��OjM��!��H�M�?�H�

K��

'��{��

�� H�>�H�O��?@��HH��

'��

$�� H�X�>�H��

<��z'�� z��H�>�H�O��HO��Hj�

1

2

3

1

2

3

4

5

6

7

8

9

10

11

12

For Inte

rnal

Use O

nly


2.5 – 18

2.5.4. Camshaft bearings

�� COE��C?E��

$� ��; �� {�� CXE��C>E�

�� C?E��

3 13 4 5

Fig. 2.5 – 12 Camshaft assembly with bearing bushes

2.5.4.1. Inspection of camshaft bearing bush

]� �� H�`�

*�� $��

1

2

For Inte

rnal

Use O

nly


2.5 – 19

2.5.4.2. Removing camshaft bearing bushesand axial bearing bushes

]� �� ^K��

K�� H�>� ;� ?O� � �� COE�'��ZM?H��>XM��

9612ZT913

9622ZT992

9612DT381

3

9612ZT5469612ZT545

9612ZT913

9612ZT546

Fig. 2.5 – 13 Extracting camshaft bearing bush

1

2

For Inte

rnal

Use O

nly


2.5 – 20

K�� H�>� ;� ?X� � �� C?E�!��H�>�;�?H��'��ZM?H��?>O��ZM?H��?>X��ZM?H��Z?O��

9612ZT913

9612DT381

9612ZT154

9622ZT992

9612ZT153

1

9612ZT153

9612ZT154

1

Fig. 2.5 – 14 Extracting camshaft axial bearing bush

$�� ZM?H��Z?O� �� ZM?H-�O`?� �� ZMHH��ZZH�

K��{��*�� X@@�� !��j`� �C�� E��*��

��

]� ��

3

4

5

6

7

For Inte

rnal

Use O

nly


2.5 – 21

2.5.4.3. Mounting camshaft bearing bush

$��

$�� ;?`@��$��

Wear low temperature resistance gloves and safety glasses duringhandling of deep frozen engine parts and take notice of the safetymeasures of the suppliers from the liquid nitrogen.

��"��

�� ZM?H��?ZX�

"�� $�� H�X�>�H�

'�� !��

*��!��H�j�H�

$��

2.5.4.4. Mounting camshaft axial bearing bush

��

]� �� H�`�?�H�

]� �� H�`�H�H�

$�� $��

$�� H�X�>�H�

$��

Note!

1

2

3

4

5

6

7

8

1

2

3

4

5

For Inte

rnal

Use O

nly


2.5 – 22

$�� K�� ZM?H��ZX �̀��


9612ZT948

Fig. 2.5 – 15 Holding bearing bushes during mounting

]� �� ZM?H��ZX`��>� ��

$��

$��

'��

$�� H�X�>�

Note!

6

7

8

9

10

11 For Inte

rnal

Use O

nly


2.5 – 23

2.5.5. Replacing cylinder head studs

<��ZM?H��ZO>��=��C��Q��E�

9612ZT935

1

Fig. 2.5 – 16 Replacing cylinder head stud

$��

-��

� �� <��

��H�X�X�M�

J�� C?E��

*�� C?E��<��

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.5 – 24

2.5.6. Crankcase safety valves

$�� $� �� ;��

*�� *��J��

%�� {�� &��

Engine stop / cool down period�� ?>� ��

��

! �� C�� E��{��

*��;��

Working*��C?E��H�>�;�?j�� CHE� ��%;�� COE� �� C��E�� CXE��

For Inte

rnal

Use O

nly


2.5 – 25

Maintenance

K�� H�X�?�

$��]��

K��%;��H�X�?��

$��%;��%;��

*�� %;�� ?�

Openposition

Closedposition

1 2 3 4

Fig. 2.5 – 17 Crankcase safety valve


1

2

3

4

5

For Inte

rnal

Use O

nly


2.5 – 26

For Inte

rnal

Use O

nly

Crankshaft, Connecting Rod, Piston and Liner ManualWärtsilä 26

2.6 – 1

2.6. Crankshaft, Connecting Rod, Pistonand Liner

For Inte

rnal

Use O

nly

Crankshaft, Connecting Rod, Piston and LinerManualWärtsilä 26

2.6 – 2

2.6.1. Crankshaft

��

$�� '��

��


2.6.1.1. Crankshaft deflections

�� C�� E� �� C�� E�� X@� �� M��M@[��

*�� y$�� z �� "#��#��

Before taking crankshaft deflections on an hot engine, the dialgauge should be warmed up to the same temperature of the enginein order to avoid temperature influence on the readings. Forinstance the dial gauge could be warmed up by placing it on theengine feet for a while (15 minutes).

=�� ;��

]� ��

�� ZM?H��`>M��

Note!

Note!

1

2

3

For Inte

rnal

Use O

nly


2.6 – 3

!��?��?>��J�� -��$��C�J-$�E��*��H�M�;�?��

operating side non–operating side

115mm

Fig. 2.6 – 1 Taking crankshaft deflection readings

K�� *��{��]�� {��

��J��

��$��

��-��

��(��

]��

$� �� H�X�� "#��#� !��%��

]��

4

5

6

7

8

9

10

11

12

For Inte

rnal

Use O

nly


2.6 – 4

2.6.1.2. Measurement axial clearance thrustbearing

=�� ;��

9612ZT376 Driving end

Fig. 2.6 – 2 Measuring crankshaft axial clearance

*��

'�� ZM?H��OjM� �� H�M�;�H��

Never apply any force on the counter weights to move thecrankshaft.

*��{��

'��

$� ��

Note!

1

2

3

4

5

6

For Inte

rnal

Use O

nly


2.6 – 5

2.6.2. Driving unit

Driving unit�� <�� <��?�H�

Connecting rod��{��C?E��CHE��COE�� {��CXE��H�M�;�O��C��Q��@�@E�� C>E� �� H�X�O�

1 1

2

3

4

5

11

2

3

4

5

$"�(G��G( $$"�(G��G(

Fig. 2.6 – 3 Connecting rod

For Inte

rnal

Use O

nly


2.6 – 6

Piston��CME��CjE��CÈ�

Do not remove the piston crown from the piston skirt.

6

7

8

Fig. 2.6 – 4 Piston

Note!

For Inte

rnal

Use O

nly


2.6 – 7

Cylinder liner��CZE��;��C?@E�� !��H�M�;�>��

�� C??E� �� C?HE��

Always handle pistons and connecting rods with care.

10

12

119

Fig. 2.6 – 5 Driving unit

Note!

For Inte

rnal

Use O

nly


2.6 – 8

2.6.2.1. Removing big end bearing shells without removing driving unit

<�� <�� ZM?H��ZO`�

]� ��

-�� H�M�H�H�z�� z�

��C$��E

<��ZM?H��ZO`��

9612ZT938

Fig. 2.6 – 6 Piston support for big end bearing inspection

��H�M�;�M��

��

]� ��

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.6 – 9

2.6.2.2. Removing driving unit

�� &� �� J�� ;��

��X@}��-$��

]� ��H�j�

<��ZM?H��Z?>��H�M�;�j��

9612ZT256

9612ZT915

Fig. 2.6 – 7 Removing anti bore polishing ring

<��ZM?H��H>M��!��-$��

]� ��

]� ��Z@}��-$�� H�M�;�`��

Be careful; the bottom side of the connecting rod cap must have passedthe side of the crank web for full support of the jack to be mounted.

Note!

1

2

3

4

5

6

For Inte

rnal

Use O

nly


2.6 – 10

Removing big end bearing cap

Take good care for the correct pressure in relation with the usedhydraulic jacks! See also section 2.4.4.

<��ZM?H��XjM��*��H�M�;�`��

K��ZM?H��ZXX��ZM?H��Xjj��^�K��ZM?H-�O`?�� ZMHH��ZZH�� M��

The jacks mounted should not rest on or touch the crank webs /counter weights.

9612DT381 9612DT381

9612ZT4779612ZT476

9612ZT944

9622ZT992

Fig. 2.6 – 8 Hydraulic tool for connecting rod studs

$�� C�>[E�� <�� H�X�X�>�

=��?@��

Note!

Note!

7

8

9

10

For Inte

rnal

Use O

nly


2.6 – 11

]��

<�� J�� j��`�

]��Z��??�� J��

��-$�

K�� ZM?H��ZHZ�� C?E�� !��H�M�;�Z�

K��CHE��COE��C?E�

!��CHE��

=��CHE��C?E�

]� ��CHE�

!��

9612ZT929

1

2

3

Fig. 2.6 – 9 Lowering big end bearing cap

11

12

13

14

15

16

17

18

19

20

For Inte

rnal

Use O

nly


2.6 – 12

Lifting driving unitK��ZM?H��??X��

��

K��ZM?H��??O�� !��H�M�;�?@��

]� ��ZM?H��H>M��H�M�;�j��

9612ZT112

9612ZT911

9612ZT113

9612ZT114

12 13

Mark on cylinder linerMark on piston

Fig. 2.6 – 10 Lifting driving unit

$��ZM?H��?Z>�

<��ZM?H��Z??��H��C?HE��H�M�;�?@��

��

K��ZM?H��??H��H�M�;�?@��

21

22

23

24

25

26

For Inte

rnal

Use O

nly


2.6 – 13

K�� C?OE��ZM?H��Z??�C��H�M�;�?@�E��

If the driving unit does not move easily then carry out the procedureextracting the driving unit.

=��?@��

$�� %��

$�� ZM?H��Zj@��H�M�;�??��

9612ZT970

Fig. 2.6 – 11 Protecting crank pin journal

$��ZM?H��HXj��

Note!

