WÄRTSILÄ 41508 Instruction Manual
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WÄRTSILÄ 41508 Instruction Manual

WÄRTSILÄ 41508 Instruction Manual

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Vaasa Factory
Vaasa Factory
Tarhaajantie 2, FIN-65101 Vaasa, Finland
Tarhaajantie 2, FIN-65101 Vaasa, Finland
Tel. +358 10 709 0000, Tlx 74251 wva sf
Tel. +358 10 709 0000, Tlx 74251 wva sf
Fax (Service) +358 6 356 7355
Fax (Service) +358 6 356 7355
Fax (Spare parts) +358 10 709 1380
Fax (Spare parts) +358 10 709 1380
41508- 41514
41508- 41514
SURMA ENERGY
SURMA ENERGY
WÄRTSILÄ 18V34SG
WÄRTSILÄ 18V34SG
22606, 22607, 22608, 22609
22606, 22607, 22608, 22609
174415
174415

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  • Page 1 41508- 41514 41508- 41514 SURMA ENERGY SURMA ENERGY WÄRTSILÄ 18V34SG WÄRTSILÄ 18V34SG 22606, 22607, 22608, 22609 22606, 22607, 22608, 22609 174415 174415 Vaasa Factory Vaasa Factory Tarhaajantie 2, FIN-65101 Vaasa, Finland Tarhaajantie 2, FIN-65101 Vaasa, Finland Tel. +358 10 709 0000, Tlx 74251 wva sf Tel.
  • Page 2 © © Copyright by W yright by Wä ä rt rt silä Finla silä Finla nd Oy nd Oy All rights reserved. No part of this booklet may be reproduced or copied in All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, any form or by any means (electronic, mechanical, graphic, photocopying, recordi...
  • Page 3                                         ...
  • Page 4                         Kimmo Kohtamäki Kimmo Kohtamäki +358 10 709 2860 +358 10 709 2860 General Manager General Manager Mobile: Mobile: +358 40 558 2372...
  • Page 5   Vesa Honkela Vesa Honkela +358 10 709 2837 +358 10 709 2837 Sales Manager Sales Manager Mobile: Mobile: +358 40 550 8815 +358 40 550 8815 vesa.honkela@wartsila.com vesa.honkela@wartsila.com Eero Hakala Eero Hakala +358 10 709 1632 +358 10 709 1632 Guy Blomquist Guy Blomquist +358 10 709 3475...
  • Page 6     Leif Österroos Leif Österroos +358 10 709 2708 +358 10 709 2708 Tapani Syrjänen Tapani Syrjänen +358 10 709 3359 +358 10 709 3359 General Manager General Manager Mobile: Mobile: Manager Manager Mobile: Mobile: +358 40 505 5198 +358 40 505 5198 +358 40 502 3562 +358 40 502 3562...
  • Page 7 34SG-200328-02 34SG-200328-02 Contents, Contents, Instructions, Instructions, Terminology Terminology 00. Contents, Contents, Instructi Instructions, ons, Terminology Terminology 0 0 0 0 . . 1 1 C C o o n n t t e e n n t t s s o o f f t t h h e e M M a a n n u u a a l l 1.
  • Page 8 Contents, Instructions, Terminology 34SG-200328-02 6 After reassembling, check that all screws and nuts are tightened and locked, if necessary. 7 Check that all shields and covers are fully functional and in place. Note! Predictive maintenance is important when it comes to fire protec- tion.
  • Page 9 34SG-200328-02 Contents, Instructions, Terminology The thrust bearing rails are located at the flywheel bearing. The outer rails close to the flywheel are marked with 00 and the inner rails with 0. The camshaft bearings are designated as the main bearings, the thrust bearing bushes being designated 00 (outer) and 0.
  • Page 10 Contents, Instructions, Terminology 34SG-200328-02 valves as well as inlet valves are then somewhat open and scavenging takes place. If the crankshaft is turned to and fro near this TDC, both exhaust and inlet valves will move, a fact that indicates that the crankshaft is near the position which can be named TDC at scaveng- ing.
  • Page 11 200147 Welding Precautions Appendix B 00B.2.5 WECS 7000/8000 checklist The follow ing preca ut ions mu st be pa id a tt ention to before welding in th e vicinity of a WE CS 7000 or 8000 cont rol syst em: Deactive the system by disconnecting all external connectors •...
  • Page 12 Appendix B Welding Precautions 200147...
  • Page 13   34SG-9701 Main Data, Operating Data and General Design 01. Main Data, Operating Data and General Design 01.1 Main data for Wärtsilä 34 SG Cy linder bore ........340 mm S t roke .
  • Page 14 Carbon dioxide Carbon dioxide and  and nitrogen nitrogen will increase the methane number.  will increase the methane number. 2) Hydrogen 2) Hydrogen contents above 3 vol-% must be agreed on case by case contents above 3 vol-% must be agreed on case by case basis.
  • Page 15 34SG-200303-03 34SG-200303-03 Fuel, Fuel, Lubricating Lubricating Oil, Oil, Cooling Cooling Water Water Base oils. Base oils. Use of virgin base oils is only all  Use of virgin base oils is only allowed, i.e. recycled or refined owed, i.e. recycled or refined base oils are not allowed.
  • Page 16  Vis  Viscos cosity. ity. Should not decrease by more than 20 % and n Should not decrease by more than 20 % and not rise by more ot rise by more than 25 % above the guidance value at 100°C. than 25 % above the guidance value at 100°C.
  • Page 17 34SG-200303-03 34SG-200303-03 Fuel, Fuel, Lubricating Lubricating Oil, Oil, Cooling Cooling Water Water 02.2.4 2.4 Lubricati Lubricating oils fo ng oils for turbocharg r turbochargers Please note that different types of turbochargers can be used for the Please note that different types of turbochargers can be used for the engine.
  • Page 18 02.3. .3.2 2 Add Additiv itives  As  As ad addi ditiv tives, es, use use pr prod oduc ucts ts fr from om we well- ll-kn know own n an and d re relia liable ble su supp pplie liers rs wit with h vast distribution nets.
  • Page 19 34SG-200303-03 34SG-200303-03 Fuel, Fuel, Lubricating Lubricating Oil, Oil, Cooling Cooling Water Water Corrosion rate as a function of nitrite concentration Corrosion rate as a function of nitrite concentration o give full o give full protection the protection the Nitrite level Nitrite level   e   e...
  • Page 20 Summary of the most common cooling water additives Summary of the most common cooling water additives A A d d d d i i t t i i v v e e A A d d v v a a n n t t a a g g e e s s D D i i s s a a d d v v a a n n t t a a g g e e s s - good efficiency, if - good efficiency, if...
  • Page 21 34SG-200303-03 Fuel, Lubricating Oil, Cooling Water 02.3.3 Treatment When changing the additive or when entering an additive into a system where untreated water has been used, the complete system must be cleaned (chemically) and rinsed before fresh treated water is poured into the system.
  • Page 22 Fuel, Lubricating Oil, Cooling Water 34SG-200303-03...
  • Page 23 02A.4.2 .4.2 Personal Personal protection e protection equipment quipment Hand protection: Hand protection:   Impermeable and hydrocarbon resistant   Impermeable and hydrocarbon resistant • • gloves ( gloves (nit nit rile ru rile ru bber for exa bber for exa mple) mple).
  • Page 24 Soak liquid spills in absorbent material and collect solids in a Soak liquid spills in absorbent material and collect solids in a • • container. Wash floor with water as spillage may be slippery. container. Wash floor with water as spillage may be slippery. Cont Cont a a c c t a t a pp...
  • Page 25 0 0 2 2 A A . . 6 6 F F l l y y a a s s h h e e s s a a n n d d e e x x h h a a u u s s t t g g a a s s d d u u s s t t c c o o n n t t a a m m i i - - nated components nated components When handling the fly ashes, exhaust gas dusts and when working...
  • Page 26 02A.6 A.6.2 .2 Firs First aid measur t aid measures Inh a a lat lat io ion of ashes: Mo n of ashes: Move vi ve vic c tim t tim t o f o fresh a resh a ir, ke ir, keep ep w w a a rm a rm a nd lying...
  • Page 27 0 0 2 2 A A . . 8 8 F F l l u u o o r r i i d d e e r r u u b b b b e e r r p p r r o o d d u u c c t t s s 02A.8.1 .8.1 Handlin Handling instructions - normal sea...
  • Page 28 Decontamination Decontamination 02A.8.3.3 02A.8.3.3 Operators handling the remains of burnt fluoride rubber must wear Operators handling the remains of burnt fluoride rubber must wear impenetra impenetra ble acid- ble acid-proo proof glove f gloves t s t o pro o protect t tect t he skin he skin from t from t he h...
  • Page 30 Wärtsilä © Technology Oy Ab Finland This doc is the property of Wärtsilä Technology and shall neither be copied, shown or communicated to a third party without the consent of the owner. Subtitle Product Made 09.10.1998 KJi / HPH / Hanstén Page Document No Cooling Systems...
  • Page 31 Page Document No  2 (4) 4V92A0765 Maritech AB Marisol CW Box 143 S-29122 Kristianstad, Sweden Nalco Chemical Company Nalco 39 (L) One Nalco Centre Nalcool 2000 Naperville, Illinois 60566-1024 USA Nalfleet Marine Chemicals Nalcool 2000 PO Box 11 Nalfleet EWT 9-108 Winnington Avenue, Northwich Nalfleet CWT 9-131C Cheshire, CW8 4DX, UK...
  • Page 32 Page Document No  3 (4) 4V92A0765 Q8 Corrosion Inhibitor 50 – 100 litres 1.6 - 3.2 w-% of active compounds Long-Life measured with a supplier’s refractometer Maricol CW 8 – 16 litres 1000 – 2000 ppm as NO 2 Nalco 39 (L) 16 - 36 litres 550 - 1200 ppm as NO 2 Nalcool 2000 32 - 48 litres...
  • Page 33 Page Document No  4 (4) 4V92A0765 The installation, operation and maintenance instructions of the manufacturer should always be followed. The contact information can be found in the table below. International Watertreatment Maritime AS Elysator N-3470 Slemmestad Norway...
  • Page 34 INSTALLATION MANUAL Wärtsilä  Corporation Finland Technology This doc is the property of Wärtsilä Corp. and shall neither be copied, shown or communicated to a third party without the consent of the owner. Subtitle Product Made 11.08.1998 KJi / JNd Page Document No 4V92A0780...
  • Page 35 Page Document No 2 (3) 4V92A0780 CONDEMNING LIMITS FOR USED LUBRICATING OIL When estimating the condition of used lubricating oil, the following properties along with the corresponding limit values must be noted. If the limits are exceeded, measures must be taken.

