WÄRTSILÄ VASA 6L32 Instruction Manual
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WÄRTSILÄ VASA 6L32 Instruction Manual

WÄRTSILÄ VASA 6L32 Instruction Manual

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Document ID
Installation
Engine type
Engine number
Project
This manual is intended for the personal use of engine operators
and should always be at their disposal. The content of this manual
shall neither be copied nor communicated to a third person.
Wärtsila Finland Oy
Vaasa Factory
Tarhaajantie 2, FIN-65101 Vaasa, Finland
Tel. +358 10 709 0000, Tlx 74251 wva sf
Fax (Service) +358 6 356 7355
Fax (Spare Parts) +358 10 709 1380
VASA 6L32
PAAE051728

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Summary of Contents for WÄRTSILÄ VASA 6L32

  • Page 1 Document ID Installation Engine type VASA 6L32 PAAE051728 Engine number Project This manual is intended for the personal use of engine operators and should always be at their disposal. The content of this manual shall neither be copied nor communicated to a third person.
  • Page 2 © Copyright by Wärtsilä Finland Oy All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright owner. THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF PRINTING.
  • Page 3 Wärtsilä Finland Oy, Services Services Office Vaasa Tarhaajantie 2 FI-65380 Vaasa P.O. Box 252 FI-65101 Finland 24hrs Phone +358 10 709 080 Fax +358 10 709 1380 Switchboard +358 10 709 0000 (Office hours 7.30-16.30) E-mail service.solutions@wartsila.com Homepage www.wartsila.com/services...

  • Page 5: Contents Of The Manual

    32-200328-03 Contents, Instructions, Terminology 00. Contents, Instructions, Terminology 00.1 Contents of the Manual This Manual contains data and instructions for operation and mainte- nance of the engine as well as instruction for handling, personal protection and first aid when fuel-, lubricating oils and cooling water additives are handled during normal operation and maintenance work.
  • Page 6 Contents, Instructions, Terminology 32-200328-03 5 When replacing a worn-out or damaged part provided with an identification mark stating cylinder or bearing num- ber, mark the new part with the same number on the same spot. Every exchange should be entered in the engine log and the reason should be clearly stated.
  • Page 7 32-200328-03 Contents, Instructions, Terminology Designation of bearings. · Main bearings. The shield bearing (nearest the flywheel) is No. 0, the first standard main bearing is No. 1, the second No. 2 etc. · The thrust bearing rails are located at the shield bearing. The outer rails close to the flywheel are marked with 00 and the inner rails with 0.
  • Page 8 Contents, Instructions, Terminology 32-200328-03 a) For the first time when the exhaust stroke of the previous working cycle ends and the suction stroke of the following one begins. Exhaust 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 scavenging.

  • Page 9: Risk Reduction

    200343 Risk Reduction Appendix A 00A. Risk Reduction 00A.1 General Read the engine manual including this appendix before installing, operating or servicing the engine and/or related equipment. Failure to follow the instructions can cause personal injury, loss of life and/or property damage. Proper personal safety equipment, e.g.
  • Page 10 Appendix A Risk Reduction 200343 Chapter of engine manual Identified hazard,hazardous situation or event 8 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Inhalation of exhaust gas dust Explosion or fire if flammable gas/vapour is leak- ing into the insulation box.
  • Page 11 200343 Risk Reduction Appendix A · Crankcase explosion if oil mist is mixed with “fresh” air during inspection after an oil mist shut down, · Crankcase safety explosion valves will open if there is a crank- case explosion. 00A.1.1.3 Hazards that may be due to different leakages, break- down or improper assembly of component ·...
  • Page 12 Appendix A Risk Reduction 200343 00A.1.1.4 Hazards that may be due to electricity or incorrect connections of electricity · Fire or sparks due to damage or short circuit in electrical equipment, · Contact with electricity during maintenance work if power not disconnected, ·...

  • Page 13: Welding Precautions

    200640 Welding Precautions Appendix B 00B. Welding Precautions 00B.1 General Precautions 00B.1.1 Welding safety Before start welding, it is important to read welding safety instruc- tions and that the welder is instructed on its safe use by a qualified teacher or welder. 00B.1.1.1 Hazards and precautions Electrical shock can kill ·...
  • Page 14 Appendix B Welding Precautions 200640 Arc rays can burn eyes and skin · Select a filter lens which is comfortable for you while welding. · Always use helmet when welding. · Provide non-flammable shielding to protect others. · Wear clothing which protects skin while welding Confined space ·...
  • Page 15 200640 Welding Precautions Appendix B 00B.1.2 Main principles: · Prevent uncontrolled current loops · Prevent radiation · Prevent sparkles flying around · If convenient, disconnect all global signals like power supply, data communication etc. 00B.1.2.1 Preventing uncontrolled current loops Welding current path must always be checked, there should be a straight route from the welding point back to the return connection of the welding apparatus.
  • Page 16 Appendix B Welding Precautions 200640 00B.2 Precaution checklists 00B.2.1 Basic ECU (Despemes/Spemos) checklist The following precautions must be paid attention to before welding in the vicinity of a basic ECU system: · Close the cover of the cabinet · Deactive the system by disconnecting all external connectors (X1...X4).
  • Page 17 200640 Welding Precautions Appendix B · If an electronic module is connected through a CIB (Connection Interface Box) then open the CIB cover and disconnect all connec- tors of the unit and close cover again. · Close the covers of the cabinet ·...
  • Page 18 Appendix B Welding Precautions 200640 00 - 6...
  • Page 19 32-200634-01 Main Data, Operating Data and General Design 01. Main Data, Operating Data and General Design 01.1 Main data for Wärtsilä 32 Cylinder bore ....... . . 320 mm Stroke .
  • Page 20 Main Data, Operating Data and General Design 32-200634-01 01.2 Recommended operating data Apply to normal operation at nominal speed. See also installation specific Modbus list. Normal values Alarm (stop) limits Load 100 % 0 - 100 % Temperatures, (°C) Lube oil before engine 60-65 75 (80) Lube oil after engine...

  • Page 21: Reference Conditions

    32-200634-01 Main Data, Operating Data and General Design 01.3 Reference conditions Reference conditions according to ISO 3046/I (1995): Air pressure ......100 kPa (1.0 bar) Ambient temperature .
  • Page 22 Main Data, Operating Data and General Design 32-200634-01 The connecting rod is forged and machined of alloyed steel and is splitted horizontally in three parts to allow removal of piston and connecting rod parts. All connecting rod bolts are hydrauli- cally tightened to minimize the relative movements between mating surfaces.
  • Page 23 32-200634-01 Main Data, Operating Data and General Design For a conventional fuel system the instrumentation and auto- mation is handled by the Wärtsilä Engine Control System - WECS 2000. The instrumentation and automation for common rail system is handled by WECS 2000 and WECS 7500. Alternatively the instrumentation and automation can also be handled by the plant control system.
  • Page 24 Main Data, Operating Data and General Design 32-200634-01 Cross-section of Wärtsilä 32, in-line engine Fig 01-1 401010 01 - 6 WÄRTSILÄ 32...
  • Page 25 32-200634-01 Main Data, Operating Data and General Design Cross-section of Wärtsilä 32, V-engine Fig 01-2 400102 WÄRTSILÄ 32 01 - 7...
  • Page 26 Main Data, Operating Data and General Design 32-200634-01 01 - 8 WÄRTSILÄ 32...
  • Page 27 200549-01 Fuel, Lubricating Oil, Cooling Water 02. Fuel, Lubricating Oil, Cooling Water Note! For preventing and minimising the handling risks, read carefully chapter 02A., Environmental Hazards. 02.1 Fuel 02.1.1 General ® The WÄRTSILÄ medium-speed diesel engines are designed to operate on heavy fuel (residual fuel) with a maximum viscosity of 55 cSt at 100 °C (approx.
  • Page 28 Fuel, Lubricating Oil, Cooling Water 200549-01 02.1.2 Fuel treatment 02.1.2.1 Purification Heavy fuel (residuals, and mixtures of residuals and distillate) must be purified in an efficient centrifuge before entering the day tank. The fuel is to be heated before centrifuging. Recommended temperatures, depending on the fuel viscosity, are stated in the diagram, chapter 02, Fig 02-1.
  • Page 29 200549-01 Fuel, Lubricating Oil, Cooling Water Fuel oil viscosity-temperature diagram Centistokes 5000 2000 UNGEFÄHRE PUMPGRENZE 1000 700 cSt bei 50 C 380 cSt bei 50 C ZENTRIFUGIER- TEMPERATUR BEHÄLTER- TEMPERATUR VISKOSITÄT VOR DEN KRAFTSTOFFPUMPE EMPFOHLENER BEREICH GASÖIL HÖCHSTTEMP . SCHIFFSDIESELÖL 180 cSt bei 50 C 5.5 cSt bei 40 C 80 cSt bei 50 C...
  • Page 30 Fuel, Lubricating Oil, Cooling Water 200549-01 Viscosity conversion diagram Centistokes 5000 2000 1000 1000 2000 5000 10000 Sec. Saybolt Furol 1000 ¡ Engler 1000 2000 5000 10000 Sec.Redwood I 1000 2000 5000 10000 Sec. Saybolt Universal Fig 02-2 3202538935 When converting viscosities from one of the units on the abscissa to centistokes or vice-versa, keep in mind that the result obtained is valid only at one and the same temperature.
  • Page 31 200549-01 Fuel, Lubricating Oil, Cooling Water 02.1.3 Maximum limits of fuel characteristics ® ® The diesel engines WÄRTSILÄ Vasa 32 & 32LN, WÄRTSILÄ ® ® WÄRTSILÄ 32, and WÄRTSILÄ 46 & 46F are designed and developed for continuous operation, without reduction of the rated output, on fuels with the following properties: Fuel characteristics, maximum limits Kinematic viscosity...
  • Page 32 Fuel, Lubricating Oil, Cooling Water 200549-01 The differences between HFO 1 and HFO 2 are seen below: Fuel characteristics, maximum limits HFO 1 HFO 2 Sulphur mass-% 2.0 - 5.0 mass-% 0.05 0.05 - 0.20 Vanadium mg/kg 100 - 600 Sodium mg/kg 50 - 100...
  • Page 33 200549-01 Fuel, Lubricating Oil, Cooling Water Ignition quality. Heavy fuels may have very low ignition quality. This may cause trouble at start and low load operation, particularly if the engine is not sufficiently preheated. Low ignition quality may also result in a long ignition delay and can cause a fast pressure rise and very high maximum pressures.
  • Page 34 Fuel, Lubricating Oil, Cooling Water 200549-01 The CCAI is not an exact tool for judging fuel ignition properties. Following rough guidelines can however be given: · Engines running at constant speed and load over 50 % can without difficulty use fuels with CCAI-values of up to 870. ·...
  • Page 35 200549-01 Fuel, Lubricating Oil, Cooling Water The water content of heavy fuel oils varies widely. Water may come from several different sources, it can either be fresh or salt. It can also originate from e.g. condensation in the installation’s bunker tanks.
  • Page 36 Fuel, Lubricating Oil, Cooling Water 200549-01 High carbon residue content may lead to deposit formation in the combustion chamber and in the exhaust system, especially at low loads. · Deposit formation on injection nozzle tips will disturb the fuel atomisation and deform the fuel sprays, decreasing the com- bustion process efficiency, and even leading to locally in- creased thermal loads.

  • Page 37: General Advice

    200549-01 Fuel, Lubricating Oil, Cooling Water 02.1.5 Measures to avoid difficulties when running on heavy fuel Poor fuel quality will influence on wear, engine part lifetime and maintenance intervals adversely. In order to obtain maximum operating economy it is recommend- able: to limit maximum continuous output as much as operating condi- tions allow if fuel is known or suspected to have high vanadium...