27

28

29

30

31For Inte

rnal

Use O

nly


2.6 – 14

Extracting driving unit

� ]� �� ZM?H��??H� �� C?OE�� ZM?H��Z??��H�M�;�?@��

9612DT381 9612ZT913

9612ZT911

9622ZT992

9612ZT912

Fig. 2.6 – 12 Extracting driving unit

<��ZM?H��Z?H�� ZM?H��Z?O��ZM?H��Z??��H�M�;�?H��

$��^�K��ZM?H-�O`?�� ZMHH��ZZH��ZM?H��Z?O��

$��

]�� ZM?H��Z?O� �� ZM?H��Z?H� �� ZM?H��Z??��H�M�;�?H��

<�� C?OE� �� ZM?H��??H� �� H�M�;�?@��

$��z��z��H`�

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.6 – 15

2.6.2.3. Disassembling driving unit

'�� &� �� &� �� ZM?H��XX>��q��ZM?H��??X� ��

K��ZM?H��XX>��!��H�M�;�?O��

]� ��C?HE��ZM?H��??O�

]� ��ZM?H��Z??�

]� ��

9612ZT113

9612ZT114

9612ZT445

9612ZT911

12

Fig. 2.6 – 13 Support driving unit

'�� &� �� &� �� ZM?H��XX>��

K�� {�� ZM?H��Z??�

��

$��

K��&��

1

2

3

4

1

2

3

4

For Inte

rnal

Use O

nly


2.6 – 16

]� ��C?@E��H�M�;�?X��

G��

9612ZT250

10

Fig. 2.6 – 14 Removing gudgeon pin

$��

!��H�M�;�?X��

The gudgeon pin is heavy and needs to be supported during slidingout.

Note!

5

6

7

For Inte

rnal

Use O

nly


2.6 – 17

2.6.2.4. Inspection and maintenance of piston and connecting rod

"��

Never use emery cloth on the piston skirt.

<�� -�� &��

K�� "��

Remove used and mount new piston rings always with pliers9612ZT185, see fig. 2.6 – 17 .

$��

$��

$��

*�� !�� H�X�>�H��

'��

'��

'��

$�� !�� H�X�>�H�

Note!

Note!

1

2

3

4

5

6

7

8

For Inte

rnal

Use O

nly


2.6 – 18

2.6.2.5. Assembling connecting rod and piston

Position of connecting rod in relation to the crankshaft rotation

Clockwise rotating<�� %�� C�� E� �� Q��H�M�;�?>��

��|��

ALL CONNECTIONS WITH TEXT ”OI”AT NON–OPERATING SIDE

Fig. 2.6 – 15 Clockwise rotating

�� %�� |� ��For I

ntern

al Use

Only


2.6 – 19

Counter clockwise rotating<�� %��C��E��H�M�;�?M��

��|��

ALL CONNECTIONS WITH TEXT ”OI”AT OPERATING SIDE

Fig. 2.6 – 16 Counter clockwise rotating

�� %�� |��

For Inte

rnal

Use O

nly


2.6 – 20

K��!��H�M�;�?Z��

=��

*��

��

]��C?@E��H�M�;�?X��

)��ZM?H��?`>�� H�M�;�?j��

Both compression rings (1) and (2) look similar however they aredifferent. Check piston ring part number and location on piston inthe part catalogue, see fig. 2.6 – 17 .

Always mount piston rings with identification number facing topand with the slot opening 120 � opposite of each other.

*��

9612ZT185

1

2

Fig. 2.6 – 17 Application piston ring pliers

Note!

Note!

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.6 – 21

2.6.2.6. Mounting connecting rod with pistoninto cylinder liner

$��

'�� !��H�M�;�?`��<��G�Q��H�X�>�H�

120

70

380

550

Fig. 2.6 – 18 Cylinder liner diameter control

K��<�� ZM?H��Z>X��H�M�;�?Z��

��

-��C?H@}��E��

$��

%��

K��ZM?H��Z?j�� H�M�;�?Z��

=��&�� ZM?H��Z?j�

�� {��

$��|� ��|� ��H�M�;�?Z��

1

2

3

4

5

6

7

8

9

10

11

For Inte

rnal

Use O

nly


2.6 – 22

9612ZT917

X

X

X

9612ZT113

9612ZT114

9612ZT954

9612ZT911

10.1

10.2

Fig. 2.6 – 19 Cylinder liner, mounting / manipulator

2.6.2.7. Mounting driving unit

Preparing driving unit and cylinder block$��

�� ZM?H��Z>@��ZM?H��Z>?��

*�� -;�� C?@�?�� ?@�H�J��E� �� !��H�M�;�?Z��*��-;��<��

Make sure that the black D–ring never is in contact with oil or othertypes of grease.

$�� -;��

<��ZM?H��Z??��H��C?HE��H�M�;�H@��

Note!

1

2

3

4

5

For Inte

rnal

Use O

nly


2.6 – 23

To avoid wrong mounting, the connecting bolts are different oflength. The threaded holes in the piston crown are asymmetricpositioned.

<�� ZM?H��??O� �� C?OE��H�M�;�H@��

9612ZT112

9612ZT911

9612ZT113

9612ZT114

12 13

Mark on cylinder linerMark on piston

Fig. 2.6 – 20 Lowering driving unit

K��ZM?H��??X�!��H�M�;�H@��

%�� |�� C��E�

��

K��ZM?H��??H��H�M�;�H@��

$��

Note!

6

7

8

9

10

11

For Inte

rnal

Use O

nly


2.6 – 24

Mounting support ring cylinder liner

For correct mounting of the support ring it is necessary:– to place the driving unit within 10 minutes into the cylinder block!!– to place and tighten the cylinder head within 8 hours!!

-��CHE��C?E��COE��=��*��CHE��!��H�M�;�H?��<��=��

*��CXE�C��> E��C?E�� CHE��-��!��H�M�;�H?�z*z��<��CXE��

View X – X

XX

1

2

3

5”A”

”B”

”C”

”D”

4

4

Fig. 2.6 – 21 Support ring cylinder liner

K��CHE��C?E��C>E��-��!��H�M�;�H?�zJz��|Q|�

K�� $��{��Q��-��

Note!

1

2

3

4

For Inte

rnal

Use O

nly


2.6 – 25

*��CXE�C��> E�� CHE��-��!��H�M�;�H?�z$z��<��CXE��

=��

]� ��ZM?H��Z??�� !��H�M�;�H@��

]� ��ZM?H��??H�� H�M�;�H@��

<��ZM?H��H>M��-;��H�M�;�HH��

-�� {��Q�� COE��CHE��!��H�M�;�H?�z-z�

9612ZT256

Fig. 2.6 – 22 Securing cylinder liner

To avoid lifting of the cylinder liner while cranking the engine thesleeves 9612ZT256 must remain mounted until the cylinder head ismounted .

After the driving unit has been placed the cylinder head has to bemounted and tightened within 8 hours!!For mounting of the cylinder head see section 2.7.1.3.

Note!

Note!

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.6 – 26

Mounting big end bearing cap]� �� ZM?H��??O� ��

�� H�M�;�H@��

]� ��ZM?H��??X�� H�M�;�H@��

$��=��

K��C?E��ZM?H��ZHZ��!��H�M�;�Z��

K��CHE��COE��C?E�

=�� CHE��

]� ��ZM?H��ZHZ�

<��ZM?H��XjM��*��H�M�;�`��

K�� ZM?H��ZXX� �� ZM?H��XjM� �� ZM?H��Xjj��

The jacks mounted should not rest on or touch the crank webs /counter weights.

$��^�K��ZM?H-�O`?�� ZMHH��ZZH��H�M�;�`��

��

Take good care for the correct pressure in relation with the usedhydraulic jacks! See also section 2.4.4.

Note!

Note!

1

2

3

4

5

6

7

8

9

10

11

For Inte

rnal

Use O

nly


2.6 – 27

1st step ’A’ studs

�; K��>@@��

�; )��ZM?H��?H>��

�; $��@�@>� ��

�; ]�� {��

1st step ’B’ studs

�; K��J��$��

�; K��>@@��

�; )��ZM?H��?H>��

�; $��@�@>� ��

�; ]�� {��

�; ]� �� J��

�; K�� ZM?H��ZX@��C*��JE�� |�� H�M�;�HO��

2nd step ’B’ studs

�; K��J��$��

�; K��H�X�X�>��G��

�; ]�� {��

2nd step ’A’ studs

�; K��*��$��

�; K��G��

�; ]�� {��

3rd step ’A’ studs

�; K��G��

�; $��@�@> ��

�; ]�� {��

12

13

14

15

16

For Inte

rnal

Use O

nly


2.6 – 28

3rd step ’B’ studs

�; K��J��$��

�; K��G��

�; $��@�@> ��

�; ]�� {��

�; ]� ��

�; K�� ZM?H��ZX@��C*��JE�� H�M�;�HO��

�; $��;��|�� H�X�X�>��C��H�X�;�H@�E�

Fig. 2.6 – 23 Measuring stud elongation

In case stud elongation is outside limits the connection is NOT safe.In such a case all components have to be disconnected andexamined on deviation in material or wrong assembling.

<��H�j

<�� -;��

!��

$��

Warning!

17

18

19

20

21

For Inte

rnal

Use O

nly


2.6 – 29

2.6.3. Vibration damper crankshaft

��


�� "#��#�$�� ?`@�� <�� "#��#$�� MMOH>�Z@X*�

Dampers with a viscosity out of range may cause crankshaftbreakdown.

Note!

For Inte

rnal

Use O

nly


2.6 – 30

2.6.3.2. Liquid sampling

�� K��/

J��

]� ��

]� �� ZM?H��XZj��-��

)�� C��E��

]� ��

Fig. 2.6 – 24 Liquid sampling

]� �� '��

��

12

3

4

5

6

7

For Inte

rnal

Use O

nly


2.6 – 31

If no liquid appears:

�; ]� ��

�; !�� O�>� ��

��

%��/

�; $��&��

�; !��

)��

<�� CE��CE�� ]��

�� O>�G �

=��

*�� C�� E��/

�; �� C��E

�; ��

�; ��

�; ��

�; ��

<�� / "#��#��!��*�!��-�� J��]��OOXOX@?`�!��-��Q��

%��

'��?@�� ?�� O��

8

9

10

11

12

13

14

For Inte

rnal

Use O

nly


2.6 – 32

2.6.4. Turning gear

(�� C>E��<�� COE��C?E��CHE��H�M�;�H>��*��CME�� CjE��

3

2

1

5

4

6

7

Fig. 2.6 – 25 Turning gear

=�� )�� Q��!��?�H�?�?�H��

For Inte

rnal

Use O

nly


2.6 – 33

Maintenance��CXE��

��

$��

$��CHE��C?E��


1

2

3

For Inte

rnal

Use O

nly


2.6 – 34

For Inte

rnal

Use O

nly

Cylinder Head with Valves ManualWärtsilä 26

2.7 – 1

2.7. Cylinder Head with Valves

For Inte

rnal

Use O

nly

Cylinder Head with ValvesManualWärtsilä 26

2.7 – 2

2.7.1. Cylinder head

��C?E��CHE��C?@E��C??E��COE��CH>E��CHME��CXE��^��!��H�j�;�?��H�j�;�`��^�� CHjE��^��CME�� J�� M� �� CjE�� H�`�*��

1

710

3

11

6

8

2

4

Fig. 2.7 – 1 Cross section cylinder head

For Inte

rnal

Use O

nly


2.7 – 3

2.7.1.1. Maintenance of cylinder head

$�� !�� $�� $�� "��

*�� ZM?H��Z>`��*�� H��C?HE�

�� C?OE��C?XE�

14

13

9612ZT958

315o

0o

45o

270o

225o

180o

135o

90o

12

Fig. 2.7 – 2 Tilting frame cylinder head


Note!