  • Page 36: Table Of Contents

    t®êíëáä® cáåä~åÇ ló Power Plants Doc. id: WDAAA247714 a Date: 20-Nov-2003 Page: 1 (7) Status: APPROVED Made/Approved: MKO010 / AEK001 Project: WFI-P Power Plant Technology, IN023 Name: General Wärtsilä safety manual for lean burn gas engine Subject: TABLE OF CONTENTS (THE WHOLE MANUAL) FOR A POWER PLANT: General WDAAA247714 Engine...

  • Page 37: General

    Wärtsilä Finland Oy Power Plants Doc id: WDAAA247714 a Date: 20-Nov-2003 Page: 2 (7) 1 General ® This Wärtsilä   lean-burn gas engine safety manual gives general information on natural gas properties and hazards of using it together with description of safety equipment and measures both on site and on embedded in equipment.

  • Page 38: Properties

    Wärtsilä Finland Oy Power Plants Doc id: WDAAA247714 a Date: 20-Nov-2003 Page: 3 (7) Table 1. Composition of natural gases (by volume). Methane CH 4 70 – 90 % Ethane C 2 H 6 0 – 7 % Propane C 3 H 8 0 –...

  • Page 39: Breathing Natural Gas

    Wärtsilä Finland Oy Power Plants Doc id: WDAAA247714 a Date: 20-Nov-2003 Page: 4 (7) Breathing natural gas Natural gas in itself is not poisonous. With high concentrations it displaces air and may therefore cause suffocation. Inhaling small amounts and concentrations of natural gas does not pose any danger.

  • Page 40: Gas Leaks And Fires

    Wärtsilä Finland Oy Power Plants Doc id: WDAAA247714 a Date: 20-Nov-2003 Page: 5 (7) If the exposure to carbon monoxide continues, the person will soon loose his ability to control his/her muscles, effectively paralysing him/her and soon followed by unconsciousness. At this point, the person will need aid to get out from the area.