  • Page 38: Lubricating Oil

    Fuel, Lubricating Oil, Cooling Water 200549-01 in series. Alternatively the main and stand-by separators may be run in parallel, but this makes heavier demands on correct gravity disc choice and constant flow and temperature con- trol to achieve optimum results. Flow rate through the centri- fuges should not exceed the maximum fuel consumption by more than 10 %.
  • Page 39 200549-01 Fuel, Lubricating Oil, Cooling Water BN 30 lubricants are recommended to be used only in special cases, such as installations equipped with an SCR catalyst. Lower BN products eventually have a positive influence on cleanliness of the SCR catalyst. With BN 30 oils lubricating oil change intervals may be rather short, but lower total operating costs may be achieved because of better plant availability provided that the maintenance intervals of the SCR catalyst can be increased.
  • Page 40 Fuel, Lubricating Oil, Cooling Water 200549-01 Note! Before using a lubricating oil not listed in the table, the engine manufacturer must be contacted. Lubricating oils that are not approved have to be tested according to the engine manufac- turer’s procedures. 02.2.3 Maintenance and control of the lubricating oil Centrifuging of the system oil is recommended in order to sepa- rate water and insolubles from the oil.
  • Page 41 200549-01 Fuel, Lubricating Oil, Cooling Water Viscosity. Should not decrease by more than 20% and not rise by more than 25% above the guidance value at 100 °C. Should not decrease by more than 25 % and not rise by more than 45% above the guidance value at 40 °C.
  • Page 42 Fuel, Lubricating Oil, Cooling Water 200549-01 Fill required quantity of oil in the system, see chapter 01, section 01.1. Oil samples taken at regular intervals analyzed by the oil supplier, and the analysis results plotted as a function of operating hours is an efficient way of predicting oil change intervals.
  • Page 43 200549-01 Fuel, Lubricating Oil, Cooling Water · Depending on the governor type, oil should be separately emptied from the power cylinder. This is done by removing the plug in the bottom of the power cylinder. · Some governors are equipped with a magnetic oil plug, this plug should be cleaned in connection with an oil change.
  • Page 44 Fuel, Lubricating Oil, Cooling Water 200549-01 02.2.7 Handling of oil samples When taking fuel oil or lubricating oil samples the importance of proper sampling can not be over-emphasised. The accuracy of the analysis results is significantly dependent on proper sampling and the results will only be as good as the quality of the sample.
  • Page 45 200549-01 Fuel, Lubricating Oil, Cooling Water 02.2.7.2 Fuel oil sampling Fuel oil samples can be drawn from different places in the fuel oil system. Fuel samples “as bunkered” or “before the engine” (after fuel oil separation and filtration) are perhaps the most common sample types.

  • Page 46: Cooling Water

    Fuel, Lubricating Oil, Cooling Water 200549-01 02.3 Cooling water 02.3.1 General In order to prevent corrosion, scale deposits or other deposits in closed circulating water systems, the water must be treated with additives. Before treatment, the water must be limpid and meet the speci- fication found in the end of this chapter.
  • Page 47 200549-01 Fuel, Lubricating Oil, Cooling Water Corrosion rate as a function of nitrite concentration To give full protection the Nitrite level should be kept above X ppm. The actual concentration is additive supplier dependent. A permanent lower level will lead to an accelerated corrosion rate.
  • Page 48 Fuel, Lubricating Oil, Cooling Water 200549-01 Summary of the most common cooling water additives Additive Advantages Disadvantages - good efficiency, if - suitable as additive except dosage is controlled in air cooled heat ex- carefully changers with large soft Sodium - small active quantities, solder surfaces nitrite...

  • Page 49: Water Quality

    200549-01 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 50 Fuel, Lubricating Oil, Cooling Water 200549-01 02.5 Water quality requirements for Wärtsilä WETPACÔ system Water quality used for Wärtsilä WETPAC Humidification of inlet air system (WETPACÔ) has to fulfill the following requirements: Water quality requirements Property Maximum value Unit Hardness °dH Chlorides as Cl mg/l...

  • Page 51: Environmental Hazards

    200507 Environmental Hazards Appendix A 02A. Environmental Hazards 02A.1 General Fuel oils, lubricating oils and cooling water additives are environ- mentally hazardous. Take great care when handling these products or systems containing these products. Detailed information and handling instructions can be found in the text below. 02A.2 Fuel oils Prolonged or repetitive contact with the skin may cause irritation...
  • Page 52 Appendix A Environmental Hazards 200507 02A.2.2 Personal protection equipment · Respiratory organs protection: Oil mist: Use respirator, com- bined particle and gas filter. Evaporated fumes (hydrogen sulphide, etc.): Use respirator, inorganic gas filter. · Hands protection: Strong, heat and hydrocarbon resistant gloves (nitrile rubber for example).

  • Page 53: Natural Gas

    200507 Environmental Hazards Appendix A 02A.3 Natural gas Natural gas is non-toxic and will not harm anyone breathing in the low concentrations near minor fuel leaks. Heavy concentrations, however, can cause drowsiness and eventual suffocation. In a gas engine installation, gas may cause danger situations in some cases.
  • Page 54 Appendix A Environmental Hazards 200507 national environmental authorities. Collection, regeneration and burning should be handled by authorized disposal plants. 02A.4.2 Personal protection equipment · Hand protection: Impermeable and hydrocarbon resistant gloves (nitrile rubber for example). · Eye protection: Wear goggles if splash risk exists. ·...
  • Page 55 200507 Environmental Hazards Appendix A · Keep away from food and drinks. Do not eat, drink or smoke while handling. · Keep in well ventilated place with access to safety shower and eye shower. · Soak liquid spills in absorbent material and collect solids in a container.
  • Page 56 Appendix A Environmental Hazards 200507 02A.6 Fly ashes and exhaust gas dust contami- nated components When handling the fly ashes, exhaust gas dusts and when working inside the exhaust gas system or when handling any component contaminated with exhaust gas dust, at least the following minimum precautions and safety procedures must be applied: Note! Inhaling, eye contacts, skin contacts and swallowing of fly ashes and dusts must be avoided.
  • Page 57 200507 Environmental Hazards Appendix A 02A.6.2 First aid measures · Inhalation of ashes: Move victim to fresh air, keep warm and lying still. Give oxygen or mouth to mouth resuscitation as needed. Seek medical advice after significant exposures. · Skin contact: Hot ash on the skin should be cooled immedi- ately with plenty of cold water.
  • Page 58 Appendix A Environmental Hazards 200507 02A.8 Fluoride rubber products 02A.8.1 Handling instructions - normal sealing applica- tions In normal sealing applications the use of fluoride rubber products does not cause any health hazards. The handling of products, e.g. installation and service, can be made without any risk – provided that normal industrial hygiene is applied.
  • Page 59 200507 Environmental Hazards Appendix A tems. 02A.8.3.3 Decontamination Operators handling the remains of burnt fluoride rubber must wear impenetrable acid-proof gloves to protect the skin from the high corrosive remains of burnt fluoride rubber. Appropriate glove ma- terials are neoprene or PVC. All liquid state remains must be consid- ered to be extremely corrosive.
  • Page 60 Appendix A Environmental Hazards 200507 02A - 10...
  • Page 61     Wärtsilä REQUIREMENTS & OIL QUALITY 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 05.09.97 Page...
  • Page 62 Page Document No 2 (7) 4V92A0645 BN 30 oils are also a recommended alternative when operating on crude oil having low sulphur content. Though crude oils many times have low sulphur content, they can contain other acid compounds and thus an adequate alkali reserve is important. With crude oils having higher sulphur content BN 40 –...

  • Page 63: Change Of Lubricating Oil Brand

    Page Document No 3 (7) 4V92A0645 Base oils Use of virgin base stocks only is allowed, i.e. recycled or re-refined base oils are not allowed. 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.
  • Page 64 Page Document No 4 (7) 4V92A0645 GAS OIL AND MARINE DIESEL OIL OPERATION If gas oil or marine diesel oil is used as fuel, lubricating oils with a BN of 10-25 are recommended to be used. Also BN 30 lubricating oils included in Table 3 can be used in gas oil and marine diesel oil fuelled engines.
  • Page 65 Page Document No 5 (7) 4V92A0645 SUPPLIER BRAND NAME VISCOSITY FUEL CATEG. Energol IC-HFX 404 SAE 40 Energol IC-HFX 504 SAE 40 Castrol TLX Plus 404 SAE 40 TLX Plus 504 SAE 40 TLX Plus 554 SAE 40 Cepsa Troncoil 4040 PLUS SAE 40 Troncoil 5040 PLUS SAE 40...
  • Page 66 Page Document No 6 (7) 4V92A0645 Table 3. Approved system oils - fuel categories A, B, C and D. Lubricating oils with BN 30 included in Table 3 are designed to be used when operating on crude oil with low sulphur content (< 1 % m/m) and in special cases when operating on heavy fuel, e.g.
  • Page 67 Page Document No 7 (7) 4V92A0645 LUBRICATING OILS FOR ENGINE TURNING DEVICE SUPPLIER BRAND NAME VISCOSITY VISCOSITY VISCOSITY cSt at 40 °C cSt at 100 °C INDEX (VI) Energol GR-XP 460 27.0 Castrol Alpha SP 460 30.5 Chevron (Texaco Meropa 460 31.6 + Caltex + FAMM) ENI S.p.A.
  • Page 68 Page Document No 7 (7) 4V92A0645...
  • Page 69     RAW WATER QUALITY AND APPROVED Wärtsilä Finland Oy Finland COOLING WATER ADDITIVES This doc is the property of Wärtsilä Finland Oy and shall neither be copied, shown or communicated to a third party without the consent of the owner. Subtitle Product Made...
  • Page 70 Page Document No 2 (4) 4V92A0765 Manufacturer Additive name GE Betz Europe CorrShield NT 4293 Interleuvenlaan 25 B-3001 Heverlee, Belgium GE Betz CorrShield NT 4200 4636 Somerton Road Trevose PA 19053, United States Houseman Ltd Cooltreat 651 The Priory, Burnham Slough SL1 7LS, UK Kuwait Petroleum (Danmark) AS Q8 Corrosion Inhibitor Long-Life...
  • Page 71 Page Document No 3 (4) 4V92A0765 Product designation Dosage per 1 m³ of Concentration of active corrosion system capacity inhibitor Corrshield NT 4293 10 litres 670 – 1000 ppm as NO CorrShield NT 4200 Drewgard 4109 16 – 30 litres 640 –...
  • Page 72 Page Document No 4 (4) 4V92A0765 USE OF GLYCOL If a freezing risk exists, glycol needs to be added to cooling water. Since glycol alone does not protect the engine and cooling water system against corrosion, additionally an approved cooling water additive must always be used.
  • Page 73 32-200402-04 Start, Stop and Operation 03. Start, Stop and Operation 03.1 Turning of crankshaft Turning is performed by means of an electrically driven turning device built on the engine. 03.1.1 Electrically driven turning device The turning device consists of an electric motor which drives the turning gear through a gear drive and a worm gear.
  • Page 74 Start, Stop and Operation 32-200402-04 03.2 Start 1. Remote start 2. Local start 3. Emergency start (solenoid valve) 4. Emergency start (starting valve) Before starting the engine, check that: • the lubricating oil level is correct • the fuel system is in running order (correct preheating, correct pressure, sufficient precirculation to heat the fuel injection pumps) •...

  • Page 75: Emergency Start

    32-200402-04 Start, Stop and Operation 03.2.1 Local start 1 Start the prelubricating oil pump to obtain a lubricating oil pressure, over 0.3 bar. 2 Open the valve in the starting air supply system drain condensate via the blow-off valve. Close the blow-off valve when there is no more condensate.