For Inte

rnal

Use O

nly


2.7 – 4

Cylinder head inspection*�� $��$�� ZM?H��Z>@� �� ZM?H��Z>?��

2.7.1.2. Removing the cylinder head

J�� ;��

]� ��

��-$�� CHÈ��!��H�j�;�`��

=�� CjE�

]� ��CÈ�

-�� ZM?H��OOH�

-��C?>E��C?ME��^K��C?jE��C?È��!��H�j�;�O��

171516

18

Fig. 2.7 – 3 Disconnecting pipes from cylinder head

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.7 – 5

]� �� '��

]� ��

<�� ZM?H��Z@X��ZM?H��Z@?��ZM?H��?O?��ZM?H��?ZM��$��^K��H�j�;�X��C��X��E��H�j�;�?@��C��H��E�

%��;�� ZM?H��??Z�� H�j�;�X��*�� M��

9612DT373

9612ZT918

9612ZT942

9612ZT131

9612ZT119

9612ZT901

9612ZT196

9612DT381

9622ZT992

Fig. 2.7 – 4 Cylinder head with 4 jacks

8

910

11

For Inte

rnal

Use O

nly


2.7 – 6

K��{��`��ZM?H��?H>�

=��{��

]� ��

)��ZM?H��ZHj�� !��H�j�;�>��

9612ZT927

Fig. 2.7 – 5 Lifting cylinder head

$��CHjE��!��CHOE�� !��H�j�;�`��

"�� ZM?H��H>M�� H�j�;�M��

12

13

14

15

16

17

For Inte

rnal

Use O

nly


2.7 – 7

9612ZT256

Fig. 2.7 – 6 Securing cylinder liner

$��ZM?H��HXj�

9612ZT247

Fig. 2.7 – 7 Cylinder liner cover

)��ZM?H��`jj�� CHjE��!��H�j�;�`��

18

19

For Inte

rnal

Use O

nly


2.7 – 8

2.7.1.3. Mounting cylinder head

$��

<��%;��CH@E��CO@E��H�j�;�`��

24

27

View A – A

AA

28

22

23

21

21

7

8

29

25

26

2030

Fig. 2.7 – 8 Cylinder head build–on

1

2

For Inte

rnal

Use O

nly


2.7 – 9

<��%;�� CH?E�� ]��Q��CHHE��CHOE��

��-$��

'��ZM?H��ZHj��H�j�;�>��

K��CHXE��CHZE��!��H�j�;�`��*Q*�

K�� !��?�>�>� ��

-�� %;�� CHjE� ��

<�� ZM?H��?H>�

*��

Mounting procedure with 4 jacks<��H�j�;�X��

%�� {��

Cylinder head studs1st step

�; K��{��O@@��

�; <�� X��$��@�@>� ��

�; !��{��

�; K�� ZM?H��ZX?� �� |�� H�j�;�Z��

2nd step

�; <�� H�X��<�� X��

�; !��{��

3

4

5

6

7

8

9

10

11

12

13

14

For Inte

rnal

Use O

nly


2.7 – 10

3rd step

�; ��

�; $�� @�@>� � ��

�; !�� {��

�; ]� ��

�; K�� ZM?H��ZX?� �� H�j�;�Z��

�; -��|�� H�X�X��H�j�;�Z��

Fig. 2.7 – 9 Stud elongation

In case difference in elongation is outside limits as mentioned inchapter 2.4.4. the connection is NOT safe. In such a case allcomponents have to be disconnected and examined on deviation inmaterial or wrong assembling.

Warning!

15

For Inte

rnal

Use O

nly


2.7 – 11

Mounting procedure with 2 jacks<��ZM?H��Z@X��H�j�;�?@��

%��

Cylinder head studs

1st step ’A’ studs

�; K��{��O@@��

�; <�� *��

�; $��@�@>� ��

�; !��{��

�; ]� ��

A B

AB

9612ZT131

9612ZT119

9612ZT901

9612ZT196

9612DT3819612DT381

9622ZT992

Fig. 2.7 – 10 Cylinder head with 2 jacks

16

17

For Inte

rnal

Use O

nly


2.7 – 12

1st step ’B’ studs

�; ��

�; <�� J��

�; K��{��O@@��

�; <�� J��

�; $��@�@>� ��

�; !��{�� ]� �� J��

�; K�� ZM?H��ZX?��C*��JE�� |�� H�j�;�Z��

2nd step ’B’ studs

�; <��J��$��

�; K�� H�X��

�; ]�� {��

2nd step ’A’ studs

�; ��*��

�; <�� *�� $��

�; K��H�X��

�; ]�� {��

3rd step ’A’ studs

�; K��H�X�� G��

�; $��@�@> ��

�; ]�� {��

18

19

20

21

For Inte

rnal

Use O

nly


2.7 – 13

3rd step ’B’ studs

�; <�� J�� $��

�; K�� H�X��G��

�; $��@�@> ��

�; ]�� {��

�; ]� ��

�; K�� ZM?H��ZX?��C*��JE�� H�j�;�Z��

�; -��|�� H�X�X��H�j�;�Z��

In case the difference in elongation of studs ’A’ and ’B’ is outsidethe limits given in chapter 2.4.4. the connection is not safe. Insuch case all components have to be disconnected andexamined on deviation in material or wrong assembling.

�� ?�>�>�H�

'��CÈ��H�j�;�`��

K��CHÈ��

'��CjE��%��

*��H�j�H�

'��

$��C?È��^K��C?jE��H�Z�X��C?ME��C?>E

<��^��

K��

'��

Warning!

22

23

24

25

26

27

28

29

30

31

32

For Inte

rnal

Use O

nly


2.7 – 14

2.7.2. Adjusting valve clearance

Adjust valve clearance only after a cooling down period of 30 minutes.Adjust inlet and exhaust valves as sets.

]� ��

��-$��

=��C?E��CHE��H�j�;�??��

��

Levelling the bridge piece=��CjE��CME��COE�

��CME��

K��@�@>� ��CXE��CME�� H�j�;�??��

(�� COE��

�� CjE��

�� CjE� �� <��H�X�X�M�

Note!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.7 – 15

Adjusting the valve clearanceK��ZM?H��H>?��CÈ��COE��

��CZE��<��H�X�>�?�

��CHE��

��C?E��

�� <��H�X�X�M�

]� ��

<��

1 2

4

6

7

3

98

Fig. 2.7 – 11 Valve clearance adjustment

11

12

13

14

15

16

For Inte

rnal

Use O

nly


2.7 – 16

2.7.3. Valves and valve seats

�� CXE��%Q��C>E�� {��*��CME�� CjE�

Inlet (1) and exhaust (2) valves differ in material and must not bemixed. Inlet valves are larger in valve disc diameter.

4

1

2

5

6

7

Fig. 2.7 – 12 Valves and valve seats

Note!

For Inte

rnal

Use O

nly


2.7 – 17

2.7.3.1. Removing of valves

*�� H�Z�O�H��

*�� ZM?H��Z?Z�� ZM?H��Z?O��H�j�;�?O��

<��ZM?H��?`X��

<��H��

=��X@� �� CjE�)�� ZM?H��Z>>��

�

9612ZT913

9612ZT184

9612DT381

9612ZT955

7

Fig. 2.7 – 13 Valve spring removing

1

2

3

4

For Inte

rnal

Use O

nly


2.7 – 18

q��

%��;��

]� ��X��q��

]�� '��

Inlet valves

Cylinder head

Exhaust valves|?

|H

�?�H

Fig. 2.7 – 14 Designation of valves

5

6

7

8

For Inte

rnal

Use O

nly


2.7 – 19

2.7.3.2. Check and reconditioning of valve discand valve seat

��

'��/�� <��H�X�;�OX��H�X�;�O>��]��

Manual grinding is not permitted in order to maintain difference invalve seat angle.

'�� "#��#� $��!��-�� "#��#�!��%��<��

J��/*�� K��J��K�� -��H@[��X@[��H�j�;�?>��

*) *)

*) 20 – 40 %

*) *)

Fig. 2.7 – 15 Blueing test

Note!

1

2

3

For Inte

rnal

Use O

nly


2.7 – 20

2.7.3.3. Valve seats

��

Removing of the exhaust valve seat��$��

�� ZM?H��`>Z��C?E��CHE��COE��?@@�G ��!��H�j�;�?M��

K��CXE��ZM?H��Z?O�� ZMHH��ZZH�

*�� X>@� �� >H@�� K��C>E��

=��COE��

$�� $� �� H�X�>��H�X�;�O>��

9612ZT913

9612DT381

9612ZT859

9622ZT992

1

2

3

4

5

Fig. 2.7 – 16 Removing valve seats

1

2

3

4

5

For Inte

rnal

Use O

nly


2.7 – 21

Removing of the inlet valve seat��

��

"��X��CO�H� E�

��

$�� $� �� H�X�>��H�X�;�O>��

Mounting

Wear low temperature resistance gloves and safety glasses duringhandling of deep frozen engine parts and take notice of the safetymeasures of the suppliers from the liquid nitrogen. Before mountinga new valve seat, check condition of valve guide see section 2.7.3.4.

-��

K��/

�; (��/Q ^��Z@�$��Q$��{��;>@�$��Q=��%;��C?HE��

��H�j�;�?j��Q*��

��

�Q$��

�; ��/�Q^��Z@�$��Q$��;?`@�$��Q$��

K��CÈ��CZE��ZM?H��ZX>�� <��C?OE��C?XE��> ��

Inlet and exhaust valve seats require different counter plates,exhaust (10) and inlet (11), see fig. 2.7 – 17 .

Note!

Note!