  • Page 41: Prevention Of Gas Explosions And Minimising The Consequences

    Wärtsilä Finland Oy Power Plants Doc id: WDAAA247714 a Date: 20-Nov-2003 Page: 6 (7) Gas explosion is a quick chemical reaction between gas and oxygen, that is the gas is burning rapidly. Contrary to explosives, natural gas does not consist of any chemically bound oxygen. Thus, additional oxygen (air) is necessary for a gas explosion to take place.
  • Page 42 Wärtsilä Finland Oy Power Plants Doc id: WDAAA299978 - Date: 05-Nov-2003 Page: 11 (19) Figure 6 shows the pressure regulator in the GRU. Figure 6 The pressure regulator with functional units regulator, pilot valve and SAV valve. The pilot operated pressure regulator is operated using control air from I/P converter. The regulator consists of the main valve body and the functional units “regulator”, “pilot valve”...
  • Page 43 Wärtsilä Finland Oy Power Plants Doc id: WDAAA299978 - Date: 05-Nov-2003 Page: 12 (19) Compressed Air  Vent Vent Pressure Pressure  Transmitter  Switch Figure 7 The shut-off valves with actuator (1), solenoid operated air valve (2) and solenoid operated vent valve (3). The GRU is equipped with two shut-off valves, installed in series.
  • Page 44 Wärtsilä Finland Oy Power Plants Doc id: WDAAA299978 - Date: 05-Nov-2003 Page: 13 (19) Control Air  Main gas line Shut-off valves Pressure regulator  GenSet Figure 8 The flow chart of fuel gas regulating unit. The gas pressure must always remain higher than the charge air pressure. There is a minimum and maximum offset for the pressure difference.
  • Page 45 Wärtsilä Finland Oy Power Plants Doc id: WDAAA299978 - Date: 05-Nov-2003 Page: 14 (19) Table I Normal operation for fuel gas regulating unit. Normally the maximum inlet pressure to the GRU is 6 bar g and optionally 16 bar g when regulating valve V07 is supplied with safety shut off valve (SAV).
  • Page 46 Wärtsilä Finland Oy Power Plants Doc id: WDAAA299978 - Date: 05-Nov-2003 Page: 15 (19) Option is that a gas detector only gives an alarm and the operator takes the necessary actions. In this case, a plant emergency mode would only be possible to activate only by pressing emergency button in a common control panel.
  • Page 47 Wärtsilä Finland Oy Power Plants Doc id: WDAAA299978 - Date: 05-Nov-2003 Page: 16 (19) The normal operation and supervision of the fuel gas system consist mainly of simple daily checks, such as: 1. Check temperature and pressures in the system. 2.
  • Page 48 34SG-200349-10 Maintenance Schedule 04. Maintenance Schedule 04.1 General The maintenance necessary for the engine is mainly dependent on the operating conditions. The periods stated in this schedule are guidance values only, but must not be exceeded during the guarantee period. It may be possible to lengthen the stated maintenance intervals consid- erably depending on the engine load.
  • Page 49 Maintenance Schedule 34SG-200349-10 Caution! Accidental turning of engine may cause engine damage and/or personal injury. 04.2 Every second day, irrespective of the engine being in operation or not Automatic prelubrication 03.2 Check operation 18.9 Once a week irrespective of the engine being in operation or not 04.3 Start process Test start (if the engine on stand-by).
  • Page 50 34SG-200349-10 Maintenance Schedule 04.5 Interval: 500 operating hours Cooling water 19.2 Check water quality Check content of additives. 02.3 Lubricating oil Take oil sample 02.2.3 In a new installation or after change to use of a new lub- ricating oil brand, take samples for analyzing. 04.6 Interval: 1000 operating hours Air filter (on-built)
  • Page 51 Maintenance Schedule 34SG-200349-10 Lubricating oil 18.2 Change lubricating oil Change oil in a new installation (wet sump installations). Take 02.2 samples for analyzing. If the analyzing values are positive and if the oil supplier or engine manufacturer so recommend, the intervals between changes can be based on regular analyzing.
  • Page 52 34SG-200349-10 Maintenance Schedule Starting air system Clean the starting air filter Clean the filter and replace sealing’s. Valves and piston rings 12.A Check cylinder tightness Check cylinder tightness (valves, piston rings) with a pneumatic test. 04.9 Interval: 8000 operating hours Exhaust manifold Check for leaks Replace parts if necessary.
  • Page 53 Maintenance Schedule 34SG-200349-10 Lube oil pump driving gear 18.3.4 Inspect lube oil pump driving gear Replace parts if necessary. 06.2 Oil thermostatic valve 18.6 Clean and inspect oil thermostatic valve Clean and check the thermostatic element, valve cone-cas- ing and sealing’s. Turbocharger Inspect turbocharger bearings 15.2...
  • Page 54 34SG-200349-10 Maintenance Schedule Flexible coupling Check the flexible coupling (Oil filled) Dismantle and check flexible coupling acc. to manufacturers recommendations. Gas admission valves 17.4 Replace the main and prechamber gas admission 17.5 valves Woodward In installations where connectors used, replace also the female connector.
  • Page 55 Maintenance Schedule 34SG-200349-10 04.13 Interval: 32000 operating hours Connecting rods Replace connecting rod screws Replace connecting rod screws at latest 32 000 h with new 11.3.3 ones. 06.2 Connecting rods Replace connecting rod shims Replace connecting rod shims at latest 32 000 h with new 11.3.3 ones.
  • Page 56 32-9801 Maintenance Tools 05.Maintenance Tools 05.1 General Ma int ena nce of a engine requires some specia l tools developed in t he course of engine design. Some of these tools are supplied with the engine, and others are available through our service stations or for direct purcha se by the customer.
  • Page 57 Maintenance Tools 32-9801 Main Bearings Code Description Drawing No. 803000 Stud remover M42 4V80D0012 846058 Stud remover M56 3V84G0189 851000 Turning tool for main bearing shell 4V85B0023 851010 Turning tool for main bearing shell 4V85B0016 851020 Turning tool for thrust washers & bearing shell 3V85B0015 860081 Flexible hose 3000 mm, (low p.
  • Page 58 32-9801 Maintenance Tools Cylinder Liner Code Description Drawing No. 800009 Dismantling tool for antipolishing ring (1) 2V83G0077 834050 Hydraulic extractor 3V83E0061 835041 Assembly tool for antipolishing ring 3V83F0105 836000 Suspending & removing tool, complete 836017 Dismantling tool for antipolishing ring (2) 3V83G0073 836018 Lifting tool...