  • Page 76: Manual Stop

    Start, Stop and Operation 32-200402-04 03.3 Stop 03.3.1 Manual stop 1 Idle the engine 1 min before stopping. 2 Stop the engine by moving the stop lever into stop posi- tion or by pressing the stop button (LCP). The time of slowing down offers a good opportunity to detect possible disturbing sounds.
  • Page 77 32-200402-04 Start, Stop and Operation 03.4.1 Every second day or after every 50 running hours 1 Read all temperatures and pressures as well as the load of the engine. All temperatures are more or less dependent on the load, and the lubricating oil, cooling water pressures (built- -on pumps) are dependent on the speed.
  • Page 78 Start, Stop and Operation 32-200402-04 Condensation in charge air coolers f=40 f=60 f=80 f=100 f=Relative humidity % P=Air manifold pressure bar abs P=1,5 P=2,5 P=4,5 P=3,5 .01 .02 .03 .04 .05 .06 .07 .08 .09 Water content (kg water/kg dry air) Fig 03-2 3203528930 Example: If the ambient air temperature is 35°C and the relative...
  • Page 79 32-200402-04 Start, Stop and Operation 03.4.2 Other maintenance works To avoid malfunction of the engine a regulary maintenance work must be done, see chapter 04. 03.4.3 In connection with maintenance work 1 Record the following steps and the running hours in the engine log: •...

  • Page 80: Manual Start

    Start, Stop and Operation 32-200402-04 03.5 Start after a prolonged stop (more than 8 h) 03.5.1 Manual start 1 Check • the lubricating oil level • the cooling water level in the expansion tank • the water supply to heat exchangers •...
  • Page 81 32-200402-04 Start, Stop and Operation 7 Start the priming pump. Vent the lubricating oil filter. Check that lubricating oil appears from all bearings and lubricat- ing nozzles, from the piston cooling oil outlet and from the valve mechanism. Check that there is no leakage from the pipe connec- tions inside or outside the engine.
  • Page 82 Start, Stop and Operation 32-200402-04 • Check the content of additives in the cooling water • Check the cylinder pressures • Listen for jarring sounds • Check the crankcase pressure. 03.8 Running-in The running-in of a new engine must be performed according to programme in Fig 03-3.
  • Page 83 32-200402-04 Start, Stop and Operation Running-in programme Engine load % After change of piston rings, pistons or cylinder liners, after honing cylinder liners Operating hours Stop. Check big end bearing temperatures End of running-in programme. Engine may be put on normal mode Fig 03-3 4003029701 03.9...
  • Page 84 Start, Stop and Operation 32-200402-04 03 - 12 WÄRTSILÄ 32...

  • Page 85: Maintenance Schedule

    32-200623-01 Maintenance Schedule 04. Maintenance Schedule 04.1 General The actual operating conditions, and above all the quality of the fuel used, will largely determine the maintenance necessary for the engine. Because of the difficulty in anticipating the various operating conditions that may be encountered in the field, the periods stated in the schedule should be used for guidance pur- poses only, but must not be exceeded during the warranty period.
  • Page 86 Maintenance Schedule 32-200623-01 Caution! When overhauling the engine, make absolutely sure that the automatic start and the priming pump are disconnected. Make also sure that the starting air shut-off valve located before main starting valve is closed. Then drain the engine starting air system to avoid engine damage and/or personal injury.
  • Page 87 32-200623-01 Maintenance Schedule Every second day, irrespective of the engine being in operation or 04.2 Automatic prelubrication 03.2 Check operation 18.9 Crankshaft 03.1 Marine engine: In a stopped engine, turn the crankshaft into a new position. Once a week irrespective of the engine being in operation or not 04.3 Start process 03.2...
  • Page 88 Maintenance Schedule 32-200623-01 Main bearings 10.3.3 Check tightening of main bearing screws Check the tightening of main bearing screws after the first 50 07.3 operating hours on a new engine and, after overhaul, those screws that have been opened. Note! Pump to stated pressure. Tighten if possible. Do not loosen! Multiduct Check tightening of the multiduct screws 07.1...
  • Page 89 32-200623-01 Maintenance Schedule 04.7 Interval: 1000 operating hours Air filter (on-built) 15.2 Clean turbocharger air filter Remove the filter(s) and clean according to instructions of the manufacturer (more often, if necessary). Automation 23.2 Functional check of automation Check function of the alarm and automatic stop devices. 01.2 Electrical fuel feed pump Regrease electrical fuel feed pump...
  • Page 90 Maintenance Schedule 32-200623-01 04.8 Interval: 2000 operating hours Air cooler(s) 15.5 Check waterside of charge air cooler(s) The first time check and possible cleaning of the waterside. If in good condition and deposits insignificant: future intervals 4000 running hours. Electro-pneumatic over- Check el.-pneumatic overspeed trip device 22., 23 speed trip device...
  • Page 91 32-200623-01 Maintenance Schedule 04.9 Interval: 4000 operating hours Air cooler(s) 15.5 Clean charge air cooler(s) Clean and pressure test. Look carefully for corrosion. Check for possible leakage. Replace parts if necessary. Check accurate pressure difference over the charge air cooler (air side) by using u-tube.
  • Page 92 Maintenance Schedule 32-200623-01 Lubricating oil cooler 18.5 Check lubricating oil cooler Check that the lubricating oil temperature before the engine is within normal operating values (Section 01.1). Check for possible leakage. Starting fuel limiter 22., 23. Check starting fuel limiter Check the function.
  • Page 93 32-200623-01 Maintenance Schedule 04.11 Interval: 12000 operating hours Fuel system Replace fuel feed pipes between A- and B-bank (Only V-engines) The fuel pipes between A- and B-bank has to be replaced. Governor driving gear 22.4.2 Inspect governor driving gear Replace parts if necessary. 06.2 HT-water pump 19.3.1...
  • Page 94 Maintenance Schedule 32-200623-01 Overhaul interval Fuel Average load > 75 % Average load < 75 % HFO 2 12 000 16 000 HFO 1 16 000 20 000 20 000 24 000 04.12 Interval: see table above Connecting rods 11.3.4 Replace big end bearings Replace big end bearings.
  • Page 95 32-200623-01 Maintenance Schedule 04.13 Interval: 12000 - 16000 operating hours Electro-pneumatic over- 22.3.3 Overhaul of overspeed trip device cylinder on injection speed trip device pump Replace worn parts. Replace sealing and O-ring. Injection pumps 16.2.5 Overhaul of injection pumps Clean and inspect injection pumps, replace worn parts. Replace the erosion plugs.
  • Page 96 Maintenance Schedule 32-200623-01 Overhaul interval Fuel Average load > 75 % Average load < 75 % ¾ 16 000 20 000 04.15 Interval: See table above Camshaft 10.4.1 Inspect camshaft bearings Replace if necessary. 06.2 Crankshaft 10.2.2 Inspect main bearings One main bearing to be inspected, if in bad condition, change and 06.2 check/change all main bearings.
  • Page 97 32-200623-01 Maintenance Schedule 04.17 Interval: 48000 operating hours Camshaft driving gear 13.1 Replace intermediate gear bearings Replace bearings, replace other parts if necessary. 06.2 Crankshaft Inspect crankshaft Inspect the crankshaft for wear. 06.2 Engine foundation Check flexible elements of engine foundation Flexible mounted Replace if necessary.
  • Page 98 Maintenance Schedule 32-200623-01 04 - 14 WÄRTSILÄ 32...

  • Page 99: Maintenance Tools

    32-200237 Maintenance Tools 05.Maintenance Tools 05.1 General Maintenance of the Wärtsilä engines requires some special tools devel- oped in the course of engine design. Some of these tools are supplied with the engine, and others are available through our service stations or for direct purchase by the customer.

  • Page 100: Main Bearing

    Maintenance Tools 32-200237 Main Bearing Code Description Drawing No. 800004 Turning tool for main bearing shell 4V85B0024 800005 Turning tool for thrust bearing shell, L-engine 3V85B0026 800005 Turning tool for thrust bearing shell, V-engine 3V85B0031 800041 Hydraulic cylinder M42 (1) 3V86B0078 800042 Distance sleeve M42...

  • Page 101: Cylinder Liner

    32-200237 Maintenance Tools Cylinder Liner Code Description Drawing No. 800007 Extracting & lifting tool 3V83G0078 800008 Honing equipment 2V84C0031 800009 Dismantling tool for antipolishing ring 2V83G0077 800053 High pressure pump (1000 bar) (1) 4V86A0033 800056 Flexible hose 3000 mm (1) 800103 Assembly tool for piston 3V83F0135...
  • Page 102 Maintenance Tools 32-200237 Connecting Rod, L-engine Code Description Drawing No. 800015 Locking tool for connecting rod big end 2V83F0200 800017 Guiding plug 4V83F0157 800018 Limiter 3V83F0156 800098 Assembly rail (1) 2V83F0183 800099 Support (1) 3V83F0186 800100 Mounting sledge (1) 2V83F0191 800101 Mounting sledge (1) 2V83F0189...
  • Page 103 32-200237 Maintenance Tools Connecting Rod, V-engine Code Description Drawing No. 800018 Limiter 3V83F0156 800098 Assembly rail (1) 2V83F0238 800099 Support (1) 3V83F0240 800100 Mounting sledge (1) 2V83F0191 800101 Mounting sledge (1) 2V83F0189 800102 Support arm 3V83F0363 800107 Protecting sleeve for connecting rod 3V83F0249 800108 Support (1)

  • Page 104: Connecting Rod

    Maintenance Tools 32-200237 Connecting Rod Code Description Drawing No. 800020 Hydraulic tools M27x2 (1), including 800097 2V86B0214 800021 Stud remover M27x2 4V80D0032 800022 Pin for tightening of nuts M27x2 4V86B0231 800053 High pressure pump (1000 bar) (1) 4V86A0033 800056 Flexible hose 3000 mm (1) 800057 Flexible hose 1100 mm (1) 800097...
  • Page 105 32-200237 Maintenance Tools Piston Code Description Drawing No. 800001 Piston ring pliers 4V84L0018 800002 Pliers for securing ring 4V84L0016 800012 Lifting tool (1) 3V83D0234 800012 Lifting tool (2) 2V11T1482 800013 Clamp tool for piston rings 1V84D0011 800105 Measurement tool for piston ring grooves 800106 Spare tips for pliers 800002, straight 800160...

  • Page 106: Cylinder Head

    Maintenance Tools 32-200237 Cylinder Head Code Description Drawing No. 800026 Lifting tool 2V83C0191 800027 Mounting & dismantling tool for valves 2V12T0110 800028 Turning tool for grinding of valves 3V84B0197 800047 Hydraulic tools M56 (1), including 800096 2V86B0224 800050 Lifting tool for hydraulic cylinders 1V87B0054 800053 High pressure pump (1000 bar) (1)
  • Page 107 32-200237 Maintenance Tools Cylinder Head Code Description Drawing No. 800000 Pliers for securing ring 800010 Stud remover 5-20 800029 Removing tool for injection & starting valve 3V83H0202 800030 Valve clearence feeler gauge 3V84K0052 800031 T-wrench for indicator valve 4V80K0006 800049 Pin for tightening of nuts M56 4V86B0002 800056...
  • Page 108 Maintenance Tools 32-200237 Intermediate Gear and Camshaft Tools 130 Code Description Drawing No. 800024 Extractor plate 3V83H0201 800049 Pin for tightening of nuts 4V86B0002 800053 High pressure pump (1000 bar) (1) 4V86A0033 800056 Flexible hose 3000 mm (1) 800062 Mounting & removing tool 3V83H0167 800063 Hydraulic extractor (1)

  • Page 109: Injection Equipment

    32-200237 Maintenance Tools Injection Equipment Code Description Drawing No. 800033 Dismantling tool for injection pump 3V84G0406 800034 Testing tool for injection valve 1V86E0115 800035 Socket wrench 36 mm 4V80H0025 800036 Flare nut wrench for tightening of injection pipes 41 mm 4V80G0053 800037 Socket wrench 55 mm for nozzle cap nut...
  • Page 110 Maintenance Tools 32-200237 Turbocharger Code Description Drawing No. 800070 Tools for turbocharger EGT 295i, 6L and 12V 800070 Tools for turbocharger EGT 297, 6L and 12V 800071 Tools for turbocharger EGT 355i, 8L, 9L, 16V and 18V 800071 Tools for turbocharger EGT 357, 8L, 9L, 16V and 18V 800078 Tools for turbocharger TPL 65, 6L and 12V 800079...