1

2

3

4

1

2

3

For Inte

rnal

Use O

nly


2.7 – 22

*�� C>��E�

8

9

9612ZT945 11

10 12 13 14

Fig. 2.7 – 17 Mounting valve seats

Machine grinding of valve seat*��

�� (�� H�j�O�H�

4

5

For Inte

rnal

Use O

nly


2.7 – 23

2.7.3.4. Valve guide

$��'�� H�X�>�H�]��

Extracting valve guide]� ��

H�j�;�H?��H�j�;�HO��

K�� ZM?H��Z@Z� ��ZM?H��Z?O�

9612ZT909

9612ZT913

Fig. 2.7 – 18 Extracting valve stem guide

*��ZM?H��Z?O��

$��

Mounting valve guide'��

^��Z@�$�

$��CQ?>@�$E�


%��

K��ZM?H��HOO��=�� H�X�H�j�

Note!

1

2

3

4

5

67

89

For Inte

rnal

Use O

nly


2.7 – 24

If the valve guide is renewed the contact faces of the valve disc andseat have to be checked by the blueing test, see section 2.7.3.2.

'��H�j�;�H?��H�j�;�HO�

2.7.3.5. Assembling of valves

$�� ]��

$��%;��C?OE�

13

Fig. 2.7 – 19 Valve stem guide

=��

<�� J��]��

$��H�j�O�H�

'��

K�� ZM?H��Z?Z� �� ZM?H��Z?O��H�j�;�?O��

$� ��

)��$��

Note!

10

1

2

3

4

5

6

7

8

9

For Inte

rnal

Use O

nly


2.7 – 25

2.7.4. Valve rotators

(��

*��

-�� -��

�� J�� $�� -��

2.7.4.1. Inlet valve rotator

Maintenance of valve rotator*�� CjE��

�� H�j�;�H@��

��

]� ��CME�

]� ��CHE�

]� ��COE�

]� ��CXE��C>E�

$��C?E��

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.7 – 26

$�� ]��

-��

7 5 413

2 6

Fig. 2.7 – 20 Inlet valve rotator

Removing/mounting the valve spring washer of the valve rotator*�� & ��ZM?H��ZXj��

9612ZT947

Fig. 2.7 – 21 Removing/mounting of valve spring washer

8

9

For Inte

rnal

Use O

nly


2.7 – 27

2.7.4.2. Exhaust valve rotator

Maintenance of valve rotator

*�� CjE�� CZE��C?@E��C??E��CÈ��H�j�;�HH��

10

11 8 7

913

12

15

14

Fig. 2.7 – 22 Exhaust valve rotator

]� ��

]� �� C?XE�� C?>E�

�� C??E�

�� C?HE��J��

$��

$��

��

$�� C?OE� ��

$��C?@E��

$��

]��

1

2

3

4

5

6

7

8

9

10

11

12

For Inte

rnal

Use O

nly


2.7 – 28

]��

*� ��-��

J��

-��

Removing/mounting the valve spring washer of the valve rotator

*�� C?>E�� & ��ZM?H��Z>M�

$��;��ZM?H��Z>M��H�j�;�HO��C?>E�

��

9612ZT956

15

Fig. 2.7 – 23 Removing/mounting ring bottom drive section

13

14

15

16

1

2

For Inte

rnal

Use O

nly


2.7 – 29

2.7.5. Injector sleeve


(��

%�� ZM?H��ZMH�

�

9612ZT962

Fig. 2.7 – 24 Grinding of seal cylinder head with injector

*��

<�� ZM?H��ZMH��

For Inte

rnal

Use O

nly


2.7 – 30

2.7.5.2. Extracting injector sleeve

K�� ZM?H��ZOH��

K��

]� ��

Maximum pressure hydraulic jack 600 bar.

9612ZT932

Fig. 2.7 – 25 Extracting injector sleeve

Note!

1

2

3

For Inte

rnal

Use O

nly


2.7 – 31

2.7.5.3. Mounting injector sleeve

$��

^��Z@�$�

$��;>@�$�

*�� ]� ��

K��ZM?H��ZXM��

��C?E�� >� ��

�

9612ZT946

1

Fig. 2.7 – 26 Mounting new injector sleeve

1

2

3

4

5

6

For Inte

rnal

Use O

nly


2.7 – 32

2.7.6. Indicator cock and Safety valve

Indicator cock(��C?E��H�j�;�Hj��$��

J��

*��

*��

*�� C��?@@@°$E��

*��ZM?H!">?@��C?E��H�j�;�Hj��

1

2

Fig. 2.7 – 27 Indicator cock / safety valve

Safety valve(��CHE�� ;�� '��


1

2

3

4

5

For Inte

rnal

Use O

nly

Camshaft and Valve Drive ManualWärtsilä 26

2.8 – 1

2.8. Camshaft and Valve Drive

For Inte

rnal

Use O

nly

Camshaft and Valve DriveManualWärtsilä 26

2.8 – 2

2.8.1. Camshaft driving gear

�� C?E�� CHE�� COE�� H� �̀;�?� ��

1

2

3

Fig. 2.8 – 1 Gearwheel drive camshaft

For Inte

rnal

Use O

nly


2.8 – 3

�� CXE� �� C>E� �� CME�� H�`� ;� H� ��

(�� CjE��

��

6 5 7 4 7 8

Fig. 2.8 – 2 Camshaft

*�� CÈ��H�`�;�H��

<�� <�� ?�H�

For maintenance background information, safety aspects,intervals, tolerances, inspections, and torque spanner instructions,see chapter 2.4.

Note!

For Inte

rnal

Use O

nly


2.8 – 4

2.8.1.1. Crankshaft gear wheel

��CZE�� C?@E� �� C??E� �� H�`�;�O��

9

9

10

11

Fig. 2.8 – 3 Crankshaft gear wheel

Inspection camshaft driving gear

�� H�X��(��

For Inte

rnal

Use O

nly


2.8 – 5

2.8.1.2. Camshaft gear wheel

2.8.1.2.1. Removing of camshaft gear wheel

Turning the crankshaft with disconnected camshaft can result indamaging of in– and exhaust valves.

(��

]� �� H�j�

]� ��;��

-�� ( ��

]� ��

J��-$�� z?z��

]� ��C?@E�� H�`�;�>��

*��ZM?H��Ojj�� !�� C??E��H�`�;�>��

]� ��

]� ��ZM?H��ZMO��?��H�`�;�X��

$�� ZM?H��`>H� �� ZM?H��ZMO��$�� {��

$��ZM?H��`>H��$��

$��COE��ZM?H��`>H�� C?E�

!�� ZM?H��`>H� ��

Warning!

1

2

3

4

5

6

7

8

9

10

11

12

13

14

For Inte

rnal

Use O

nly


2.8 – 6

9612ZT852

9612ZT963

1

Lifting eye3

2

Fig. 2.8 – 4 Removing camshaft gear wheel

]� �� CXE� �� H�`�;�>��

]� ��CME�� C>E�

4

79

8

65

10 9612ZT377

11

Fig. 2.8 – 5 Camshaft gear wheel

15

16

For Inte

rnal

Use O

nly


2.8 – 7

]� �� CjE� �� CÈ� �� CZE�

K�� ZM?H��Z`H� �� K�� !��H�`�;�M�

9612ZT982

Fig. 2.8 – 6 End journal camshaft gear wheel

!�� {��=��COE��H�`�;�X�

17

18

19

For Inte

rnal

Use O

nly


2.8 – 8

2.8.1.2.2. Mounting of camshaft gear wheel

<�� ZM?H��ZMO� �� ZM?H��`>H��ZM?H��ZMO��!��H�`�;�X��

$��ZM?H��`>H��

$��

K�� {�� COE��

=�� C?E��!��H�`�;�X��

$�� M��H�`�?�H�?�

!��CÈ�� CjE��H�`�;�>��C?E��ZM?H��ZMO�� H�`�;�X��=��CHE�

]� ��ZM?H��`>H��ZM?H��ZMO�

As connection between crankshaft and camshaft still not exist,barring of crankshaft is only permitted within a few crankshaftdegrees.

J�� C??E��H�`�;�>��C?@E��

��C?@E��H�`�H�O�

��CjE�

'��C>E��CME�

$��H�X�

'��CXE�

$��

'��

-�Q��

Note!

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

For Inte

rnal

Use O

nly


2.8 – 9

2.8.2. Camshaft


�� H�X�'�� *�� (��

2.8.2.2. Removing camshaft section andjournal

Camshaft section��

��ZM?H��ZH>�� H�Z�H�?�

�� ZM?H��ZHX�� H�`�;�j��

9612ZT924

Fig. 2.8 – 7 Tappet assembly inlet / exhaust

1

2

For Inte

rnal

Use O

nly


2.8 – 10

]� �� ZM?H��>M@��ZM?H��>>`�� C?E��CHE�� =��O��!��H�`�;�`��

1 2

34

Fig. 2.8 – 8 Camshaft section and journal

K��ZM?H��Ojj��COE� �� !��H�`�;�Z��]��CXE�

9612ZT377

Fig. 2.8 – 9 Separating camshaft section from journal

3

4

For Inte

rnal

Use O

nly


2.8 – 11

��ZM?H��Z`>�� H�`�;�?@��

9612ZT985

2

Fig. 2.8 – 10 Tool for camshaft section

<��ZM?H��Z`>��CHE��H�`�;�?@��

�� )��

Removing camshaft journalJ��

�� ZM?H��`>O� �� H�`�;�??��!��

9612ZT853

Fig. 2.8 – 11 Sliding out camshaft journal

5

6

7

8

For Inte

rnal

Use O

nly


2.8 – 12

2.8.2.3. Mounting camshaft section andjournal

Not all camshaft journals are identical! Before mounting, check theparts catalogue for correct location of camshaft journal.