  • Page 59 Maintenance Tools 32-9801 Connecting Rod, O-Profile Code Description Drawing No. 803000 Stud remover M42 4V80D0012 835010 Protecting sleeve for connecting rod tooth (1) 4V83F0062 835020 Protecting sleeve for connecting rod tooth (1) 2V83F0063 846000 Lifting tool for big end bearing cap (1) 1V84G0191 860100 High pressure pump (1000 bar) (2)
  • Page 60 32-9801 32-9801 Maintenance Maintenance Tools Tools Conn nnec ecti tion R on Rod od, M , Mar arin ine He e Head ad, R- , R-en eng. g. 1 1 10 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n D D r r a a w w i i n n g g N N o o .
  • Page 61 Conn nnec ecti tion on Ro Rod, d, Ma Mari rine ne He Head ad, V , V-e -eng ng. . 11 110 0 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n D D r r a a w w i i n n g g N N o o .
  • Page 62 32-9801 32-9801 Maintenance Maintenance Tools Tools P P i i s s t t o o n n 1 1 1 1 0 0 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n D D r r a a w w i i n n g g N N o o .
  • Page 63 P P i i s s t t o o n n , , 3 3 2 2 D D F F a a n n d d 3 3 4 4 S S G G 1 1 1 1 0 0 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n D D r r a a w w i i n n g g N N o o .
  • Page 64 32-9801 32-9801 Maintenance Maintenance Tools Tools C C y y l l i i n n d d e e r r H H e e a a d d 1 1 2 2 0 0 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n D D r r a a w w i i n n g g N N o o .
  • Page 65 C C y y l l i i n n d d e e r r H H e e a a d d 1 1 2 2 0 0 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n D D r r a a w w i i n n g g N N o o .
  • Page 66 32-9801 32-9801 Maintenance Maintenance Tools Tools T T o o o o l l s s f f o o r r P P r r e e C C h h a a m m b b e e r r , , V V - - e e n n g g i i n n e e 1 1 2 2 0 0 C C o o d d e e D D e e s s c c r r i i p p t t i i o o n n...
  • Page 67 Maintenance Tools 32-9801 Tools for Intermediate Gear Code Description Drawing No. 803010 Mounting tool for shaft 3V80D0013 834050 Hydraulic extractor (1) 3V83E0061 834053 Mounting & dismantling tool for bearing 834055 Mounting tool 3V83E0078 834056 Mounting tool 4V83E0080 834057 Mounting tool 3V83E0133 834058 Mounting tool...
  • Page 68 32-9801 Maintenance Tools Tools for Planetary Gear, R-engine Code Description Drawing No. 834050 Hydraulic extractor (1) 3V83E0061 834059 Mounting tool 3V83E0135 834060 Mounting tool 3V83E0137 834064 Guiding ring 3V84G0377 860100 High pressure pump (1000 bar ) (1) 4V86A0033 861011 Flexible hose 800 mm (1) (1)  I ncluding q uick couplings...
  • Page 69 Maintenance Tools 32-9801 Injection Equipment Code Description Drawing No. 806050 Flare nut wrench for tightening, 36 mm 4V80G0032 809018 Long socket wrench 24 x 12.5L with 1/2" 809019 Long socket wrench 27 x 12.5L 809022 Long socket wrench 41 x 20L with 3/4" 820001 Torque wrench 70-330 Nm 4V80L0006...
  • Page 70 32-9801 Maintenance Tools Tools for Multi-Needle injection Valve Code Description Drawing No. 806050 Flare nut wrench for tightening, 36 mm 4V80G0032 806056 Tightening tool for gas injection valve 4V80G0035 807052 Socket wrench 4V80H0017 809019 Long socket wrench 27 x 12.5L 809033 Long socket wrench 56 x 12.5L 809034...
  • Page 71 Maintenance Tools 32-9801 Hand Tools Code Description Drawing No. 803021 Screw driver 2 x 12M 4V84L0019 804000 Non recoiling hammer D40 4V80L0005 806012 Key for hexagon socket screw 4 806013 Key for hexagon socket screw 5 806014 Key for hexagon socket screw 6 806015 Key for hexagon socket screw 8 806016...
  • Page 72 32-9801 Maintenance Tools Hand Tools Code Description Drawing No. 807001 Box wrench 10-11 807002 Box wrench 12-14 807003 Box wrench 13-17 807004 Box wrench 19-22 807005 Box wrench 30-32 807011 Engineers wrench 10-11 807012 Engineers wrench 12-14 807013 Engineers wrench 13-17 807014 Engineers wrench 19-22 807015...
  • Page 73 Maintenance Tools 32-9801...
  • Page 74 34SG-200314-06 Adjustments, Clearances and Wear Limits 06. Adjustments, Clearances and Wear Limits 06.1 Adjustments 06.1.1 Valve timing The va lve timing is fixed an d ca nn ot be cha nged individua lly, cylinder by cylinder. Schematic valve timing Inlet valve opens Outlet valve closes      E      V...
  • Page 75 Adjustments, Clearances and Wear Limits 34SG-200314-06 06.2 Clearances and wear limits (at 20°C) Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) Turning device driving gear backlash drive gear/ flywheel gear rim 1.20 0.30 Main bearing clearance 0.270-0.374 (also flywheel bearing) Journal, diameter...
  • Page 76 34SG-200314-06 Adjustments, Clearances and Wear Limits Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) Bore diameter in piston 150.022 150.010 150.050 Compression ring end gaps (C95) 1.00 -1.30 (C86) 1.30 -1.60 Oil scraper ring end gaps (C87) 1.20 -1.50 Piston ring height clearance:...
  • Page 77 Adjustments, Clearances and Wear Limits 34SG-200314-06 Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) 18 Lubricating oil pump diameter of shaft 49.920 49.895 Bush hole diameter, mounted 50.039 50.000 Bearing clearance 0.085-0.190 0.25 Axial clearance 0.20 -0.30 Backlash for driving gear - R32...
  • Page 78 Tightening Torques and Use of Hydraulic Tools 34SG-200339-09 We recommend the use of torque measuring tools also when tightening other screws and nuts. The following torques apply to screws of the strength class 8.8; when oiled with lubricating oil or treated with Loctite.
  • Page 79 34SG-200339-09 Tightening Torques and Use of Hydraulic Tools 07.3 Hydraulically tightened connections 07.3.1 Tightening pressures for hydraulically tightened connections Hydraulically tightened connections 4V86B144 3V86B0150 3V86B135 4V86B02 Fig 07-14 3207979542 Max. hydraulic pressure (bar) Hydraulic Pos. Screw connection cylinder tightening loosening 1.
  • Page 80 Tightening Torques and Use of Hydraulic Tools 34SG-200339-09 The stud bolts are tightened to the casting at the following torques: Screw dimension Tightening torque (Nm) M56 Cylinder head  M56 Main Bearing  M42 and M48 x 3  M24 and M30 Connecting rod ...
  • Page 81 34SG-200339-09 Tightening Torques and Use of Hydraulic Tools pressure gauge can be connected to the plug hole (7), the outlet hose of the pump being connected direct to the pressure gauges. 07.3.3 Dismantling hydraulically tightened screw connections 1 Attach distance sleeves and hydraulic cylinders according to Fig 07-15 A.