  • Page 111: Miscellaneous Tools

    32-200237 Maintenance Tools Miscellaneous Tools Code Description Drawing No. 800062 Mounting & removing tool for camshaft bearing bush 3V83H0167 800063 Hydraulic extractor (1) 3V83E0061 800064 Checking tool for cylinder/valves tightness 800065 Deflection indicator 4V84K0058 800066 Locking plate for injection pump tappet 4V83E0121 800067 Securing pin for valve tappet...
  • Page 112 Maintenance Tools 32-200237 Miscellaneous Tools Code Description Drawing No. 800029 Removing tool for term. valve, see also section 120 3V83H0202 800127 Tool for connection piece flange screw 3V80G0056 800131 Extractor tool for thermostatic valve 2V83H0481 800141 Tool for cylinder liner temperature sensor 3V80G0059 800150 Mounting tool for camshaft piece...

  • Page 113: High Pressure Pump

    32-200237 Maintenance Tools High Pressure pump Code Description Drawing No. 800053 High pressure pump (1000 bar) (1) 4V86A0033 800054 Sign plate 3V52B0476 800055 Flexible hose 800 mm (1) 800056 Flexible hose 3000 mm (1) 800057 Flexible hose 1100 mm (1) 860150 Manometer 4V51L0085...

  • Page 114: Low Pressure Pump

    Maintenance Tools 32-200237 Low Pressure Pump Code Description Drawing No. 800059 Low pressure pump (150 bar) (1) 1V86A0018 800060 Flexible hose 3000 mm (1) 860074 Straight male stud 4V34L0135 860076 Quick coupling, male 4V86A0012 860079 Quick coupling, female 4V86A0012 860080 Flexible hose 3000 mm 4V86A0067 (1) Including quick couplings...
  • Page 115 32-200237 Maintenance Tools Tightening Tools Code Description Drawing No. 800093 Torque wrench 75-400 Nm 4V92K0207 806000 Hexagon bar kW 27 4V80G0018 820000 Torque wrench 20-100 Nm 4V92K0207 820003 Ratchet handle 20x630 with 3/4" square drive 4V80K0014 820004 Ratchet handle 12.5x300 with 1/2" square drive 820005 Speed brace B12.5x500 820006...

  • Page 116: Hand Tools

    Maintenance Tools 32-200237 Hand Tools Code Description Drawing No. 800094 Box wrench head 24 mm 4V92K0208 803021 Screwdriver 2x12M 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...
  • Page 117 32-200237 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 118 Maintenance Tools 32-200237 Hand Tools Code Description Drawing No. 809011 Socket wrench 10x12.5 with 1/2" square drive 809012 Socket wrench 13x12.5 with 1/2" square drive 809013 Socket wrench 17x12.5 with 1/2" square drive 809014 Socket wrench 19x12.5 with 1/2" square drive 809015 Socket wrench 24x12.5 with 1/2"...

  • Page 119: Measuring And Testing Equipment

    32-200237 Maintenance Tools Measuring and testing equipment Code Description Drawing No. 800105 Micrometer for piston ring grooves 800121 Pressure calibrator -1 bar ... 25 bar, Keller 800134 Frequency generator 4V50T0014 800135 Tools for timing check 2V86T0012 800136 Tools for meas. backlash of direct driven fuel feed pump 3V17T0007 800137 Tools for meas.
  • Page 120 Maintenance Tools 32-200237 Measuring and testing equipment Code Description Drawing No. 800117 Cylinder pressure indicator, Kistler 2515A electronic model 800118 Laser temp.meter Thermo-Hunter PT3LF 800119 Multi loop calibrator Jofra MLC 800120 Charger for Jofra MLC 847010 Pressure sensor tester 3V84H0038 848030 Tachometer 848031...
  • Page 121 32-200507-07 Adjustments, Clearances and Wear Limits 06. Adjustments, Clearances and Wear Limits 06.1 Adjustments Valve timing The valve timing is fixed and cannot be changed individually, cylinder by cylinder. Valve timing Exhaust valves closes Inlet valve opens Inlet valve Exhaust valve closes opens Fig 06-1...
  • Page 122 Adjustments, Clearances and Wear Limits 32-200507-07 06.2 Clearances and wear limits (at 20°C) Normal Part, measuring point clearance (mm) Wear limit (mm) Main bearing clearance 0.225-0.346 (also flywheel bearing) Journal, diameter 339.85 Journal, out of circularity 0.05 Journal, taper 0.025/100 Main bearing shell thickness Section Trimetal shells...
  • Page 123 32-200507-07 Adjustments, Clearances and Wear Limits Normal Part, measuring point clearance (mm) Wear limit (mm) Valve guide diameter assembled 24.25 Valve stem diameter 23.90 Valve stem clearance 0.100-0.156 00.30 Intermediate gear of camshaft drive (camshaft: 230mm) bearing clearance 0160-0.269 0.35 axial clearance 0.35-0.55 Camshaft driving gear backlash:...
  • Page 124 Adjustments, Clearances and Wear Limits 32-200507-07 Normal Part, measuring point clearance (mm) Wear limit (mm) Lubricating oil pump bearing clearance -L32 0.13 -0.17 0.20 -V32 0.19 -0.25 0.30 Axial clearance 0.20 -0.40 Backlash for driving gear -L 32 0.24 -0.62 - V32 0.27 -0.75 Base tangent length (driving gear)
  • Page 125 32-200643-01 Tightening Torques and Use of Hydraulic Tools 07. Tightening Torques and Use of Hydraulic Tools 07.1 Tightening torques for screws and nuts Note! See section 07.3 for hydraulically tightened connections! The position numbers in the tables below refer to the correspond- ing figures A to K, which are located in the engine according to Fig 07-1.
  • Page 126 Tightening Torques and Use of Hydraulic Tools 32-200643-01 A: Crankshaft and flywheel Fig 07-2 4007029601 Pos. Screw connection Torque (Nm) 600 ± 30 1. Flywheel bolts, fitted bolts, M30 1200 ± 60 2. Flywheel elongation bolts, M30 550 ± 30 3.
  • Page 127 32-200643-01 Tightening Torques and Use of Hydraulic Tools B: Intermediate gear and camshaft Fig 07-3 4007049601 Pos. Screw connection Torque (Nm) 290 ± 10 1. Camshaft flange connection screws 290 ± 10 2. Camshaft driving gear screws 117 ± 10 3.
  • Page 128 Tightening Torques and Use of Hydraulic Tools 32-200643-01 B: Governor drive Fig 07-4 4007149913 Pos. Screw connection Torque (Nm) 80 ± 5 1. Governor drive shaft screw 07 - 4 WÄRTSILÄ 32...
  • Page 129 32-200643-01 Tightening Torques and Use of Hydraulic Tools C: Cylinder head Fig 07-5 400705 Pos. Screw connection Torque (Nm) 400 ± 20 1. Rocker arm console, fastening screws 55 ± 5 2. Starting valve fastening screws 35 ± 5 3. Nut for starting valve spindle 125 ±...
  • Page 130 Tightening Torques and Use of Hydraulic Tools 32-200643-01 D: Injection pump Fig 07-6 4007069601 Torque (Nm) Screw connection DELPHI L’Orange 105 ± 10 160 ± 10 1. Fastening screws for head piece, M16 120 ± 10 2. Fastening screws for head piece, M12 215 ±...
  • Page 131 32-200643-01 Tightening Torques and Use of Hydraulic Tools D: Injection pump, Common Rail Fig 07-7 4007340240 Screw connection Torque (Nm) 80 ± 8 1. Fastening screw for pump element M10. 33 ± 3 2. Fastening screw for head piece M8. 60 ±...
  • Page 132 Tightening Torques and Use of Hydraulic Tools 32-200643-01 D: Valve tappet housing Fig 07-8 4007139837 Pos. Screw connection Torque (Nm) 200 ± 10 1. Valve tappet housing fastening screw 23 ± 5 2. Guide plate fastening screw Apply Loctite 242 on threads, see section 07.2. 07 - 8 WÄRTSILÄ...
  • Page 133 32-200643-01 Tightening Torques and Use of Hydraulic Tools E: Fuel injection valve Friction ring Fig 07-9 4007079601 Pos. Screw connection Torque (Nm) 140 ± 10 1. Injection pipe cap nut to injection pump 90 ± 10 2. Injection pipe cap nut to connection piece 160 ±...
  • Page 134 Tightening Torques and Use of Hydraulic Tools 32-200643-01 E: Fuel injection valve, DWI Fig 07-10 400729200143 Pos. Screw connection Torque (Nm) 265 ± 10 1. Injection pipe cap nut to injection pump 180 ± 10 2. Injection pipe cap nut to connection piece 70 ±...
  • Page 135 32-200643-01 Tightening Torques and Use of Hydraulic Tools E: Fuel injection valve, Common Rail Fig 07-11 4007439601 Pos. Screw connection Torque (Nm) 290 ± 30 1. Injection pipe cap nut to injection pump 210 ± 20 2. Injection pipe cap nut to connection piece Apply engine oil on threads and seat cones.
  • Page 136 Tightening Torques and Use of Hydraulic Tools 32-200643-01 E: Water injection flow fuse, DWI FLOW FUSE #5 FLOW FUSE #7 Fig 07-12 4007320243 Flow fuse #5 Pos. Screw connection Torque (Nm) 79 ± 5 1. Fastening screw 80 ± 5 2.
  • Page 137 32-200643-01 Tightening Torques and Use of Hydraulic Tools E: High pressure pipes, Common Rail Distances X for HP pipe ends (positions A - E) Fig 07-13 400733 Pos. Connection Torque (Nm) 290 ± 30 3. Injection pipe cap nut to accumulator and pump Apply engine oil on threads and seat cones.
  • Page 138 Tightening Torques and Use of Hydraulic Tools 32-200643-01 E: Accumulator, Common Rail Fig 07-14 4007330240 Pos. Connection Torque (Nm) 80 ± 5 1. SSV-valve connection piece fastening screw Apply Loctite 243 on threads. 80 ± 5 2. Fastening screws for air bottle. 110 ±...
  • Page 139 32-200643-01 Tightening Torques and Use of Hydraulic Tools F: Piston Piston with 4 screws Piston with 2 screws Piston of type 1 Piston of type 2 Fig 07-15 400708200142 Piston type 1 Pos. Screw connection Torque (Nm) 1. Piston crown connection screws. 1.
  • Page 140 Tightening Torques and Use of Hydraulic Tools 32-200643-01 F: Piston View A Piston with 4 screws Piston of type 3 Fig 07-16 400730200142 Piston type 3 Pos. Screw connection Torque (Nm) 3. Piston crown connection screws. 1. Lubricate threads and contact surfaces with engine oil.
  • Page 141 32-200643-01 Tightening Torques and Use of Hydraulic Tools G: Turbocharger fastening screws Fig 07-17 4007129601 Pos. Screw connection Torque (Nm) 1. Turbocharger fastening screw 560 ± 20 — TPL61, TPL65, M20 560 ± 30 — NA295, NA297, M20 650 ± 30 —...
  • Page 142 Tightening Torques and Use of Hydraulic Tools 32-200643-01 H, I: Engine driven pumps Fig 07-18 4007099601 Pos. Screw connection Torque (Nm) 1. Driving gear of engine driven pumps: Tighten screws crosswise 32 ± 2 — Fuel feed pump (*) 75 ± 5 —...
  • Page 143 32-200643-01 Tightening Torques and Use of Hydraulic Tools H, I Engine driven control oil pump, Common Rail 1. Screw Fig 07-19 4007360243 Pos. Screw connection Torque (Nm) 35 ± 2 1. Fastening screws for driving gear Tighten the screws crosswise The screws are treated with locking compound and can be used only once.
  • Page 144 Tightening Torques and Use of Hydraulic Tools 32-200643-01 J: Free end of crankshaft Fig 07-20 4007109601 Pos. Screw connection Torque (Nm) 1800 ± 25 1. Screws of pump driving gear at free end of crankshaft. Lubricate threads with engine lubricating oil. We recommend the use of torque measuring tools also when tightening other screws and nuts.
  • Page 145 32-200643-01 Tightening Torques and Use of Hydraulic Tools K: Sensors for HT-water Fig 07-21 400745 Pos. Screw connection Torque (Nm) 40 ± 5 1. Temperature sensor pocket 2. Temperature sensor pocket WÄRTSILÄ 32 07 - 21...
  • Page 146 Tightening Torques and Use of Hydraulic Tools 32-200643-01 07.3 Hydraulically tightened connections 07.3.1 Tightening pressures Hydraulically tightened connections Fig 07-22 4007159901 Max. hydraulic pressure (bar) Hydraulic Pos. Screw connection cylinder tightening loosening 1. Cylinder head screws M56 in two steps: 2V86B224 First step Second step...
  • Page 147 32-200643-01 Tightening Torques and Use of Hydraulic Tools Pos. 6 see installation instructions. The stud bolts are tightened to the casting at the following torques: Screw dimension Tightening torque (Nm) 400 ± 20 M56 Cylinder head 300 ± 10 M56 Main Bearing 100 ±...
  • Page 148 Tightening Torques and Use of Hydraulic Tools 32-200643-01 Hydraulic tightening tool for connecting rod shank screw Previous design New design 1. Hydraulic tightening tool 2. Nut 3. Screw Fig 07-23 400731200227 Cylindrical hydraulic tool 1. Cylinder 2. Piston 3. Sleeve Fig 07-24 4007440501 07.3.3 Filling, venting and control of the high pres-...
  • Page 149 32-200643-01 Tightening Torques and Use of Hydraulic Tools The non-return valves in the hoses are integrated with the quick-coupling’s and are opened by the pins located in the centre of the male and female parts. If these pins get worn the coupling must be replaced because of the risk of blocking.
  • Page 150 Tightening Torques and Use of Hydraulic Tools 32-200643-01 07.3.4 Dismantling hydraulically tightened screw connections Warning! Do not stand absolute next to a pressurized hydraulic tool. 1 Attach distance sleeves and hydraulic cylinders according to Fig 07-25 A. Screw on cylinders by hand. 2 Connect the hoses to the pump and cylinders according to scheme Fig 07-25 B.
  • Page 151 32-200643-01 Tightening Torques and Use of Hydraulic Tools 07.3.5 Reassembling hydraulically tightened screw connections Check that the threads and contact surfaces are clean and free from particles. 1 Screw on nuts and attach distance sleeves. Screw cylinders by hand. 2 Connect the hoses to the pump and cylinders. Check that the release valve is open and screw the cylinders in clockwise direction to expel possible oil.
  • Page 152 Tightening Torques and Use of Hydraulic Tools 32-200643-01 07.4 Use of hydraulic extractor cylinder For some power demanding operations a hydraulic extractor cylinder (800063) is used. In connection with this cylinder, the hydraulic high pressure hand pump is utilized, coupling scheme acc.
  • Page 153 32-200643-01 Tightening Torques and Use of Hydraulic Tools Relation between pressure and force Max pressure 2000 4000 6000 8000 10000 12000 14000 16000 18000 20000 22000 24000 26000 20000 40000 60000 80000 100000 120000 140000 160000 180000 200000 220000 240000 Fig 07-27 400727200142 07.5...
  • Page 154 Tightening Torques and Use of Hydraulic Tools 32-200643-01 07 - 30 WÄRTSILÄ 32...