Camshaft journal

�� <�� H�>�

$��$�� $��

$��*��ZM?H��`>O�� H�`�;�??��

Camshaft section$��

�� ZM?H��Z`>� �� H�`�;�?@��K��

'�� <�� H�`�;�`��

<��

)��ZM?H��>M@��ZM?H��>>`��

)��H�X�X�j��'��

$��@�@>� ��

Warning!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.8 – 13

��H�X�X�j��/

�; �� >� �� J��

�; �� ?`@��>��J��

�; �� Z@��>��J��

�; �� ?`@�� M��

$��

]� ��ZM?H��ZHX��ZM?H��ZH>�

!��

11

12

13

14

For Inte

rnal

Use O

nly


2.8 – 14

2.8.3. Valve drive mechanism

��

Tappet assembly�� C?E��CHE��H�`�;�?H��

Valve lifting gear��C??E��{�� C?>E�� C?@E��C?ME�� C?HE��Q��

3

3

4

8

9

1

2

6 7 5

10

15

1116

12

4

Fig. 2.8 – 12 Tappet assembly and valve lifting gear

For Inte

rnal

Use O

nly


2.8 – 15

2.8.3.1. Removing valve drive mechanism

Mark parts properly before removing.

Bracket of valve lifting gear]� ��

��

��-$��C��E�

]� ��C?OE�� C??E��'?M�C?XE�� H�`�;�?O��

]� ��

14

12

13

10

11

17

Fig. 2.8 – 13 Valve lifting gear

Tappet assemblyK��ZM?H��ZHX��H��

��H�`�;�j��

-�� COE��H�`�;�?H��

=��

Note!

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.8 – 16

Roller and shaft��

]� ��ZM?H��ZHX��CHE��CXE��C>E�� CME��CjE��H�`�;�?H��

2.8.3.2. Inspection of valve lifting gear

Rocker arm$��

*��]��H�X��

Pivots��C?È�� C?@E

�� C?jE��H�`�;�?X��

17

10

15

1116

18

Fig. 2.8 – 14 Valve lifting gear

8

9

1

2

For Inte

rnal

Use O

nly


2.8 – 17

Tappet assembly$�� $��

��

'�� ]��H�X�

Push rods$��

$��

2.8.3.3. Mounting valve drive mechanism

=��

!�� C>E� �� CME� ��CjE��CHE��CXE��H�`�;�?H��

$�� <�� %;��CÈ��CZE��

<��ZM?H��ZHX��H�`�;�j��

K�� COE��!��H�`�;�?H��

]� ��ZM?H��ZHX�

!��

��

$��

*��C?jE��C?HE��H�`�;�?O��C?OE��!��H�X�

Take care, rollers are resting on base circle before mounting valvelifting gear.

$��

$��H�j��'��

Note!

3

4

5

6

1

2

3

4

5

6

7

8

9

10

11

12

For Inte

rnal

Use O

nly


2.8 – 18

2.8.4. Actuator drive

��C?E��CHE�� COE�

1

2

3


K��{��

Maintenance*�� /

]��!��H�X�

J��

%��

$��

If helical gear wheels are damaged, both gear wheels have to berenewed as a set.Special tools are necessary to adjust the gearwheels.


Warning!

1

2

3

4For I

ntern

al Use

Only

Injection System ManualWärtsilä 26

2.9 – 1

2.9. Injection System

For Inte

rnal

Use O

nly

Injection SystemManualWärtsilä 26

2.9 – 2

2.9.1. High Pressure (HP) fuel pump

(��^K�� C?E��H�Z�;�?��^K��CHE�� Q��

�� ^K�� CXE��CjE��

(��^K�� COE�� {��

2

5

6

12

3

1

4

7

Fig. 2.9 – 1 HP fuel pump

For maintenance background information, safety aspects,intervals, tolerances, inspections, tools and torque spannerinstructions, see chapter 2.4.

Note!

For Inte

rnal

Use O

nly


2.9 – 3

2.9.1.1. Removing HP fuel pump

J�� ^K�� C?ME�� C?jE��H�Z�;�j��

$��

-�� ?�?�X�

]� ��C>E�

�� ^K��CHE��H�Z�X�

The connecting pipe and HP fuel pipe must not be rotated with oragainst each other. Take care the locking plate remains tight.

]� ��CME��COE�

-��CÈ�� CZE�� C?@E��C??E��H�Z�;�H��

10

118

9

A

View A

Fig. 2.9 – 2 Fuel rack connection to common fuel control rod

-��^K�� C?E�� C?HE��H�Z�;�?��

��'?H��CZE��^K�� !��H�Z�;�X�

Carefully lift the HP fuel pump in centre line direction to avoidclamping of push rod top (15) in fuel pump bottom section, see fig.2.9 – 7 . Cover immediately all openings with tape or plugs to avoiddirt admission.

Note!

Note!

1

2

3

4

5

6

7

8For I

ntern

al Use

Only


2.9 – 4

2.9.1.2. HP fuel pump disassembling

HP fuel pump parts should be kept matched during overhaul.

J��

K��

Plunger (7) is spring loaded. See fig. 2.9 – 3

J�� ZM?H��Zj?��C?E��CHE��!��H�Z�;�O��

'��ZM?H��Zj?��CXE

'��CHE��C?E��ZM?H��XXH��COE��

]��C>E��C?E��ZM?H��XXH�

]� ��ZM?H��Zj?�

]� ��CME��C>E��CjE��

2

3

4

4

5

6

7

1

9612ZT442

9612ZT971

Fig. 2.9 – 3 Disassembling HP fuel pump

Note!

Note!

1

2

3

4

5

6

7

8

For Inte

rnal

Use O

nly


2.9 – 5

9

16

25

29

241722

2823

7

26

65

3

’A’

19

158

1012

11

1314

2120

18

17

27

29

Fig. 2.9 – 4 HP fuel pump

]� ��CÈ��CZE��C?@EE��H�Z�;�X��

]� �� C??E� �� C?HE� �� C?OE��C?XE�

K��C?jE��{��C@� E�� CHOE��CHÈ�

�� C?ME�� C?>E��ZM?H��HH>�� "�� E��H�Z�;�>��

�� C?jE� �� C?È��C?ZE��CH@E�� CH?E��CHHE��C?jE�

9

10

11

12

13

For Inte

rnal

Use O

nly


2.9 – 6

9612ZT22515

16

Fig. 2.9 – 5 Removing barrel

Protect parts against rust and don’t touch plunger element surfaceswith bare fingers.Keep pump element and pump barrel always matched as a pair.

<��

2.9.1.3. HP fuel pump maintenance andinspection

Maintenance�� H�X��

Inspection$��C?HE��C?XE��]��

��H�Z�;�X��

��C??E��C?OE�� C??E� ��C?OE� ��C??E�

$��C?@E��C?ME��!��

$��CHOE�� C?ME��$��

$��C?ME��CjE��]�� H�X�

The barrel and the plunger of the fuel pump are matched andmachined to each other. Barrel and plunger may therefore not beexchanged with another barrel or plunger.

Note!

Note!

14

1

2

3

4

5

For Inte

rnal

Use O

nly


2.9 – 7

$��C?ME��*��

$��

$��CHZE��

$��C?jE��<��

$��C>E

2.9.1.4. Assembling the HP fuel pump

"�� -��

]��C?XE��C?OE�� C??E��C?HE��C?ME��H�Z�;�X��

To prevent leakage always renew cover (10) and bolts (8), see fig.2.9 – 4

K��C?@E��CZE��CÈ�

*��%;��CHXE��CH>E��

�� CHME��K�� <��C?>E�

K�� C?>E��H>G ��H�X�X�`�

��CÈ��?@G ��H�X�X�`��C?ME��CZE��C��&&�@�O� �E�

]��CÈ��

�� %��C?jE��*��CHHE�

%��CHOE��{��C@� E��CHjE��

'�� CHÈ�

*��CjE��C>E��CME��

The protruding vanes at both sides of the plunger lower side haveto slide into the grooves of the control sleeve. To make this easygoing move at the same time the fuel rack to and fro.

Note!

Note!

6

7

8

9

10

1

2

3

4

5

6

7

8

9

10

11

12

For Inte

rnal

Use O

nly


2.9 – 8

)��ZM?H��Zj?�� C>E��COE��H�Z�;�O��

]��

'��

$��

Unless the HP fuel pump is immediately mounted on the engine, oilit well before storage. All openings in the pump house should bewell covered by plastic caps or tape.

2.9.1.5. HP fuel pump adjustment

�� !��

Checking of the injection timing is always necessary after majorcomponents have been replaced, e.g. HP fuel pump element, pumpdrive, camshaft section or some maintenance has been done ongears, especially to the intermediate gear.

Checking the fuel pump drive]� ��^K�� !��H�Z�?�?�

'��^K��

]� �� C?ME�� C?jE��H�Z�;�M��

K��C?>E�� z|z��C?>E��^K�� CXE�

$��z|z��H�X�>��H�X�;�X@��

�� z|z� �� H�Z�H�X�� H�Z�H�>�

Note!

Note!

13

14

15

16

1

2

3

4

5

6

For Inte

rnal

Use O

nly


2.9 – 9

Checking the fuel injection timing!�� z|z��

��C?ME�� C?jE�

K��ZMHH-�Hj>��H�Z�;�M�� CXE��C?>E��{��

��

-��X�>� �� @�?� �� C�� E�

9622DT275

”X”

15

4

16

17

Fig. 2.9 – 6 HP fuel pump adjustment

2.9.1.6. HP fuel pump mounting

J�� ^K�� ^K�� |��H�Z�?�>��

$��^K��

$��

7

8

9

10

1

2

For Inte

rnal

Use O

nly


2.9 – 10

K��%;��C?OE��%;��C?XE�� !��H�Z�;�j��

1413 12

15

16

17

Fig. 2.9 – 7 Fuel pump bracket

$��^K�� %;��C?XE�

��C?HE��H�X�X�`�

�� ^K��CHE��H�Z�X�

The connecting pipe and HP fuel pipe must not be rotated with oragainst each other.

'��C>E��CME��COE��H�Z�;�?�

$�� !��H�Z�;�H��

]�� /

�; *��

�; *�� ?� �

%��

Note!

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.9 – 11

2.9.2. Fuel pump bracket

�� CXE��C?È��C?ZE��CH@E�� C?E�

�� CH?E��%;��C?OE��C?ZE��CH@E�� ^K�� CXE�� COjE��C?>E�

�� CXE��CHHE��CHOE��H�Z�;� �̀�

19

1

20

22 4 18 1821

1537 23 24 26 27 2818

13


For Inte

rnal

Use O

nly


2.9 – 12

2.9.2.1. Removing fuel pump bracket

$��

-�� ?�?�X��

]� ��^K�� H�Z�?�?�

-�� CjE� �� H�Z�?��H�Z�;�?�

!��CHXE��H�Z�;�`��

!��H�Z�;�`��

When the fuel pump bracket (4) next to the end cover (22) has to beremoved, first remove the adjacent fuel pump bracket with the pipesections (18). Next shift the internal pipe sections (23) of the bracketout of the end cover (22).