  • Page 82 Operating Troubles 34SG-200414-04 Start Blocks (STB) messages by WECS Code Message Reason Action CCU0_1E032SBL STB, CCU CCU configuration Check that the rotary switches are configuration fault missmatch according to the engine electrical drawings CCU0_1E031SBL STB, CCU power CCU supply voltage Check the CCU supply voltage acc.
  • Page 83 34SG-200414-04 Operating Troubles Sensor Failure (SF) messages by WECS Code Message Reason Action SVL0_1P003SF SF, LT water pressure, Sensor broken or Check acc. to Fig 08-3. 4-20 mA inlet, PT451 wiring fault (broken sensor failure or loose connections) NGA0_1T001SF SF, Air temp., TC A Sensor broken or Check acc.
  • Page 84 Operating Troubles 34SG-200414-04 Sensor Failure (SF) messages by WECS Code Message Reason Action BAG0_1T001SF SF, Generator Sensor broken or Check acc. to Fig 08-1. PT-100 sensor winding temp., L1, wiring fault (broken failure TE753 or loose connections) BAG0_1T002SF SF, Generator Sensor broken or Check acc.
  • Page 85 34SG-200414-04 Operating Troubles Sensor Failure (SF) messages by WECS Code Message Reason Action DCU0_1T003SF SF, Temp. in DCU3, Internal temperature Replace I/O board TE833 measurement of I/O board broken SMU0_1T102SF SF, Temp. in SMU1-2, Internal temperature Replace I/O board TE841 measurement of I/O board broken SMU0_1T103SF...
  • Page 86 Inductive pickup sensor failure Inductive pickup sensor failure START START Stop the engine Stop the engine Turn the engine Turn the engine with turning gear with turning gear Check fuses Check fuses ur ure volt between GND and between GND and in WECS in WECS fr fre...
  • Page 87 Magnetic pickup sensor failure Magnetic pickup sensor failure START START ur ure fr freque eque betwee n sensor n sensor wires wires s fr quenc quency Stop the engine Stop the engine measured? measured? ncre e th ensor ensor Correct the sensor Correct the sensor turbo speed turbo speed...
  • Page 88 Knock sensor failure Knock sensor failure START START Tighten the sensor Tighten the sensor Is the Is the to the engine with to the engine with sensor tightly sensor tightly 20 Nm, use loctite 20 Nm, use loctite mounted? mounted? on threads on threads ur ure th...
  • Page 89 Power supply failure CCU Power supply failure CCU START START Open the Open the cover of the cover of the Check green Check green LED D11 LED D11 on CCU board on CCU board 24 VDC 24 VDC Is the Is the missing, check missing, check...
  • Page 90 Power supply failure KDU Power supply failure KDU START START Open t Open cover of cover of the KDU the KDU Replace fu Replace Check green Check green LED D LED D 11 on 11 on KDU board KDU board 24 VDC 24 VDC Is the...
  • Page 91 CAN-bus failure CCU CAN-bus failure CCU START START Open the Open the cover cover Disconnect Disconnect yellow LED yellow LED power from the power from the blinking? blinking? WECS WECS Check flat cable, Check flat cable, CCU software CCU software resistance 33-37 and resistance 33-37 and is probably...
  • Page 92 CAN-bus failure KDU CAN-bus failure KDU START START Open Open the cover the cover CAN LED D CAN LED only blinking only blinking when engine when engine is running is running Disconnect Disconnect power from power from the WECS the WECS resist resistance ance...
  • Page 93 34SG-200414-04 Operating Troubles CAN-bus failure DCU START DCU CAN LED not blinking Fix the DVRX configuration configuration compile and reload it Open the cover and reset the DCU Disconnect CAN LED power from blinking? the WECS DCU software is Check flat cable, probably DCU and SMU resistance 31-65...
  • Page 94 Operating Troubles 34SG-200414-04 Main/PCC gas valve and ignition test Start Switch off the CCU power by disconnecting power connector X1 Turn all rotating switches on the CCU cover board to 0 position (tes ting position) Switch on the CCU power supply by reconnecting connector X1...
  • Page 95 34SG-200414-04 Operating Troubles Shutdowns, Emergency (EMG) messages by PLC Code Message Reason Action CFC0_1S020EST EMG, Control room Genset control panel emergency emergency push pushbutton button activated CFC0_1K001SDI EMG, Emerg. circuit Safety relay tripped Check the separately informed safety relay ind. emergency indications CFC0_1S023EST EMG, Engine room...
  • Page 96 Operating Troubles 34SG-200414-04 Shutdowns (SHD) messages by PLC Code Message Reason Action BAE0_1F87NSDI SHD, Differential Generator stator Check the generator stator current relay tripped short circuit according to the generator protection activated manufacturer manuals CFC0_1D008SDI SHD, Engine did not After stop command Check bus communication stop in 20 min given is maximum 20...
  • Page 97 34SG-200414-04 Operating Troubles Alarm (ALM) messages by PLC Code Message Reason Action CFC0_1F010ALI ALM, AC-power CFC panel AC- Check the fuse for the AC supply failure CFC Panel power supply failure SOB0_1F150ALI ALM, Automatic Some of the derating Check the separately informed derating active causes are active derating cause...
  • Page 98 Operating Troubles 34SG-200414-04 Alarm (ALM) messages by PLC Code Message Reason Action NHA0_1A001VFI ALM, Exh.vent.valve Exhaust ventilation Check the ventilation valve fault valve is not opened functionality, Check the valve open within pre-defined indication switch, Check the air time from the supply command NHA0_1V001OPN ALM, Explosion relief...
  • Page 99 34SG-200414-04 Operating Troubles Alarm (ALM) messages by PLC Code Message Reason Action BAE0_1Q001ALI ALM, Gen. breaker Breaker service and Check the position contacts and truck position error isolated signals wiring active OR none of the signals active BAE0_1Q009ALI ALM, Gen. earthing Breaker open and Check the position contacts and disconnector position...
  • Page 100 Operating Troubles 34SG-200414-04 Alarm (ALM) messages by PLC Code Message Reason Action BAE0_1F32AOPR ALM, Gen. Prot., Activation of Check the prot. relay event recorder. Reverse power P- trip protection for the Check for reverse power flow reasons prime mover in order to ensure that the generator will not act as a motor.
  • Page 101 34SG-200414-04 Operating Troubles Alarm (ALM) messages by PLC Code Message Reason Action BAE0_1F51VOPR ALM, Gen. Prot., Activation of back- Check the prot. relay event recorder. Voltage restr. up protection to Check also for overcurrent indications Overcurrent I 7> (U) disconnect the generator if a system fault has not been cleared by other...