  • Page 155: Troubleshooting

    32-200402-01 Operating Troubles, Emergency Operation 08. Operating Troubles, Emergency Operation 08.1 Trouble shooting Preventive measures, see chapter 03. and 04. Some possible operating troubles require prompt action. Operators should ac- quire knowledge of this chapter for immediate action when needed. Trouble See chapter, Possible reason...
  • Page 156 Operating Troubles, Emergency Operation 32-200402-01 e) Injection valve faulty; nozzle holes clogged f) Piston rings ruined; too low compression pressure 11.3.3 g) 8...18-cylinder engines. It may be troublesome to make these fire on all cylinders when idling, due to the small quantity of fuel required. In normal operation this is acceptable.
  • Page 157 32-200402-01 Operating Troubles, Emergency Operation c) Charge air temperature too high Test Rec, 01.2 - charge air cooler clogged on water side or dirty on air side - water temperature to air cooler too high, water quantity insufficient 01.3 - engine room temperature abnormally high 01.3 d) Excessive deposits in cylinder head inlet or exhaust ports 04.4, 04.5,...
  • Page 158 Operating Troubles, Emergency Operation 32-200402-01 b) Insufficient cooling water flow through oil cooler (faulty pump, air in system, valve 19.1.4 closed), too high raw water temperature 01.3 c) Oil cooler clogged, deposits on tubes 18.5 d) Faulty thermostat valve 18.6 01.2 Abnormally high cooling water outlet temperature, difference between cooling water inlet and outlet temperatures too large...

  • Page 159: Emergency Operation

    32-200402-01 Operating Troubles, Emergency Operation 08.2 Emergency operation 08.2.1 Operation with defective air cooler(s) If the water tubes of an air cooler are defective, the cooling water may enter the cylinders. If water or water mist flows out of the drain pipe at the bottom of the cooler housing, check whether it is raw water or condensate.
  • Page 160 Operating Troubles, Emergency Operation 32-200402-01 Valve cams Stop fuel injection to the cylinder concerned, see chapter 16. Remove the valve push rods and hang up the tappet in upper position by locking pins 800067 included in the tool set. Mount the tubes covering the push rods.
  • Page 161 32-200402-01 Operating Troubles, Emergency Operation 08.2.5 Torsional vibrations and other vibrations When running the engine with one cylinder, or more, out of operation, the balance of the engine is disturbed and severe, or even dangerous, vibrations may occur. The vibration conditions are, in practice, dependent on the type of the installation.
  • Page 162 Operating Troubles, Emergency Operation 32-200402-01 08 - 8 WÄRTSILÄ 32...
  • Page 163 2005-01 Specific Installation Data 09. Specific Installation Data 09.1 General Marine installations Chapter 09 is reserved for specific installation data. Depending on installation, the specific installation data can also be found from separate binder, “Attachments”. 09.2 General Power installations All test reports and certificates are collected in series 8 Quality records.
  • Page 164 Specific Installation Data 2005-01 09 - 2...
  • Page 165 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner 10. Engine Block with Bearings, Oil Sump and Cylinder Liner 10.1 Description The engine block is cast in one piece. The main water and Data and dimensions lubricating oil distributing pipes and the charge air receiver are Material: Nodular cast iron integrated in the engine block.

  • Page 166: Main Bearings

    Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 10.3 Main bearings 10.3.1 Dismantling of the main bearing 1 Remove the crankcase covers on each side of the bear- ing, on both sides of the engine. 2 Remove the main bearing temperature sensor and the clamps for the cable.
  • Page 167 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner Use of hydraulic cylinders Operating side Rear side Hydraulic cylinder combination Screw Hydraulic tool Main bearing and thrust bearing screws Main bearing screws Cylinder 800041 (3V86B78) 800046 (3V86B218) Sleeve 800042 (3V86B46) 800095 (3V86B333) 800043 (4V86B11) 800049 (4V86B02)
  • Page 168 Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 18 Cover the main bearing journal oil holes with tape. Note! At least every third main bearing must always remain mounted to support the crankshaft. Hydraulic jack Straight side of main bearing cap Connection for DOWN...
  • Page 169 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner Mark the new bearings with the bearing numbers. The main bearing journals should be inspected for surface finish. Damaged journals, i.e. rough surface, scratches, marks of shocks etc., should be polished. If, after a longer running period, consid- erably uneven wear appears, see section 06.2, the crankshaft may be reground and used together with thicker bearing shells, see Spare Parts Catalogue.
  • Page 170 Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 8 Remove the quick coupling from the return hose and reverse the oil feed to the hydraulic jack. Mount the quick coupling male part to the free end of the hose and place it in the crankcase.
  • Page 171 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner ) to full stated pressure. 23 Tighten the side screw (A 24 Remove the tools, mount the main bearing temperature sensor, the cable clamps and the crankcase covers. 10.4 Flywheel/thrust bearing 10.4.1 Dismantling of flywheel/thrust bearing 1 Remove the crankcase covers next to the flywheel end, DISMANTLING...
  • Page 172 Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 15 Insert the turning tool 800005 into the bearing journal radial oil hole. 16 Turn the crankshaft carefully until the bearing shell has turned 180° and can be removed. Remove the turning tool. 17 Remove the thrust washers.
  • Page 173 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner 5 Insert the turning tool 800005 into the bearing journal ra- dial oil hole and turn the crankshaft carefully until the bearing shell has turned into position. Caution! A bearing shell forced into its place can be completely de- stroyed due to deformation.
  • Page 174 Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 18 Apply the sleeve and hydraulic cylinder onto main bearing screw (B ) by the same procedure. 19 Tighten the nuts of the main bearing screws as scribed in adjacent figure. Both screws must be tightened at the same time and in two steps, see Fig 10-1.
  • Page 175 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner • • • • The pitch angle of the honing lines in the cross hatch pattern should be about 30°, which is achieved by combining for example 40 strokes/min with a rotational speed of 100 RPM. 30˚...
  • Page 176 Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 3 Mount the water jacket (1) and tighten the fixing screws by hand. 4 Lubricate the guiding faces with grease and assemble the lifting tool, see Fig 10-4. 5 Check that the O-ring grooves of the cylinder liner are clean and insert new O-rings.
  • Page 177 32-200150 Engine Block with Bearings, Oil Sump and Cylinder Liner Removing and lifting of cylinder liner 800007 800123 800007 Lifting tool for cylinder liner 800123 Fastening tool for cylinder liner 1. Water jacket 2. O-ring 3. O-ring 4. O-ring Distinct mark 5.
  • Page 178 Engine Block with Bearings, Oil Sump and Cylinder Liner 32-200150 10 - 14 WÄRTSILÄ 32/34SG...
  • Page 179 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston 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 Wärtsilä 32 engines have counterweights on all webs.
  • Page 180 Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 5 Turn crank of the first cylinder near BDC (bottom dead centre) and fit the transducer to the centre marks (marked with yellow paint mark) between two crank webs. The distance between centre mark and contact surface of the counter weight and crank web is 145 mm, see Fig 11-1.
  • Page 181 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston 9 Following limits of misalignment are stated for an engine having normal running temperature (within 10 min after run- ning at 60 % load, or higher, for 6 h, or more): For evaluating the vertical alignment should the difference be- tween C and it’s opposite reading, i.e.