�� C?ME�� C?jE��ZM?H��ZH>��!��H�Z�;�Z��

9612ZT925

A

A

3025

2530

A – A16


�� C?ME�� C?jE��!��H�Z�;�j��

]� ��CH>E��H�Z�;�Z��

Note!

1

2

3

4

5

6

7

8

9

For Inte

rnal

Use O

nly


2.9 – 13

<��ZM?H��ZM?�� H�Z�;�?@��

=��

$��

<�� H�Z�H�>�

9612ZT961

Fig. 2.9 – 10 Lifting fuel pump bracket

10

11

12

For Inte

rnal

Use O

nly


2.9 – 14

2.9.2.2. Mounting fuel pump bracket

If the fuel pump bracket next to the end cover has been removed,start the mounting procedure with this bracket.

$�� CXE��C?È�

$��

]��CHME��CHjE��CHÈ��C?È��!��H�Z�;�`��

'��ZM?H��ZH>��!��H�Z�;�Z�

]�� %;�� CHZE� �� H�Z�;�??��

17

16

29

15

32

|

37

31


��C?È��CHXE��CXE��H�Z�;�`��

�� C?ME�� C?jE��!��H�Z�;�??��

Note!

1

2

3

4

5

6

7

For Inte

rnal

Use O

nly


2.9 – 15

$�� CO@E�� ]�� %Q��H�Z�;�Z��

<��CH>E��H�Z�;�Z��H�X�X�`��

�� ZM?H��ZH>�

�� C?ME�� C?jE��H�Z�;�??��

'��^K��

$��CO?�OHE�� ]��H�Z�H�O��

K��C?>E�� z|z��C?>E��CXE��H�Z�;�M��

$��z|z��H�X�>��H�X�;�X@��

�� z|z� �� H�Z�H�X�� H�Z�H�>�

!��CHXE��H�Z�;�`��

'��CjE�� H�Z�?��H�Z�;�?�

'��^K�� H�Z�?�M�

%��

Do not run the engine with tool 9612ZT925 mounted.

2.9.2.3. Renewal sealing set push rod

�� %;��CO?E��COHE��H�Z�;�??��

Mounting push rod sealing set$��

Warning!

8

9

10

11

12

13

14

15

16

17

18

19

20

1

For Inte

rnal

Use O

nly


2.9 – 16

=��%;��CO?E�� H�Z�;�??��

<�� COHE�� COOE�� H�Z�;�?H��

K��COXE��

]��COOE�

K�� CO>E� �� COHE��

*�� COME��COOE��

�� C?>E�

33

35

9612ZT953

34

33

36

Fig. 2.9 – 12 Mounting push rod seal set

2

3

4

5

6

7

8

For Inte

rnal

Use O

nly


2.9 – 17

2.9.2.4. Inspection of fuel pump push rod

�� COjE� �� C?>E��H�Z�;�??��-�� -�� *� ��

Fuel pump push rods are precision ground to the exact length foreach individual pump bracket. Do not interchange these push rods.<�� C?>E��C?ME�� ZM?H��>Xj�� H�Z� ;� ?O� �� 8��?� ��|��<��H�X�>��H�X�;�X@��

9612ZT547

16

Fig. 2.9 – 13 Depth gauge for push rod

Note!

For Inte

rnal

Use O

nly


2.9 – 18

2.9.2.5. Inspection of fuel pump tappet

]� �� H�Z�H�?�

]� ��

K��ZM?H��ZM@��H�Z�;�?X��ZM?H��OX?��ZM?H��ZM@�� ZM?H��Z>>�

9612ZT341

9612ZT960

38

40

39

Fig. 2.9 – 14 Assembling tool fuel pump bracket

$� �� ZM?H��ZH>��H�Z�;�Z��

!��

��

K��COÈ��COZE�� !��H�Z�;�?X��

$��

<�� -��CX@E��

K��ZM?H��ZH>��H�Z�;�Z��

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.9 – 19

2.9.3. Fuel injector

^K��C?E��H�Z�;�?>��

!��CXE��CXE�

=�� C>E�

�� CHE��COE��*��*��%;��

21

45

1

2

3

45

3

Fig. 2.9 – 15 Cylinder head with injector

For Inte

rnal

Use O

nly


2.9 – 20

2.9.3.1. Fuel injector maintenance

<�� C�� E��!��H�X�

2.9.3.2. Fuel injector removing

]� ��^��;J��

�� ^K��CHE��^K��COE��H�Z�X�

The connecting pipe and HP fuel pipe must not be rotated with oragainst each other. Take care the locking plate remains tight.

6

7

8

Fig. 2.9 – 16 Fuel injector in cylinder head

Don’t start engine lubrication when an injector is removed fromcylinder head. Lubricating oil may uncontrolled enter top of piston.

Note!

Warning!

1

2

For Inte

rnal

Use O

nly


2.9 – 21

]� ��CME��CjE��CÈ��H�Z�;�?M��

(��ZM?H��?j`��ZM?H��ZO?��

Check if the sealing washer (20) is present on the injector tip (15),if not remove it from the cylinder head. See fig .2.9 – 18 .

9612ZT178 9612ZT931

Fig. 2.9 – 17 Extracting fuel injector

$��

$��^K��

Note!

3

4

5

6

For Inte

rnal

Use O

nly


2.9 – 22

2.9.3.3. Fuel injector overhaul

�� {{�� {{��

�� ZM?H��ZOX�� !��H�Z�>�

$��{{��

]� �� CZE� �� ZM>@��?@`�� '��J�� H�Z�;�?`��

]� ��C?@E��ZM?H��?`j��C??E��C?HE��C?OE��C?XE��H�Z�;�?`��

’C’’ ’E’9 21 1110 13 14 151617 19 20

’B’12 ’D’


1

2

3

4

5

For Inte

rnal

Use O

nly


2.9 – 23

K��ZM?H��Zj`��<�� !��H�Z�;�?Z�

9622DT216

9612DT260

9612DT259

9612ZT978

15

16

Fig. 2.9 – 19 Tools for loosening / tightening sleeve nut

]� ��C?>E�� C?ME��ZM?H-�H>Z� ��ZM?H-�HM@��ZMHH-�H?M�

Carbon deposits can make it difficult to slide injector tip out offsleeve nut. In such a case place injector tip with sleeve nut on a softsupport and knock injector tip out by using a piece of pipe.Never knock directly on injector tip, see fig. 2.9 – 20 .

Fig. 2.9 – 20 Separating injector tip from sleeve nut

Note!

6

7

For Inte

rnal

Use O

nly


2.9 – 24

)�� $��-��$��q��

$��/

�; G�� ; G�� ; G��; �� ; !��; '�� *��H�X�>��]��*�

�� ; $��

� ��

$��/

�; !��C?>E��C?jE�!��$�� !��H�Z�;�?`��

�; $��; <��; $��%;��

$��

K��C?>E��C?ZE��

Apply Molykote G–rapid plus or Never–Seez Regular grade NS 42 Bbetween contact surfaces ’D’ of sleeve nut and injector tip and onthe thread. See fig. 2.9 – 18 .

�� C?ME�� ZM?H-�H>Z� �� ZMHH-�H?M� �� ZM?H-�HM@� �� H�Z�;�?Z��<��H�X�X�`�

Calculate torque spanner reading according the conversion factorof the multiplier and see for torque spanner instructions section2.4.3.

��C?XE��C?OE��C?HE��C??E��C?@E��J��

$�� ZM?H��ZOX��!��H�Z�>�

*��CZE��ZM>@��?@`��H�X�X�`�

Note!

Note!

8

9

10

11

1213

14

15

16

17

For Inte

rnal

Use O

nly


2.9 – 25

2.9.3.4. Fuel injector mounting

J�� ZM?H��ZOX��{{��

]� �� CH@E� �� C�� H�Z�;�?`�E��

$��*�� ZM?H��ZMH��

K��CH@E��H�Z�;�?`��

<��%;��CH?E��!��H�Z�;�?`��

K�� CÈ�� CjE��<��CME��!��H�Z�;�?M�

'��^K��COE��H�Z�X�

<��CME��?@�G ��H�X�X�`�

��C>E��H�Z�;�H?��

'��^K��CHE��H�Z�X�

The connecting pipe and HP fuel pipe must not be rotated with oragainst each other.

!��

Note!

1

2

3

4

5

6

7

8

9

10

For Inte

rnal

Use O

nly


2.9 – 26

2.9.4. HP fuel pipe

��^K�� C?E��CXE��^K��CHE��COE� ��CXE��H�Z�;�H?��

3 462

’A’

5

1

’A’

Fig. 2.9 – 21 HP fuel pipe

2.9.4.1. Removing HP fuel pipe

Removing HP fuel pipe]� ��C>E��!��H�Z�;�?�

In order to prevent leakages caused by damaged seating cones, the connecting pipe (3) and HP fuel pipe (2) must not be rotated withor against each other. Take care locking plate (5) remains tight.See fig. 2.9 – 21 .

Note!

1

For Inte

rnal

Use O

nly


2.9 – 27

^��COE��^K��CHE�� ^K��]� ��^K��CHE�

Removing connecting pipe

=�� C>E��

�� COE�� CXE��ZM?H��H>>�

2.9.4.2. Mounting HP fuel pipe

Mounting connecting pipeJ�� ^K��CHE��

��COE��C*�E�� =��'��

<��%Q��CME��COE�

��CXE��ZM?H��H>>�� ZMHH-�H?>�� H�X�X�`�

K��C>E��H�Z�O�X�

��C>E��

Mounting HP fuel pipe

!��^K��

In order to prevent leakages caused by damaged seating cones, the connecting pipe (3) and HP fuel pipe (2) must not be rotated withor against each other. See fig. 2.9 – 21 .

��ZM?H��OO?��ZMHH-�H?>�� H�X�X�`�

'��C>E��!��H�Z�;�?�

Note!

2

3

4

1

2

3

4

5

6

7

8

For Inte

rnal

Use O

nly


2.9 – 28

2.9.5. Testing of fuel injectors

Be careful in testing fuel injectors. Fuel jets are powerful and willpenetrate skin and underlying skin layers and blood. Such anaccident calls for direct specialistic treatment. Should this aid notbe available disinfect affected part of body. However, it remainsnecessary to consult a specialist.