  • Page 102 Operating Troubles 34SG-200414-04 Alarm (ALM) messages by PLC Code Message Reason Action SQA0_1P005AH ALM, Lub.oil filter diff. Lubrication oil filter Check and clean the lubrication pressure clogged filter CFC0_1S021ALI ALM, Power Monitor Generator power Check the power monitoring unit Unit fault monitoring unit display or use the power monitoring internal fault...
  • Page 103 34SG-200414-04 Operating Troubles Alarm (ALM) messages by PLC Code Message Reason Action VDA0_1M002MFI ALM, Water Water preheater Check the overcurrent/shortcircuit preheater 2 control overcurrent/shortcircu relay center fault it tripped VDA0_1M002AFI ALM, Water Water preheater Check the functionality of the main preheater 2 activation is not contactor, Check the wiring for...
  • Page 104 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701 2 Loosen the nuts of the side screws on the bearing in ques- tion and on both adjacent bearings, Fig 10-1 (A). 3 Lift the distance sleeve 3V86B46 into position on the side screw.
  • Page 105 34SG-9701 Engine Block with Bearings, Cylinder and Oil Sump 6 Lift the distance sleeves 3V86B 39 into position a nd in sert t he pins 4V86B02. 7 Lift the hydraulic tool 3V86B79 into position by using the tool 3V86B 52 a nd pr oceed w ith opening of the ma in bear ing nut s (B ). 8 Remove the nuts of the main bearing screws.
  • Page 106 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701 10.2.2 Inspection of main bearings and journals Clean the bearing shells and check for wear, scoring and other dam- ages. a) Trimetal bearings  can be used unt il the overla y is par tia lly worn off. When t he un der-la ying n ickel-ba rr ier or t he lining ma teria l is exposed in an y a rea, th e bearing must be replaced.
  • Page 107 34SG-9701 Engine Block with Bearings, Cylinder and Oil Sump 4 Place the end of the bearing shell in the slot between the journa l an d th e bear ing bore, wit h t he lug guiding in th e oil groove, a nd push it by h a nd a s fa r a s possible (recommended 2/ 3 of its length).
  • Page 108 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701 20 Screw on the hydraulic tool 3V86B78 a nd proceed w ith t ight- ening of side screw nut s (A ). Tight en t o full sta ted pressure. 10.3 Flywheel/thrust bearing 10.3.1 Dismantling of flywheel/thrust bearing 1 Remove the two crankcase covers next to the flywheel end,...
  • Page 109 34SG-9701 Engine Block with Bearings, Cylinder and Oil Sump Thrust bearing End recesses End recesses Fig 10-3 3210568935 10.3.2 Assembling of flywheel/thrust bearing 1 Clean the bearing shells, washers, cap and journal very carefully. 2 Take off the protecting tape from the bearing journal radial oil holes an d lubrica te t he journa l wit h clea n engine oil.
  • Page 110 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701 6 Remove the turning tool. 7 Lubricate the bearing surfaces and back sides of the upper thrust washers and push the washers into position by hand. To facilita te the mount ing of the wa sher, the cra nksha ft ca n be a xia lly displaced in ea ch direction.
  • Page 111 34SG-9701 Engine Block with Bearings, Cylinder and Oil Sump 10.4 Camshaft bearings 10.4.1 Inspection of the camshaft bearing bush When the camshaft bearing journal has been removed, the inner diam eter of the bea ring bush ca n be mea sured at site, by using a ba ll a nvil micrometer screw .
  • Page 112 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701 6 Pump pressure to the hydraulic tool t o w i t h d r a w t h e be a r i n g bush. The pressure must n ot exceed the va lue sta ted in cha pter 07, Fig 07-14.
  • Page 113 34SG-9701 Engine Block with Bearings, Cylinder and Oil Sump 7 Lubricate the bearing surface of the bearing bush a n d i n - sert the ca msha ft bea ring journa l. 8 Mount the camshaft pieces, guide blocks, injection pumps and ca msha ft covers.
  • Page 114 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701 As coolant a honing oil is preferred, but a light fuel oil 2-15 cSt • could a lso be used. After h oning, t he liner bore must be car efully clean ed by using a •...
  • Page 115 Engine Block with Bearings, Cylinder and Oil Sump 34SG-9701...
  • Page 116 32-200138 Piston Overhaul Appendix B 11B. Piston Overhaul 11B.1 General  All the engines mentioned in the table below are fitted with composite type pistons. Manufacturer/ type marked in Instruction Manual Fastening screws for the 32LN W32DF W34SG crown KS / (type 1) Four (4) M16 screws X(1) Mahle / (type 2)
  • Page 117 Appendix B Piston Overhaul 32-200138 11B.2 Pistons The piston assembly must be dismantled for inspection of mating surfaces between piston skirt and piston crown and for inspection and cleaning of cooling oil spaces. 11B.3 Piston crown 11B.3.1 Visual inspection The combustion space must be checked for corrosion and/or burning marks.
  • Page 118 32-200138 Piston Overhaul Appendix B 11B.4 Piston skirt 11B.4.1 Visual inspection The running surface of the skirt is coated with a graphite-phosphate layer. Consequently cleaning with use of emery cloth or other abrasives is not allowed. Excessive wear marks and/or scoring/seizure marks on the run- •...
  • Page 119 Appendix B Piston Overhaul 32-200138 11B.4.4 Measuring of piston crown and piston skirt Measurements of the distance between the inner and outer support surfaces must be measured according to the measurement record 3211V025GB. 11B.4.5 Assembling of pistons (All types) If the inspections are resulting in a conclusion that a piston can be reused the same pair of crown and skirt must be assembled together again.
  • Page 120 200414-05 Crank Mechanism: Crankshaft, Connecting Rod, Piston 34SG/32DF 11. Crank Mechanism: Crankshaft, Connecting Rod, Piston 11.1 Counterbalancing of crankshaft 11.1.1 General The crankshaft is counterbalanced by means of weights on the crank webs. The V-engines have counterweights on all webs. 11.1.2 Counterbalancing of 18-cylinder V-engines The counterbalancing of the free moment of the 18-cylinder V- engines is accomplished by means of a supplementary weight at the free end of ...
  • Page 121 34SG/32DF Crank Mechanism: Crankshaft, Connecting Rod, Piston 200414-05 11.2 Crankshaft 11.2.1 Description of crankshaft The crankshaft is forged in one piece and provided with counter- weights fastened with hydraulically tensioned screws. At the driving end of the engine, the crankshaft is equipped with a  V-ring for sealing off the crankcase, a combined flywheel/thrust bearing and a split gear wheel for camshaft driving.