  • Page 182: Connecting Rod And Piston

    Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 11.3 Connecting rod and piston 11.3.1 Description of connecting rod and piston The connecting rod is of a three-piece design, so called “Marine type connecting rod”. The combustion forces are distributed over a maximum bearing area. The relative movements between mat- ing surfaces are minimized.
  • Page 183 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston 2 Remove the cylinder head according section 12.2.1. 3 Mount the fastening tool for cylinder liner 800123, see Fig 10-4. 4 Remove the anti-polishing ring. Insert the tool 800009 in the cylinder, by cranking the engine, the piston pushes the anti-polishing ring out, see Fig 11-3.
  • Page 184 Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 Caution! The screws will be overloaded if the maximum hydraulic pressure is exceeded. It is recommended to change the screws if maximum hydrau- lic pressure is exceeded for some reason. 10 Release the pressure slowly and disconnect the hoses, un- screw the tightening nuts and remove hydraulic tool as one package.
  • Page 185 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston Caution! The screws will be overloaded if the maximum hydraulic pressure is exceeded. It is recommended to change the screws if maximum hydrau- lic pressure is exceeded for some reason. 6 Release the pressure slowly and disconnect the hoses, unscrew the tightening nuts and remove hydraulic tool as one package.
  • Page 186 Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 Caution! The screws will be overloaded if the maximum hydraulic pressure is exceeded. It is recommended to change the screws if maximum hydrau- lic pressure is exceeded for some reason. 17 Release the pressure slowly and disconnect the hoses, unscrew the tightening nuts and remove hydraulic tool as one package.
  • Page 187 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston 24 Pull lower part of the big end bearing cap out of crankcase, by using the sledge. Take care not to damage the crank pin. Support the lower half sideways and don’t drop it. 25 Pull the upper part of the big end bearing cap out of the crankcase rear side of the engine, by using the sledge.
  • Page 188 Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 5 Measure the height of the piston ring grooves, e.g. with an inside micrometer. 6 Inspect anti-polishing ring. Turn ring upside down after first period. Change the ring every second period. When mounting a new cylinder liner, or honing the old liner, all rings are to be replaced by new ones, acc.
  • Page 189 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston Note! Never compress the securing ring more than necessary to fit into the groove. If the ring is loose in its groove after mounting, it must be replaced by a new one. 3 Take off the protecting tape from the crank pin oil holes and lubricate the crank pin with clean engine oil.
  • Page 190 Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 6 Clean the big end upper half carefully. Lubricate bearing surface and back side of the bearing shell with oil. Mount the shell, so that the lug guides in its groove. Note! It is very important that the bearing shells are mounted straight. 7 Lift the upper big end half with the sledge in the mount- ing flute.
  • Page 191 32-200020 Crank Mechanism: Crankshaft, Connecting Rod, Piston 21 Mount the piston rings by using the pliers 800001. If rings are reused, take care not to turn them upside down. The rings should be placed with gaps located 120° in relation to each other.
  • Page 192 Crank Mechanism: Crankshaft, Connecting Rod, Piston 32-200020 33 Mount the anti-polishing ring. Note! Check that the connecting rod is movable axially after tight- ening. 11 - 14 WÄRTSILÄ 32...
  • Page 193 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 194 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 195 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 196 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 197: General Description

    32-200646-01 Cylinder Head with Valves 12. Cylinder Head with Valves 12.1 General description The cylinder heads are cast of nodular cast iron. Each head Data and dimensions includes two inlet valves, two exhaust valves, a centrally located Material: nodular cast iron injection valve and an indicator valve.
  • Page 198 Cylinder Head with Valves 32-200646-01 12.1.1 Functions The flame plate of the cylinder head is a part of the combustion chamber. During the combustion, the flame plate is exposed to high pressures and high temperatures. Combustion air is led from the air receiver through the multiduct and the cylinder head inlet channel into the cylinder.
  • Page 199 32-200646-01 Cylinder Head with Valves 9 Put on the distance sleeves and hydraulic cylinders 800047 and proceed with opening of cylinder head nuts. 10 Remove the cylinder head nuts. 11 Apply the lifting tool 800026 and lift off the cylinder head.
  • Page 200 Cylinder Head with Valves 32-200646-01 12.2.3 Mounting the cylinder head screws Before mounting the cylinder head, following actions are recom- mended: · Change the cylinder head screws, if the maximum pressure is exceeded when applying the hydraulic tool. · Change the O-rings (48) at every piston overhaul, see Fig 12-3.
  • Page 201 32-200646-01 Cylinder Head with Valves 12.2.4 Mounting of the cylinder head 1 Clean the sealing surfaces and put a new cylinder head gasket, new multiduct gasket and new O-rings for the cooling water jacket, push rod protecting pipes and sliding connec- tions.
  • Page 202 Cylinder Head with Valves 32-200646-01 3 Press the fixed end of the yoke against the valve stem by pressing down the adjustable end. Screw down the adjusting screw (3) until it touches the valve end and note the position of the spanner (pos. a). Now press down the fixed end. Keep on screwing down while the yoke tilts, until the guide clearance is on the other side and the fixed end of the yoke starts lifting from the valve stem.
  • Page 203 32-200646-01 Cylinder Head with Valves 12.3 Exhaust and inlet valves and seat rings 12.3.1 General description The cylinder head has four valves fitted, two inlet valves and two Data and dimensions exhaust valves. The inlet valves are bigger than the exhaust Material: High quality steel valves.
  • Page 204 Cylinder Head with Valves 32-200646-01 6 Note the marks of the valves or mark them so they can be re-installed into the same guide if they are in good condition. 12.3.3 Checking and reconditioning of valves and seats 1 Clean the valves, seats, ducts and guides as well as the underside of the cylinder head.
  • Page 205 32-200646-01 Cylinder Head with Valves 5 Before grinding, check the valve stem clearance. If the clearance is too large, measure the stem and guide, and change the worn part; the valve guide can be pressed out. Check the bore in the cylinder head. When refitting, cooling in with liquid nitrogen is recommended, but pressing in with oil lubrication can also be accepted.
  • Page 206 Cylinder Head with Valves 32-200646-01 3 Seat ring for the inlet valve: The seat angle of the inlet valve seat ring is 20° with a tolerance of -0.30°- -0.10°. The seat can be ground until the outer seat diameter is 113 mm; after that, the ring must be replaced by a new one.
  • Page 207 32-200646-01 Cylinder Head with Valves 12.3.6.3 Fitting an exhaust valve seat ring There are two different kind of seat rings in use in Wärtsilä 32 engines. The old model had two O-rings and the cylinder head bore had to be lubricated with water-soap solution (option Molyk- ote 55 O-ring grease) before mounting.
  • Page 208 Cylinder Head with Valves 32-200646-01 12.3.6.4 Fitting an old type of exhaust valve seat ring 1 Clean the cylinder head bores carefully by grinding gently with a grit 400 or finer emery cloth. After grinding the surface must be cleaned with Loctite 7063 Cleaning spray. 2 Check the bore diameter in the cylinder head, see sec- tion 06.2 in this manual.
  • Page 209 32-200646-01 Cylinder Head with Valves 12.3.6.5 Fitting a new type of exhaust valve seat ring 1 Clean the cylinder head bores carefully by grinding gently with a grit 400 or finer emery cloth. After grinding the surface must be cleaned with Loctite 7063 Cleaning spray. 2 Check the bore diameter in the cylinder head, see sec- tion 06.2 in this manual.
  • Page 210 Cylinder Head with Valves 32-200646-01 Cylinder head bores Fig 12-8 4012120611 1. Lower bore, use water-soap solution or Molykote 55 O-ring grease, 2. Upper bore, use Loctite 641 12.3.7 Reassembling of the engine valves 1 Check the valve springs for cracks, corrosion or wear marks, and if any, replace the springs by new ones.
  • Page 211 32-200646-01 Cylinder Head with Valves 12.4 Indicator valve 12.4.1 Operation and maintenance of the indicator valve The inside construction of the indicator valve is such that the pressure in the cylinder tightens it. Consequently the force needed to close the valve is relatively low. The valve has a left-handed screw and is opened and closed respectively as fol- lows, Fig 12-9.
  • Page 212 Cylinder Head with Valves 32-200646-01 12.4.2 Pf “Maximum firing pressure”, measured at the indicator valve The Pf “Maximum firing pressure” has to be measured as a mean value of at least 32 cycles. It is recommended to measure the Pf by using Kistler Engine tester type 2507A or 2515A (848033) and sensor type 7613B or 7613C.
  • Page 213 32-200142 Testing of cylinder tightness Appendix A 12.A. Testing of cylinder tightness 12.A.1 Testing A tool can be used for control of cylinder and valve tightness. Note! Should be done immediately after engine stop. Turn the piston to TDC (all valves closed) for the cylinder con- cerned.
  • Page 214 Appendix A Testing of cylinder tightness 32-200142 Testing tool of cylinder tightness WÄRTSILÄ 20, 848020 WÄRTSILÄ 32, 800064 VASA 32, 848020 WÄRTSILÄ 34SG, 848020 WÄRTSILÄ 32DF, 848020 848 052 848 052 848 061 Fig A-1 321260200142 12.A.1.4 Measurement Connect air to the tool with a pressure of 6-7 bar (= normal working air pressure).
  • Page 215 32-200142 Testing of cylinder tightness Appendix A 4, 19 and 18 seconds. This shows that cyl.no.4 is the one to be suspected for a blow-by. The test can be verified by listening for leaking sounds inside crankcase during testing. If the time is limited to overhaul only one piston, it is recom- •...
  • Page 216 Appendix A Testing of cylinder tightness 32-200142 A - 4 Wärtsilä 20/32/34...

  • Page 217: Camshaft Driving Gear

    32-200546-02 Camshaft Driving Gear 13. Camshaft Driving Gear 13.1 General description The camshaft is driven by the crankshaft through a gearing. The gearing consists of a gear wheel ring (6), which is splitted and fixed to a flange on the crankshaft by the axial screws (26) and two intermediate gears (3 and 5) and a camshaft driving gear (1), see Fig 13-1.
  • Page 218 Camshaft Driving Gear 32-200546-02 13.2 Intermediate gears and camshaft gear The intermediate gear wheels are case hardened. The wheels have a common shaft and are fixed to each other by a friction connection. The lubrication for the bearings is arranged through drilling’s in the crankshaft, engine block and for the wheels from a distributing pipe through the nozzles.
  • Page 219 32-200546-02 Camshaft Driving Gear 4 Turn the engine and camshaft by using turning device in the rotation direction until the dial indicator shows that the adjusting screw (24) is lifted 6 mm (total depth 74±0,02mm). Note, it is recommended to do the final turning by using the hand wheel of the turning device.
  • Page 220 Camshaft Driving Gear 32-200546-02 Camshaft driving gear 1. Gear wheel for camshaft 2. Extension piece 3. Bigger intermediate gear wheel 4. Bearing bush 5. Smaller intermediate gear wheel 6. Gear wheel for crankshaft 7.Crankshaft 8. Extension piece 9. Screw 10. Thrust bearing 11.
  • Page 221 32-200546-02 Camshaft Driving Gear 7 Crank the engine and lock all valve- and injection pump tappets in upper position, see section 14.2.2. Warning! When the valve tappet(s) is/are locked in the upper position the rocker arm bracket(s)/ push rods must be removed, oth- erwise when cranking the engine the pistons will come in contact with the valves.
  • Page 222 Camshaft Driving Gear 32-200546-02 Caution! The bolt will be overloaded if the maximum hydraulic pressure is exceeded. It is recommended to change the bolt if maximum hydraulic pressure is exceeded for some reason. 21 Release the pressure slowly, disconnect the hoses and remove hydraulic tool.
  • Page 223 32-200546-02 Camshaft Driving Gear 6 Mount the cover (33) and replace the O-rings (29) and (30) with new ones. Tighten the screws (31) to stated torque. 7 Screw in the bolt (20) by using the tool 800114 and tighten to the torque stated in chapter 07.3. The locking screw of the tool has left-hand threads.
  • Page 224 Camshaft Driving Gear 32-200546-02 Note! Check the valve timing before the engine is started. 13.3 Crankshaft gear wheel If only the split gear wheel has to be changed, one half of the wheel can be removed/mounted at a time. Hereby the valve timing will be unchanged and it will not be necessary to adjust it.
  • Page 225 32-200546-02 Camshaft Driving Gear 9 Check the gear wheel roundness. Place a cylindrical pin (ø16 mm) in the tooth gap as shown in Fig 13-3. Turn the engine and use a dial indicator to get an indication for the diameters. The maximum permissible difference between the measured values is 0.05 mm.
  • Page 226 Camshaft Driving Gear 32-200546-02 13 - 10 WÄRTSILÄ 32...

  • Page 227: Valve Mechanism

    32-200106 Valve Mechanism and Camshaft 14. Valve Mechanism and Camshaft 14.1 Valve mechanism 14.1.1 Description of valve mechanism The valve mechanism operates the inlet and outlet valves at the required timing. The valve mechanism consists of piston type valve tappets (9) moving in a common guide block (8), tubular push rods (6 ) with ball joints, rocker arms (2) journalled on a rocker arm bearing bracket (5), yokes (4) guided by a yoke pin (15) at the cylinder head.
  • Page 228 Valve Mechanism and Camshaft 32-200106 14.1.2 Function The movement of the valve tappets (9) is governed by the cam profile on the camshaft. The valve tappets transfer the movement through push rods (6) to the rocker arms (2). The rocker arms operate the inlet and exhaust valves through a yoke (4).
  • Page 229 32-200106 Valve Mechanism and Camshaft 3 Unscrew the screws (1) and remove the rocker arm bear- ing bracket (5) with accessories from the cylinder head. 4 Remove the retainer rings (3) by using pliers 800002. Re- move the positioning screw (1) and press out the shaft (20). 5 Remove the push rods (6) and the protecting pipes (7).
  • Page 230 Valve Mechanism and Camshaft 32-200106 5 Mount necessary pipes and injection pipe. Tighten the injection pipe to the stated torque according to chapter 07. 6 Grease the O-rings (21), insert the protecting pipes (7) and push rods (6) into the guide block. 7 Mount the yoke.
  • Page 231 32-200106 Valve Mechanism and Camshaft Warning! When the valve tappet(s) is/are locked in the upper position the rocker arm bracket(s)/ push rods must be removed, oth- erwise when cranking the engine the pistons will come in contact with the valves. 2 Unscrew the flange connection screws (4) from both ends of the camshaft piece.