Testing the opening pressure<��

��

9612ZT934

Fig. 2.9 – 22 Testing device fuel injectors

$��

J��

��

�� ?@��<��H�X�>�?�

Warning!

1

2

3

4

5

For Inte

rnal

Use O

nly


2.9 – 29

Adjusting the opening pressure]� �� CZE� �� ZM>@��?@`��

H�Z�;�?`��

<��z��z�

��C?@E��ZM?H��?`j��H�Z�;�?`��

*��CZE��ZM>@��?@`��H�X�X�`�

Checking the spray pattern<��

^��{{��

$��

�� ]��

Checking the needle seat tightness�� H@��

��

q��?@��

$�� *��

�� ]��

Prevent that spill fuel from drain hole ”F” reaches the injector tip.

”F”


Note!

1

2

3

4

1

2

3

4

1

2

3

4

For Inte

rnal

Use O

nly


2.9 – 30

Checking the needle spindle tightness�� H@��

��

$�� H@@��

�; *��?@��H@��; *��

��&��; H>� !�� J��

��

Only install satisfactorily tested fuel injectors in the engine or storethem with the hole ’F’ and the nozzle tip closed by a plastic cap.


Note!

1

2

For Inte

rnal

Use O

nly

Annex A ManualWärtsilä 26

3.1 – 1

3.1. Annex A

Internal systems/ Pipe arrangement

9998 ZT 169 Internal Fuel System9998 ZT 163 Internal Lube Oil System9998 ZT 167 Internal Start/Stop Air System9998 ZT 162 Internal Cooling Water System9998 ZT 165 Internal Charge & Exhaust Gas System

For Inte

rnal

Use O

nly

Annex AManualWärtsilä 26

3.1 – 2

For Inte

rnal

Use O

nly

Annex B ManualWärtsilä 26

3.2 – 1

3.2. Annex B

Electrical documentation

9510 ZT 132 Connection Diagram9510 ZT 294 Connection Diagram9530 ZT 130 Instrument Data List9530 ZT 157 Code List

For Inte

rnal

Use O

nly

Annex BManualWärtsilä 26

3.2 – 2

For Inte

rnal

Use O

nly

INDEX ManualWärtsilä 26

ii– 1

A

Actuatorchecking linkage, 1.6 – 7mounting, 1.6 – 11removing, 1.6 – 10stop position check, 1.6 – 10

Adjusting, valve clearance, 2.7 – 14

Adjustmentsfuel delivery commencement, 2.4 – 111nominal speed, 2.4 – 111overspeed stop, 2.4 – 111valve clearance, 2.4 – 111

Assembling, oil pump, 1.2 – 23

Automatic back–flushing , lubricating oil filter, 1.2 –32

Automatic back–flushing filter, trouble shooting, 1.2– 39

Axial clearance, thrust bearing, measurement, 2.6– 4

Axial thrust rings and thrust collars, inspection, 2.5– 17

B

Background informationeasy going nut, 2.4 – 71genuine parts, 2.4 – 72hydraulic tools and torque spanners, 2.4 – 71locking fluids, 2.4 – 72rolled thread, 2.4 – 71studs, 2.4 – 71

Bank, A–bank and B–bank, 0.0 – 3

BDC, 0.0 – 4

Bearing’0’–bearing

assembling, 2.5 – 17inspection, 2.5 – 17removing, 2.5 – 16

axial thrust rings, inspection, 2.5 – 17big end bearing, removing, with mounted piston,

2.6 – 8camshaft, inspection, 2.5 – 18camshaft axial bearing bushes

mounting, 2.5 – 21removing, 2.5 – 19

camshaft bearing bushesmounting, 2.5 – 21removing, 2.5 – 19

crankshaft axial locating, 2.5 – 15main bearing

assembling, 2.5 – 9inspection, 2.5 – 9removing, 2.5 – 3

thrust bearing, axial clearance measurement, 2.6– 4

BN, 1.2 – 8

Booster, 1.6 – 4

Booster maintenance, governing system, 1.6 – 12

Bottom dead centre, 0.0 – 4

CCamshaft, 2.8 – 9

Camshaft bearings, 2.5 – 18

Camshaft driving gear, 2.8 – 2inspection, 2.8 – 4

Camshaft gear wheelmounting, 2.8 – 8removing, 2.8 – 5

Camshaft journalmounting, 2.8 – 12removing, 2.8 – 9, 2.8 – 11

Camshaft sectionmounting, 2.8 – 12removing, 2.8 – 9

CCAI, 1.1 – 17

Centrifugal filter, 1.2 – 40cleaning, 1.2 – 42operation, 1.2 – 41

For Inte

rnal

Use O

nly

INDEXManualWärtsilä 26

ii– 2

Charge aircleaning cooler stack, 1.5 – 11cooler, 1.5 – 5cooler stack, 1.5 – 6cooler stack repairs, 1.5 – 12internal system, 1.5 – 3maintenance cooler, 1.5 – 9multiduct, 1.5 – 14operation system, 1.5 – 7system, 1.5 – 4

Cleaning procedurecompressor, 1.5 – 21turbine, 1.5 – 23

Clockwise rotating, 0.0 – 3

Compressed air starter motordescription, 1.3 – 6general, 1.3 – 5

Condemming limits, lubricating oil main, 1.2 – 7

Condesate drain, charge air cooler, 1.5 – 7

Connecting roddescription, 2.6 – 5inspection and maintenance, 2.6 – 17

Connecting rod and pistonassembling, 2.6 – 18mounting into cylinder liner, 2.6 – 21

Cooling water, 1.4 – 2additives, qualities, 1.4 – 4control, 1.4 – 5multiduct, 1.5 – 14requirements, 1.4 – 3

Cooling water pump, 1.4 – 12maintenance, 1.4 – 14renewal seals, 1.4 – 13

Cooling water systemcleaning, 1.4 – 18flexible pipe connections, 1.4 – 17maintenance, 1.4 – 18venting, 1.4 – 19

Counter–clockwise rotating, 0.0 – 3

Crankcase breathing system, 1.2 – 44

Crankcase safety valves, 2.5 – 24

Crankshaftdeflections, 2.6 – 2gear wheel, 2.8 – 4

Crankshaft axial locating bearing, 2.5 – 15

Crude oil, quality, 1.1 – 6

Cylinder head, 2.7 – 2inspection, 2.7 – 4maintenance, 2.7 – 3mounting, 2.7 – 8removing, 2.7 – 4

Cylinder head studs, replacing, 2.5 – 23

Cylinder liner, 2.6 – 7

Cylinder pressure, maximum, 2.3 – 17

DDerating conditions, 1.0 – 4

Designationof bearings, 0.0 – 6of cylinders, 0.0 – 3

Dimensions and massesengine components, 2.4 – 122main parts, 2.4 – 123

Dismantling, oil pump, 1.2 – 22

Distillate fuel oil, specification, 1.1 – 7

Distillate fuel oil , quality, 1.1 – 7

DMX, DMA, DMB, DMC, 1.1 – 8

Draining, fuel system, 1.1 – 19

Driving end, 0.0 – 3

Driving unitdescription, 2.6 – 5disassembling, 2.6 – 15mounting, 2.6 – 22removing, 2.6 – 9

EEmergency operation

defective air cooler(s), 2.3 – 25defective turbocharger, 2.3 – 26one cylinder misfiring, 2.3 – 26

Engine definitions, 0.0 – 3

Engine log sheet example, 2.3 – 16

Exhaust , compensators, 1.5 – 16

Exhaust gasinsulation box, 1.5 – 17Internal system, 1.5 – 3internal system, 1.5 – 13maitenance system, 1.5 – 18manifold, 1.5 – 13multiduct, 1.5 – 14operation system, 1.5 – 18

Exhaust valve seat, removing, 2.7 – 20

FFiltration suction air, 1.5 – 2

For Inte

rnal

Use O

nly


ii– 3

Fixed pitch propeller, 2.3 – 15

Flywheel, marks, 0.0 – 5

Free end, 0.0 – 3

Fuelconditioning, 1.1 – 13purification, 1.1 – 13

Fuel control mechanism, 1.6 – 5maintenance, 1.6 – 12

Fuel injection timing, checking, 2.9 – 9

Fuel injectoradjusting, opening pressure, 2.9 – 29general, 2.9 – 19maintenance, 2.9 – 20mounting, 2.9 – 25overhaul, 2.9 – 22removing, 2.9 – 20testing

needle seat tightness check, 2.9 – 29needle spindle tightness check, 2.9 – 30opening pressure, 2.9 – 28spray pattern, 2.9 – 29

Fuel oilDistillate fuel oil

DMA, 1.1 – 7DMB, 1.1 – 7DMC, 1.1 – 7DMX, 1.1 – 7

quality before engine, 1.1 – 9

Fuel pump , fuel pump (HP), 2.9 – 2

Fuel pump bracket, 2.9 – 11mounting, 2.9 – 14removing, 2.9 – 12

Fuel pump drive, checking, 2.9 – 8

Fuel pump push rodinspection, 2.9 – 17sealing set renewal, 2.9 – 15

Fuel pump tappet, inspection, 2.9 – 18

Fuel rack, checking linkage, 1.6 – 8

GGoverning system, trouble shooting, 1.6 – 11

Governor, drive, 2.8 – 18

Governor drive, maintenance, 2.8 – 18

HHand–operated hydraulic pump, operating, 2.4 –

80

HFO, 1.1 – 4

HFO engines running on distillate

HP fuel pipemounting, 2.9 – 27removing, 2.9 – 26

HP fuel pump, 2.9 – 2adjustment, 2.9 – 8assembling, 2.9 – 7disassembling, 2.9 – 4inspection, 2.9 – 6load indication, 1.6 – 6maintenance, 2.9 – 6mounting, 2.9 – 9removing, 2.9 – 3

HT cooling water system, 1.4 – 7

Hydraulic pumphand–operated, 2.4 – 80pneumatic driven, 2.4 – 72

Hydraulic toolsextractor, 2.4 – 77HP hose, 2.4 – 78HP quick–release coupling, 2.4 – 79jack, 2.4 – 76safety instructions, 2.4 – 81