  • Page 122 200414-05 Crank Mechanism: Crankshaft, Connecting Rod, Piston 34SG/32DF By using a electronic deflection indicator: 4 Combine extensions with the transducer (3) to the required length. 5 Connect cable (2) on the measuring unit (1). 6 Turn on the measuring unit by pressing Power-button. Push "Light"...
  • Page 123 34SG/32DF Crank Mechanism: Crankshaft, Connecting Rod, Piston 200414-05 For both methods: 11 Repeat this procedure with other cylinders. 12 Following limits of misalignment are stated for an engine hav- ing normal running temperature (within 10 min after running at 60% load, or higher, for 6 h, or more): a) ...
  • Page 124 200414-05 Crank Mechanism: Crankshaft, Connecting Rod, Piston 34SG/32DF 11.2.4 Cleaning of oil lock at crankshaft seal 1 Remove the outer plug (1), Fig 11-3. 2 Blow through the bores of the oil lock  from outside with com- pressed air. There is no need for refilling the oil lock with oil after cleaning. Oil lock at crankshaft seal 1.
  • Page 125 34SG/32DF Crank Mechanism: Crankshaft, Connecting Rod, Piston 200414-05 Connecting rod parts 1. Connecting rod, upper part 2. Shim 3. Big end, upper half 4. Big end, lower half 5. Big end Fig 11-4 3211649544 11.3.2 Removing of piston and upper part of connecting rod for overhaul 1 Remove the cylinder head, see chapter 12.
  • Page 126 32-200310-08 Turbocharging and Air Cooling The injected water does not act as a solvent, the cleaning effect is achieved by the physical impact of the drops on the deposit. It is therefore advisable to use clean water containing no additivities either in the form of solvents or softening agents, which could be precipitated in the compressor and form deposits.
  • Page 127 Turbocharging and Air Cooling 32-200310-08 2 Fill the water container (2) with clean water and close the cover of the water container. 3 Check and turn the valve (1) to the choosen compressor. 4 Open the slid valve (3). 5 Close the valve (3) after 5 - 10 seconds. 6 Repeat the readings taken in step 1 above for comparative purposes.
  • Page 128 32-200310-08 Turbocharging and Air Cooling 15.4.2 Cleaning of air cooler Cleaning of the water and air side heat exchange surfaces is imperative for a long and trouble free operation of the engine and must be done at regular intervals. 1 Remove the cooling water pipes. Unscrew the fixing screws (8) at the bottom of the charge air cooler housing, see Fig 15-1.
  • Page 129 Turbocharging and Air Cooling 32-200310-08 Air cooler cleaning tank Steam or air Perforated pipes Cooler insert Fig 15-4 3215869701...
  • Page 130 32-200247 Turbocharging and Air Cooling Appendix C 15.C. Exhaust Gas Wastegate 15.C.0.1 Description  A reliable and safe performance of the engine requires a correct air-fuel ratio during all kind of site conditions. If the air-gas mixture becomes too lean, misfire will occur and if the air-gas mixture becomes too rich, knocking will occur.
  • Page 131 Appendix C Turbocharging and Air Cooling 32-200247 15.C.0.2 Function The wastegate control system gets compressed air from the instrument air system. The pressure is approx. 6 - 7 bar. The instrument air needs to be clean, dry and oil free to secure the function of the components. See also chapter 21.
  • Page 132 32-200247 Turbocharging and Air Cooling Appendix C Wastegate control system 1. Actuator 2. Butterfly valve 6. Solenoid valve 8. I/P converter 9. Positioner Fig 15C-2 3215102200147 Actuator position OPEN SHUT...
  • Page 133 Appendix C Turbocharging and Air Cooling 32-200247 Wastegate positioner Control air from I/P converter Control air 6 - 8 bar 11. Positioner pilot valve 12. Screw 13. Lever 14. Cam 15. Screw 16. Screw Connections 17. Adjusting screw to and from 18.
  • Page 134 32-200247 Turbocharging and Air Cooling Appendix C 15.C.0.5 Calibrating the wastegate I/P converter Before starting calibration of the wastegate I/P converter, the wastegate positioner must first be adjusted. See section 15.C.0.4. The calibration can be done in the following ways: Using the software service tool WECSplorer (only for WECS 8000).
  • Page 135 Appendix C Turbocharging and Air Cooling 32-200247 Wastegate I/P converter mA - mA + 20. Zero adjustment screw 21. Span adjustment screw Fig 15C-5 3215105200243...
  • Page 136 34SG-200143 Injection and Ignition Systems 16. Injection and Ignition Systems 16.1 General The Wärtsilä 34SG is a spark ignited, gas-otto engine working accord- ing to the lean burn concept. In a lean burn gas engine the mixture of air and fuel in the cylinder is lean, i.e.
  • Page 137 34SG-9501 Cooling Water System, V-engines 19. Cooling Water System, V-engines 19.1 Description 19.1.1 General The engine is cooled by a closed circuit cooling water system, divided int o a h igh t empera tu re circuit (HT) a nd a low tempera tu re circuit (LT). The cooling w a ter is cooled in a separa te centr a l cooler.
  • Page 138 Cooling Water System, V-engines 34SG-9501 19.1.2 HT circuit The H T circuit cools t he cylinders, cylinder h ea ds a nd th e tur bocha rg- ers. A centr ifuga l pump (9) pumps the wa ter t hrough t he HT circuit. From the pump the water flows to the distributing duct, cast in the engine block (in V-engines th e wa ter is dist ribut ed to the dist ribut ing ducts of each cylinder bank t hrough ducts ca st int o the pump cover a t t he free...
  • Page 139 34SG-9501 Cooling Water System, V-engines 19.1.6 Monitoring The temperatures mentioned in chapter 01., section 01.2, should not be exceeded. H t a nd LT pressures aft er the pumps ca n be checked from the local display unit. The pressures depend on th e speed a nd t he insta llat ion. Ala rms a re set for low H T a nd L T pressure a nd for high H T w a ter outlet a fter t he engine.
  • Page 140 Cooling Water System, V-engines 34SG-9501 described below . More deta iled inst ructions for clean ing of coolers a re sta ted in cha pter 18., section 18.5. Mechanical cleaning A grea t dea l of the deposits consists of loose sludge a nd solid pa rt icles w hich can be brushed a nd rinsed off w ith w a ter.
  • Page 141 34SG-9501 Cooling Water System, V-engines ring a ga inst a fixed ring (2) w hich seals a ga inst t he housing by means of its r ubber coat . P ossible leak-off wa ter fr om the sea ling ca n flow out th rough t he opening (9).