  • Page 232: Camshaft Bearing

    Valve Mechanism and Camshaft 32-200106 4 Insert the other connection screws and tighten to the stated torque. 5 Mount the cover (1) of the starting air distributor, gover- nor drive, etc. 6 Release the tappets and mount the rocker arm brackets. 7 Check the valve clearances, see section 12.2.4.
  • Page 233 32-200106 Valve Mechanism and Camshaft Removing of camshaft bearing bush 3V83E61 3V83H165 4V83G45 Screw 3V83H61 Hydraulic cylinder Bearing 3V83H164 Guide sleeve 3V83H165 Distance piece 3V83H166 Pressure plate 3V83H164 3V83G45 3V83H166 Fig 14-3 4014019601 14.3.3 Mounting of camshaft bearing bush 1 Lightly lubricate the new bearing bush with clean en- gine oil on the outer surface and put it on the guide sleeve 3V83H164.
  • Page 234 Valve Mechanism and Camshaft 32-200106 Mounting of camshaft bearing bush 4V83G45 Screw 3V83E61 3V83H165 3V83H61 Hydraulic cylinder 3V83H164 Guide sleeve 3V83H165 Distance piece 3V83H166 Pressure plate Bearing 3V83H166 3V83H164 3V83G45 Fig 14-4 4014049601 14 - 8 WÄRTSILÄ 32...
  • Page 235 32-200549-10 Turbocharging and Air Cooling 15. Turbocharging and Air Cooling 15.1 Description The turbochargers are of axial turbine type. The charge air coolers are of rigid frame -type and are on in-line engines fitted to the side of the engine block, while V-engines have the cooler fitted to the turbocharger bracket.

  • Page 236: Turbocharger Maintenance

    Turbocharging and Air Cooling 32-200549-10 Charge air system V-engine 1. Bellows 2. Air duct 4. Charge air cooler 7. Cover 8. Drain pipe 9. Cover 10. Cover 11. Screw 12. Plate 13. Screw 37. Cover 38. Cable Alternative 1 Alternative 2 Fig 15-2 4015190406 15.2...
  • Page 237 32-200549-10 Turbocharging and Air Cooling 15.3 Water cleaning of turbocharger during operation 15.3.1 Water cleaning of turbine The dirt deposits on the turbine side can be reduced by periodic cleaning (washing) during operation. The overhaul periods can thus be extended. Dirty turbines cause higher temperatures of the exhaust gas and higher stress to the bearings due to imbal- ance.
  • Page 238 Turbocharging and Air Cooling 32-200549-10 Water cleaning of turbocharger 1. Valve for turbine cleaning 2. Valve for compressor cleaning 3. Quick-coupling 4. Flow meter 5. Valve Fig 15-3 4015049708 15.3.2 Turbine cleaning procedure The turbocharger is designed without drain pipe. 1 Record charge air pressure, cylinder exhaust gas tem- peratures, charger speed at nominal load, for later use to evaluate efficiency of the cleaning.
  • Page 239 32-200549-10 Turbocharging and Air Cooling 3 Open the valve (1) and check that the nozzles are not clogged, see Fig 15-3. 4 Connect the water hose. 5 Open the valve (5) slowly and increase the water flow until the correct flow is reached according to the table shown in section 15.3.1.
  • Page 240 Turbocharging and Air Cooling 32-200549-10 15.3.3 Water cleaning of compressor The compressor can be cleaned by injecting water during opera- tion. The method is efficient provided that contamination is not too far advanced. If the deposit is very heavy and hard, the compressor must be dismantled and cleaned mechanically.
  • Page 241 32-200549-10 Turbocharging and Air Cooling 6 Disconnect the water hose. 7 Open the valve (2) and drain out the water. 8 Repeat the readings taken in step 1 above for evalu- ation. The success of injection can be recognized by the change in charge air pressure and in the exhaust gas temperature.
  • Page 242 Turbocharging and Air Cooling 32-200549-10 15.4 Operation with damaged turbocharger 15.4.1 General In case of a serious breakdown of the turbocharger, a blanking device can be fitted according to the instructions below, see also turbocharger manual, section 06. In an emergency situation like this, the engine can be temporarily operated at max.20 % output.
  • Page 243 32-200549-10 Turbocharging and Air Cooling 8 Mount the lifting equipment and open the screws. Re- move the cartridge assembly. Blanking device 1. Blanking cover 2. Screen plate 3. Distance sleeve 4. Plug 5. Plug 6. Cover plate 7. Flange 8. Nut Fig 15-4 401507200102 9 Mount the plugs (4) and (5) with O-rings in the lubricat-...

  • Page 244: Charge Air Cooler

    Turbocharging and Air Cooling 32-200549-10 15.5 Charge air cooler The charge air cooler is of self-supported type. The housing is Data and dimension fitted to the engine block. Material The air cooler is of tube type. The tubes are provided with thin -Tubes: copper alloy -Water boxes: cast iron.
  • Page 245 32-200549-10 Turbocharging and Air Cooling 5 Remove the additional supports on both the banks. Air cooler housing 13. Screw 14. Nut 15. Nut 16. Air box 17. Air box 19. Cover 20. Protecting plate Fig 15-5 4015210306 6 Unscrew and remove the screws (13), see Fig 15-5. En- sure that there is a gap (approx.
  • Page 246 Turbocharging and Air Cooling 32-200549-10 Air cooler lifting tool 18. Screw 22. Cooler assembly 23. Screw 24. Stud 25. End cover 26. Air cooler (B) 27. Central connector 800 077 28. Air cooler (A) 29. Screw 30. Screw 800 077 Lifting tool Fig 15-6 4015160351 11 Remove the center studs (24) with help of double nuts to...
  • Page 247 32-200549-10 Turbocharging and Air Cooling Air cooler top fastening screws 33. O-ring 34. Distance sleeve Section A-A 35. Screw Fig 15-7 4015260408 15 Remove the flanges (40), see Fig 15-11. 16 Slightly lower the air cooler. Ensure that all screws are removed and that the cooler moves freely.
  • Page 248 Turbocharging and Air Cooling 32-200549-10 18 Split the cooler assembly into 3 parts (A-bank, B-bank and central connector). 19 Remove the end covers (25) of the air coolers, see Fig 15-8. 15.5.3 Cleaning of air cooler Clean air cooler heat exchange surfaces are essential for a long and trouble-free engine operation.
  • Page 249 32-200549-10 Turbocharging and Air Cooling 15.5.4 Pressure testing of air cooler 1 Mount the testing tool, see Fig 15-10 onto the cooler and fill it up with water by the hand pump. 2 Pressure test the air cooler for 30 minutes. See instruc- tions for testing device, according to cooler type, in the table below.
  • Page 250 Turbocharging and Air Cooling 32-200549-10 Test pressure tools -2-stage cooler V-engines: 3V84H0157 Valve 3 2V84H0151 3V84H0144 LT-out LT-IN HT-IN Valve 2 HT-IN HT-IN HT-out Bottom Valve 1 -2-stage cooler V-engines: 3V84H0190 Valve 3 Valve 2 Bottom Valve 1 -2-stage cooler L-engines: 1V84H0180/1V84H0187 -1-stage cooler: 3V84H0159/3V84H0186 Valve 1 HT-circuit...
  • Page 251 32-200549-10 Turbocharging and Air Cooling 15.5.5 Assembling (V-engines) 1 Mount the coolers (26) and (28), see Fig 15-8 and the central connector (27) with the screws (31). Note! Renew all gaskets! Take care that the coolers are well supported. The central connector has to be fitted with 2 pieces of O-rings on both sides.
  • Page 252 Turbocharging and Air Cooling 32-200549-10 9 Mount all screws (18), (30) and (35) of the air cooler, see Fig 15-6 and Fig 15-7, and tighten these according to chapter 07. Remove the lifting tool. 10 Mount the studs and lift the air inlet box (16) into posi- tion, see Fig 15-5.
  • Page 253 32-200549-10 Turbocharging and Air Cooling U-tube manometer Fig 15-12 401508200050 WÄRTSILÄ 32 15 - 19...
  • Page 254 Turbocharging and Air Cooling 32-200549-10 15 - 20 WÄRTSILÄ 32...

  • Page 255: Injection System

    32-200627-01 Injection System 16. Injection System 16.1 Injection pump 16.1.1 General description The engine is designed with one injection pump per cylinder. The Data and dimensions injection pump is located in a “multihousing”, see Fig 16-1. The Multihousing: functions of the multihousing are: - material special cast iron - weight:...
  • Page 256 Injection System 32-200627-01 16.1.2 Function The injection pump pressurises fuel to the injection nozzle. It has a regulating mechanism for increasing or decreasing the fuel feed quantity according to the engine load and speed. The pumps are governed by the governor. The plunger, pushed up by the camshaft via the roller tappet and pulled back by the spring acting on the plunger, reciprocate in the element on a predetermined stroke to feed fuel under...
  • Page 257 32-200627-01 Injection System 16.2 Maintenance of injection pump Most maintenance operations can be done without removing the multihousing from the engine. It is recommendable that the engine will be run 5 minutes with light fuel before stopped for overhaul of injection pump. During maintenance utmost cleanli- ness must be observed.
  • Page 258 Injection System 32-200627-01 Injection pump 1. Screw 2. Screw 3. Head piece 4. Pin 5. Erosion plug 6. Control sleeve 7. Spring plate 8. Spring 9. Spring holder 10. Retainer ring 11. Screw 12. Cover 13. Screw 14. Flange 15. Push spindle 16.
  • Page 259 32-200627-01 Injection System 6 Connect the fuel pipes between the multihousings con- cerned. Move the fuel line connecting sleeves on the adjacent fuel pipes by using the tool 800039. 7 Check the adjustment of the injection pump according to work steps 2 to 6 in section 16.2.3. 8 Clean the contact faces of the guide block and injection pump.

  • Page 260: Adjustment Of Injection Pump

    Injection System 32-200627-01 16.2.3 Adjustment of injection pump Pump timing can alter due to manufacturing tolerances in pumps, cams and gears or when doing some modifications to the engine. To get best possible operation to the engine it is important that fuel pump adjustments are done properly and are according to the setting table, see test records.
  • Page 261 32-200627-01 Injection System 16.2.4 Injection pump overhaul It is supposed that the multihousing is removed from the engine and it is properly cleaned. Note! The element cylinder, plunger and delivery valve assembly are matched and they must be kept together during the overhaul.
  • Page 262 Injection System 32-200627-01 13 Re-install the delivery valve with spring (28) and pres- sure relief valve with spring (30) into the head piece (3). 14 Screw the element cylinder together with head piece using the screws (2). Check that the fixing pin (29) is fitted properly.
  • Page 263 32-200627-01 Injection System 16.2.5 Changing of erosion plugs 1 Remove the locking wire between the locking screws and erosion plugs (5). 2 Change erosion plugs and tighten to correct torque, see chapter 07.1. 3 Lock the erosion plugs with a locking wire to the fasten- ing screw, see Fig 16-2 Note! To prevent a risk of a high pressure fuel leakage, the erosion...
  • Page 264 Injection System 32-200627-01 Note! Before starting the washing procedure, check that the pipes to the clean leak fuel system are open. 1 Remove the plug (1) from the injection pump. Fit the connection piece (2). 3 Connect the hose (3) to the connection piece (2). 4 Connect the suction hose (4) to a 10 l canister contain- ing clean light fuel oil.
  • Page 265 32-200627-01 Injection System 16.3 Injection line The injection line consists of two parts, the connection piece, which is screwed sideways into the nozzle holder, and the injection pipe. The connection piece seals with plain metallic surfaces and these surfaces are to be checked before mounting. Always tighten the connection piece to correct torque before mounting the injec- tion pipe;...