Hydraulically tightened connectionloosening, 2.4 – 82tightening, 2.4 – 84

IIndicator cock, 2.7 – 32

Influences on the lubricating oil condition, 1.2 – 5

Injector sleeveextracting, 2.7 – 30maintenance, 2.7 – 29mounting, 2.7 – 31

Inlet valve seat, removing, 2.7 – 21

Inlet–Exhaust valve seatmachine grinding, 2.7 – 22mounting, 2.7 – 21

Inspection, oil pump, 1.2 – 23

Internal cooling water system, 1.4 – 6

Internal systemfuel, 1.1 – 18lubricating oil, 1.2 – 11

For Inte

rnal

Use O

nly


ii– 4

JJack pressure

big end bearing, 2.4 – 97cylinder head, 2.4 – 99engine block with bearings, 2.4 – 92

LLFO, 1.1 – 7

Load decrease, before stop, 2.3 – 11

Load increase, sudden, 2.3 – 13

Load indication HP fuel pump, 1.6 – 6

Local start, 2.3 – 4

Locking fluids, 2.4 – 72

Low load and idling, restrictions, 2.3 – 11

LT cooling water system, 1.4 – 11

Lubricants, 1.2 – 2

Lubricants additional equipmentactuator, 1.2 – 4hydraulic tools, 1.2 – 4turning gear, 1.2 – 4

Lubricating oilcharacteristics, 1.2 – 8flash point, 1.2 – 8insolubles, 1.2 – 8recommendations for refreshing, 1.2 – 10requirements, 1.2 – 3

engine, 1.2 – 4sampling, 1.2 – 6testing main oil, 1.2 – 5

Lubricating oil cooler, 1.2 – 27cooler stack

mounting, 1.2 – 28removing, 1.2 – 27

Lubricating oil filterautomatic back–flushing , 1.2 – 32trouble shooting, automatic back–flushing filter ,

1.2 – 39

Lubricating oil main, condemming limits, 1.2 – 7

Lubricating oil module, 1.2 – 26

Lubricating oil pump, removing from engine, 1.2 –22

MMain bearing journal, inspection, i, 2.5 – 9

Main bearings, 2.5 – 3

Maintenancecrankshaft explosion relief valves, 2.5 – 25stop device, 1.6 – 12

Maintenance intervals, 2.4 – 5camshaft and valve drive mechanism, 2.4 – 13charge air and exhaust gas system, 2.4 – 8cooling water system, 2.4 – 7crankshaft, connecting rod, piston, liner, 2.4 – 11cylinderhead with valves, 2.4 – 12driving gear pumps, 2.4 – 13engine arrangement, 2.4 – 5engine block with bearings, 2.4 – 10fuel system, 2.4 – 6general, 2.4 – 5injection system, 2.4 – 14lubricating oil system, 2.4 – 6starting air system, 2.4 – 7

Maintenance schedule, procedure, 2.4 – 4

Maintenance tools, see tools, 2.4 – 15

Marks on the flywheel, 0.0 – 5

Mountingcooler stack, 1.5 – 10oil pump, 1.2 – 24

Multiduct, 1.5 – 14For Inte

rnal

Use O

nly


ii– 5

NNo–go

axial clearance small end bearing, 2.4 – 116backlash driving gear, 2.4 – 118backlash oil pump, 2.4 – 113big end bearing clearance, 2.4 – 114big end bearing shell thickness, 2.4 – 114camshaft ”0”–bearing clearance, 2.4 – 114camshaft bearing clearance, 2.4 – 114camshaft thrust bearing axial clearance, 2.4 –

114clearance gudgeon pin – piston, 2.4 – 116clearance piston bottom – cylinder liner, 2.4 –

116clearance valve stem – valve guide, 2.4 – 117crankshaft thrust bearing axial clearance, 2.4 –

114cylinder liner cylindricity at TDC, 2.4 – 116cylinder liner diameter, 2.4 – 116distance fuel pump – push rod, 2.4 – 121gudgeon pin bearing clearance, 2.4 – 116HT pump, 2.4 – 113LT pump, 2.4 – 113main bearing clearance, 2.4 – 114main bearing shell thickness, 2.4 – 114nozzle needle lift, 2.4 – 121piston diameter at bottom, 2.4 – 116piston ring height clearance

compression ring 1 and 2, 2.4 – 116oil scraper ring, 2.4 – 116

sleeve bearing, 2.4 – 112small end bore, 2.4 – 116valve burn–off area, 2.4 – 117valve drive, 2.4 – 119valve guide inner diameter, 2.4 – 117valve stem diameter, 2.4 – 117

Non–operating side, 0.0 – 3

OOil flow

camshaft, 1.2 – 19connecting rod, 1.2 – 15cylinder head, 1.2 – 20engine, 1.2 – 12engine top side, 1.2 – 19gear drive, 1.2 – 17HP fuel pump drive, 1.2 – 19main bearing, 1.2 – 14piston, 1.2 – 15turbocharger, 1.2 – 18valve drive, 1.2 – 19

Oil flow actuator drive, 1.2 – 20

Operatingdata, 1.0 – 5hand–operated hydraulic pump, 2.4 – 80pneumatic hydraulic pump, 2.4 – 74problems, 2.3 – 19

Operating instructions, starting air system, 1.3 –10

Operating range, 2.3 – 15

Operating side, 0.0 – 3

Output, engine, 1.0 – 3

PPiston

description, 2.6 – 6inspection and maintenance, 2.6 – 17

Pneumatic hydraulic pump, operating, 2.4 – 74

Preheating, 2.3 – 3

Pressure control unit, 1.2 – 25maintenance, 1.2 – 25

Pump inspection and assembling, 1.2 – 23

RRemoving, cooler stack, 1.5 – 9

Residual fuel oil (HFO), quality, 1.1 – 4

Restrictionslow load and idling, 2.3 – 11operation at excessive suction air temperature,

2.3 – 11

Rules for inspection and maintenance, 2.4 – 2

Rules for maintenance and inspectiongeneral, 2.4 – 2last check, 2.4 – 3mounting, 2.4 – 3removal, 2.4 – 3

Running–in, 2.3 – 18

SSafety

aspects, 2.4 – 2instructions hydraulic tools, 2.4 – 81valves crankcase, 2.5 – 24

Sampling valve, oil, 1.2 – 43

Sealing set, push rod, renewal, 2.9 – 15

Speed control system, 1.6 – 3

For Inte

rnal

Use O

nly


ii– 6

Startafter a normal stop, 2.3 – 5after overhaul, 2.3 – 6emergency, 2.3 – 8local, 2.3 – 4putting the engine into operation, 2.3 – 3remote or automatic, 2.3 – 5

Start stop systemmaintenance, 1.3 – 11principle working, engine stop, 1.3 – 4

Starting air system, trouble shooting, 1.3 – 12

Stopfinal stop, actions, 2.3 – 28local, 1.6 – 9manual, 1.6 – 9mechanism check, 1.6 – 9remote, 1.6 – 9

Stop mechanism, 1.6 – 9

Suction air filtration, quality, 1.5 – 2

TTDC, 0.0 – 4

at firing, 0.0 – 4at scavenging, 0.0 – 4

Terminology, 0.0 – 3

Thermostatic valvecooling water, 1.4 – 9oil, 1.2 – 30operation, 1.2 – 31, 1.4 – 10maintenance, 1.2 – 31trouble shooting, 1.2 – 31, 1.4 – 10

Thermostatic valve cooling water, maintenance, 1.4– 10

Thrust collars / axial thrust rings, inspection, 2.5 –17

Tightening torquecamshaft and valve drive, 2.4 – 101control system components, 2.4 – 91cooling water system components, 2.4 – 90crankshaft, connecting rod, piston, 2.4 – 93cylinder head with valves, 2.4 – 98engine block with bearings, 2.4 – 92general table, 2.4 – 108injection system components, 2.4 – 104lubricating oil system components, 2.4 – 89

Timing fuel injection, checking, 2.9 – 9

Tolerancesbearings, 2.4 – 112big end bearing, 2.4 – 114camshaft bearing, 2.4 – 114Cooling water pump, 2.4 – 113cylinder head with valves, 2.4 – 117cylinder liner, 2.4 – 116driving gear, 2.4 – 118governor drive, 2.4 – 120injection system, 2.4 – 121lubricating oil pump, 2.4 – 113main bearing, 2.4 – 114piston, 2.4 – 116valve drive, 2.4 – 119

Toolscamshaft and valve drive mechanism, 2.4 – 58crankshaft, connecting rod, piston, liner, 2.4 – 38cylinder head with valves, 2.4 – 48engine block with main bearings, 2.4 – 33exhaust gas and charge air system, 2.4 – 32fuel system, 2.4 – 28injection system, 2.4 – 64lubricating oil system, 2.4 – 31miscellaneous, 2.4 – 22

Top dead centre, 0.0 – 4

Torque spanner, use of, 2.4 – 85

Trouble and possible reason, 2.3 – 19

Trouble shooting, starting air system, 1.3 – 12

Turbocharger, 1.5 – 19cleaning devices, 1.5 – 19compressor side cleaning, 1.5 – 20maintenance, 1.5 – 19turbine cleaning , procedure, 1.5 – 23turbine side cleaning, 1.5 – 21

Turning gear, 2.6 – 32lubricating oil, 1.2 – 4

VValve clearance, adjusting, 2.7 – 14

Valve drive mechanism, 2.8 – 14assembling, 2.8 – 17removing, 2.8 – 15

Valve guideextracting, 2.7 – 23mounting, 2.7 – 23

Valve lifting gear inspection, 2.8 – 16

Valve rotator, maintenance, 2.7 – 27

Valve rotators, 2.7 – 25

Valve seatblueing test, 2.7 – 19checks and reconditioning, 2.7 – 19machine grinding, 2.7 – 19

For Inte

rnal

Use O

nly


ii– 7

Valvesassembling, 2.7 – 24checks and reconditioning, 2.7 – 19removing, 2.7 – 17

Vibration damper crankshaftliquid sampling, 2.6 – 30maintenance, 2.6 – 29

Viscosity, conversion diagram, 1.1 – 10

WWater flow

charge air cooler HT, 1.4 – 9cylinder head, 1.4 – 8liner to cylinder head, 1.4 – 8

For Inte

rnal

Use O

nly


ii– 8

For Inte

rnal

Use O

nly

6W26.pdf

Documents

publication deals

copyright owner

service bagnoli della

internal useonly copyright

omissions inthis publication

publication orthe information

service engineer

copyright holder