  • Page 142 Cooling Water System, V-engines 34SG-9501 5 Check that the O-ring (8) is int a ct a nd in position w hen r e-in- sta lling t he volute ca sing. Check th a t t he volute ca sing is in position. The opening (14) should be turned upwards when the pump is installed.
  • Page 143 34SG-9501 Cooling Water System, V-engines 8 Check the seal (12) a nd t he bea rings for w ear a nd da ma ge, see pos. d) below. 9 Remove the bearings from the shaft . 10 Press the new bearing (13) by its inner ring with a suitable pipe.
  • Page 144 Cooling Water System, V-engines 34SG-9501 20 Re-install the conical ring elements (25). Re-install the ring elements exactly as situated in Fig 19-4. Mounting of gear wheel to water pump 16. Bearing retainer 17. Gear wheel 18. Screw 19. Pressure plate 25.
  • Page 145 34SG-9501 Cooling Water System, V-engines Replacing of radial seal This w ill be most ea sily done a t t he sa me time a s repla cing th e bea rings. If, for some reason, the seal is lea ky a nd t here is no need to cha nge the bear ing, proceed a s follow s: 1 Remove the volute casing and mechanical seal according to pos.
  • Page 146 Cooling Water System, V-engines 34SG-9501 be cha nged only by cha nging t empera ture element a ssemblies w hich is easily a ccomplished by un screwing t he housing. The va lve is ent irely self-contained, and there are no external bulbs or lines to become damaged or broken.
  • Page 147 34SG-9501 Cooling Water System, V-engines Cooling water thermostatic valve 9. Content of the element 10. Element 11. Seat To cooler By-pass From engine Fig 19-6 3219679250 19.4.3 Maintenance Norma lly, no service is required. Too low a w a ter t empera tu re depends on a defective thermostat, too high a temperature may depend on a defective thermostat, although, in most cases, it depends on a dirty cooler.
  • Page 148 34SG-200408-01 WECS 3000 PCC and main chamber gas injection CCU2 kW sensor Profibus - Main gas pressure CCU1 - Main gas press. ref. < Duration ref. - PCC gas pressure Camshaft < Timing ref. - PCC gas press. ref. rotary encoder Main gas PCC gas control valve...
  • Page 149 WECS 3000 34SG-200408-01 23.9 Air/Fuel ratio control The inlet air is compressed in the turbocharger, cooled to optimal level in the charge air cooler and enters the charge air receiver in the engine block. The air pressure in the receiver is controlled by a proportional exhaust waste-gate valve located on the turbocharger support.
  • Page 150 34SG-200408-01 WECS 3000 23.10 Ignition system 23.10.1 General The ignition system for each cylinder consists of an ignition module, an ignition coil, a high tension extender and a spark plug. Ignition control is calculated and performed by the CCU, see Fig 23-17. The ignition module is described in section 23.10.3.
  • Page 151 WECS 3000 34SG-200408-01 ignition spark goes off. The ignition output control signal from CCU to the ignition module is activated (low) during the dwell time period and the start point is derived from the signal from the rotary encoder on the camshaft.
  • Page 152 34SG-200408-01 WECS 3000 Ignition ramp-and-fire operation Dwell time Ignition control Primary current Secondary voltage Secondary current Spark position Fig 23-19 3223069601 The physical interface for the high voltage output consists of the coil driver circuitry, ignition coil, high voltage extender and spark plug. Ignition module driver and high voltage +24 V High tension output...
  • Page 153 WECS 3000 34SG-200408-01 23.11 Engine speed & load control The speed and load control together with the synchronizing sequence will be described in the following sections. 23.11.1 General The internal governor is provided with speed setting functions for synchronising, load sharing under speed control, as well as load control. It also provides fuel limitation and acceleration ramps used at engine start.
  • Page 154 34SG-200408-01 WECS 3000 The PID-controller has different sets of dynamic parameters for opera- tion with the generator breaker open (speed dependent mapping) and closed (load dependent mapping) to obtain an optimal stability under all conditions. Some adaptive speed deviation dependent features are also provided, to minimise large speed fluctuations in island mode.
  • Page 155 WECS 3000 34SG-200408-01 23.11.4 Load sharing When two or more engines are operating in parallel, some kind of load sharing must be provided. Load sharing means that each engine will contribute equally to the total power demand, and it ensures that load changes are absorbed evenly by the engines.
  • Page 156 34SG-200408-01 WECS 3000 23.12 Cylinder balancing  An even gas admission duration setting for all gas admission valves will not result in exactly the same gas quantity in all cylinders, due to the geometry of the engine and due to some deviations in the gas valve performance.
  • Page 157 WECS 3000 34SG-200408-01 23.13 Maintenance on the physical connections of the engine control system Note ! Each and every one of the maintenance procedures below are to be done only when the engine is in Stop Mode! Connectors to be maintained: DIN43650, “Hirschmann-type”...
  • Page 158 34SG-200408-01 WECS 3000 3 Reconnect the connector to the main gas pressure sensor and drive the holding screw back into place to secure the pressure sensor. 4 Repeat the following steps with all the other connectors on the engine. 23.13.2 Maintenance of the Cannon connectors 1 Localize the Cannon connector of the main gas admission valve.
  • Page 159 WECS 3000 34SG-200408-01 23.13.4 Maintenance of the Phoenix connectors Loosen the four Torx screws in the cover of CCU by using a 4 mm Torx key and open the cover. Phoenix connectors Phoenix connector Fig 23-25 3223189723 1 Use a suitable sized flat tip screw driver and tighten all the screws of every Phoenix connector in CCU.
  • Page 160 34SG-200408-01 WECS 3000 23.13.5 Maintenance of the Weiland connectors Localize the Weiland connectors on the MCU cabinet. Squeeze by hand the fastening lever towards the body of the Weiland connector to ensure that it remains securely connected to the connection block on the back side of the MCU.
  • Page 161 WECS 3000 34SG-200408-01 23.14 Maintenance of electrical contacts To prolong the lifetime of electrical contact surfaces and to provide proper electrical connection under all conditions and to maintain a high availability of the WECS system. The maintenance is carried out by applying contact lubricants to electri- cal contact surfaces.

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