  • Page 266: Injection Valve

    Injection System 32-200627-01 16.4 Injection valve 16.4.1 Description The injection valve is centrally located in the cylinder head and Data and dimension includes the nozzle holder and the nozzle (15), see Fig 16-4. The Orifices: 10 pcs fuel enters the nozzle holder sideways through a connection piece Orifice dia.: 0.54 mm Angle:...
  • Page 267 32-200627-01 Injection System 6 Lift out the injection valve with the tool 800029. 7 Protect the fuel inlet hole of the injection valve and the bore in the cylinder head. 16.4.3 Overhauling of injection valve 1 Inspect the nozzle immediately after removing the injec- tion valve from the engine.
  • Page 268 Injection System 32-200627-01 Maximum lift of nozzle, removing of nozzle from holder Alternative 1 Alternative 2 Alternative 3 Fig 16-5 40162720026 6 Clean the components. If possible, use a chemical carb- on dissolving solution. If there is no such available, immerse the details in clean fuel oil, white spirit or similar to soak carbon.
  • Page 269 32-200627-01 Injection System 10 Reassemble the injection valve. Tighten the cap nut to the torque given in section 07.1. 11 Connect the injection valve to the test pump. Pump to expel air. Shut the manometer valve and pump rapidly to blow dirt out of the nozzle orifices.
  • Page 270 Injection System 32-200627-01 16.4.4 Testing of nozzle function in general · If abnormal running parameters are observed (abnormally high or low exh. gas temperatures, low firing pressure) one reason can be leaking or blocked fuel injector(s). · The nozzle holes can be checked with the hand test pump by giving a quick and heavy blow and using a paper under the nozzle tip, but keep your hands away.
  • Page 271 32-200627-01 Injection System Booster unit 1. From hand pump 2. Chamber 3. Valve 4. Valve 5. Control valve To the fuel valve Drain From the handpump Fig 16-6 401620200209 Note! The appearance in testing will be a big bang as well as fuel mist like in an actual engine.
  • Page 272 Injection System 32-200627-01 5 The pressurized fuel having a step pressure wave is en- tering to fuel injection valve. Now with a bigger volume than with the standard hand test device, the nozzle reaches full needle lift. After the test the pressure in high pressure line will be reduced by opening the draining valve (3).
  • Page 273 32-200627-01 Injection System 16.5 Pneumatic overspeed trip device The pneumatic overspeed trip device is mounted on the multi- housing and acts directly on the fuel rack. If the overspeed trip device is activated, pressurized air acts on a piston in a cylinder attached to the multihousing.
  • Page 274 Injection System 32-200627-01 16 - 20 WÄRTSILÄ 32...

  • Page 275: Fuel System

    32-200508-07 Fuel System 17. Fuel System 17.1 General ® The Wärtsilä 32 engine is designed for continuous Light, Heavy or Crude Oil duty. The fuel feed system pressure adjustment recommendations varies depending on fuel quality and installa- tion and the values mentioned in this chapter should be used as guidelines only.
  • Page 276 Fuel System 32-200508-07 Fuel system 3. Pressure control valve 4. Pressure transmitter 5. Temperature sensor 6. Fuel filter 9. Fuel feed pump 10. Pressure regulating valve 11. Safety valve 12. Deaeration tank 13. Circulating pump 14. Safety valve 15. Pressure regulating valve 16.

  • Page 277: Maintenance

    32-200508-07 Fuel System 17.2 Maintenance When fuel system maintenance work is carried out, always observe utmost cleanliness. Pipes, tanks and the fuel treatment equipment, such as pumps, filters, heaters and viscosimeters, included in the engine delivery or not, should be carefully cleaned before taken into use.
  • Page 278 Fuel System 32-200508-07 Warning! The pump safety valve should be adjusted rapidly as the pump may run hot if the system is closed for a lengthy time. 17.4.2 The fuel circulating pumps in unit (B) The fuel circulating pumps (13) keep the fuel in the system in constant circulation and maintain a system pressure (P3) be- tween the circulating pumps and the pressure regulating valve (15), see Fig 17-1 and section 17.5.4.

  • Page 279: Start And Stop

    32-200508-07 Fuel System 17.4.4 System operating values Fuel feed system pressures*), LFO or HFO Specification / Location (bar) Fuel feed pressure / P1 Safety valve adjustment /P2 Circulation pressure / P3 Safety valve adjustment / P4 Fuel feed pressure / P5 Safety valve adjustment / P6 *) See installation specific documentation concerning system pressure adjustments for Crude Oil engines.
  • Page 280 Fuel System 32-200508-07 17 - 6 WÄRTSILÄ 32...

  • Page 281: Lubricating Oil System

    32-200052 Lubricating Oil System 18. Lubricating Oil System 18.1 General design Normally, a wet sump system is used, but also dry sump systems can be used. The engine is provided with a lubricating oil pump (3) directly driven by the pump gear at the driving end of the crankshaft. It is possible to connect an electrically driven stand-by pump in parallel if needed.
  • Page 282 Lubricating Oil System 32-200052 Oil is led through bores to other lubricating points, like camshaft bearings (9), injection pump tappets and valves, rocker arm bearings (11) and valve mechanism gear wheel bearings, and to oil nozzles for lubricating and cooling. Turbocharger is also con- nected to the engine lubricating oil system.

  • Page 283: General Maintenance

    32-200052 Lubricating Oil System 18.2 General maintenance Use only high quality oils approved by the engine manufacturer according to the list in the end of chapter 02. Always keep a sufficient quantity of oil in the system. The oil dipstick indicates the maximum and minimum limits between which the oil level may vary.

  • Page 284: Lubricating Oil Pump

    Lubricating Oil System 32-200052 18.3 Lubricating oil pump 18.3.1 Description The pump is of the gear type. A combined pressure regulat- ing/safety valve is mounted on the housing of the pump. Identical bronze bearings are used. No outside lubrication is required. Lube oil pump 1.
  • Page 285 32-200052 Lubricating Oil System 7 Protect the connections with suitable plugs, clean plas- tic or similar. 18.3.3 Dismantling 1 Remove and inspect the regulating valve according to section 18.4. 2 Remove the pressure plate (4) by loosening the fasten- ing screws (3). 3 Pull off the gear wheel (1) without using any tool.
  • Page 286 Lubricating Oil System 32-200052 Reinstall the friction ring elements exactly as situated in Fig 18-3. The friction ring elements should fall easily in place and must not jam. Mounting of gear wheel 1. Drive gear 2. Frictional rings 3. Screw 4.
  • Page 287 32-200052 Lubricating Oil System 18.4 Lubricating oil pressure regulating valve and safety valve 18.4.1 Description The pressure regulating valve, see Fig 18-2, is integrated in the lubricating oil pump module and regulates the oil pressure before the engine by returning the surplus oil direct from the pressure side of the pump back to the sump.

  • Page 288: Lubricating Oil Cooler

    Lubricating Oil System 32-200052 18.5 Lubricating oil cooler 18.5.1 Description A tube stack (3) is inserted in a jacket which belongs to lubricating oil module. The tube stack is fixed at one end while the other one is movable in a longitudinal direction to allow expansion. Both ends are provided with two O-rings (4).
  • Page 289 32-200052 Lubricating Oil System 5 Mark the position of the tube stack relative jacket. 6 Move the tube stack towards LT control valve housing side until the second O-ring is accessible. Remove the O-ring. 7 Remove the tube stack from the lube oil thermostat housing side.
  • Page 290 Lubricating Oil System 32-200052 18.5.4 Cleaning of oil side Fouling of the oil side is normally insignificant. On the other hand, possible fouling will influence the cooler efficiency very strongly. Due to the design, the tube stack cannot be cleaned mechani- cally on the outside.

  • Page 291: Thermostatic Valve

    32-200052 Lubricating Oil System 18.6 Thermostatic valve 18.6.1 Description The Fig 18-5 shows the valve in a closed position (left). When the temperature exceeds the nominal value, the contents of the elements (1) expands and forces the valve unit (2) towards the end flange, thus passing part of the oil through the cooler.
  • Page 292 Lubricating Oil System 32-200052 4 Check the element by heating it slowly in water. Check at which temperatures the element starts opening and is fully open. The values can be found on the thermostatic element or in chapter 01.; the lower value for the lube oil temperature is the opening temperature, the higher for the fully open valve.
  • Page 293 32-200052 Lubricating Oil System The flow energy drives the turbine (9) installed in the inlet flange. The high speed of the turbine is reduced by the worm gear unit (6) and gear (10) to the lower speed required for turning the flushing arm (4).
  • Page 294 Lubricating Oil System 32-200052 Note! Should a higher differential pressure occur beforehand, all the filter candles (13) and the protective filter (2) must be checked and, if necessary, cleaned or the candles are to be replaced by new ones. A highly contaminated protective filter is a sign of prolonged operation with defective or clogged filter candles and thus (from a differential pressure of 2 bar upwards) opened overflow valves.
  • Page 295 32-200052 Lubricating Oil System high-pressure cleaning unit (Part No. 471345) and cleaner (Part No. 471346). 9 Clean the parts and check the overflow valves. Replace worn parts if necessary. 10 Mount the protective filter (2) and end plate (18). Note the position of the guiding pin.
  • Page 296 Lubricating Oil System 32-200052 driving torque to the rotor and the oil returns through the filter housing to the engine oil sump. 18.8.2 Cleaning It is very important to clean the filter regularly (chapter 04.) as it collects considerable quantities of dirt. If it is found that the filter has collected the maximum quantity of dirt (corresponds to a 18 mm thick layer) at the recommended cleaning intervals, it should be cleaned...
  • Page 297 32-200052 Lubricating Oil System 4 Lift out the rotor assembly and allow oil to drain from nozzles before removing the rotor from the filter body. Hold the rotor body and unscrew the rotor cover nut (8). Separate rotor cover from the rotor body, and remove central stand tube (4). 5 Measure the thickness of the sludge for estimating the future cleaning intervals.
  • Page 298 Lubricating Oil System 32-200052 14 Remove locating nut and remove valve body for cut off valve, spring and shuttle. Check that the spring and shuttle are undamaged and free to move. Examine O-ring for damage. Renew, if necessary. 15 Reassemble the valve assembly. 18.9 Prelubricating pump 18.9.1 Description...
  • Page 299 32-200052 Lubricating Oil System 18.9.2 Dismantling 1 Dismantle and inspect the regulating valve according to section 18.10. 2 Remove the the coupling half and the key by loosening the fastening screw. 3 Remove the bracket (4) for the electric motor by open- ing the screws (3).
  • Page 300 Lubricating Oil System 32-200052 18.9.4 Assembling 1 Before installing the gear wheels, all contact surfaces should be cleaned and oiled. 2 Mount the axial seal (11) in the cover and lubricate with grease. 3 Mount the bracket (4) Check that the O-ring in the groove is intact and in position.

  • Page 301: Cooling Water System

    32-200050 Cooling Water System 19. Cooling Water System 19.1 Description 19.1.1 General The engine is cooled by a closed circuit cooling water system, divided into a high temperature circuit (HT) and a low tempera- ture circuit (LT). The cooling water is cooled in a separate central cooler.
  • Page 302 Cooling Water System 32-200050 19.1.2 HT circuit The HT circuit cools the cylinders and cylinder heads. A centrifugal pump (7) pumps the water through the HT circuit. From the pump the water flows to the distributing duct, cast in the engine block. From the distributing ducts the water flows to the cylinder water jackets, further through connection pieces to the cylinder heads where it is forced by the intermediate deck to flow along the flame plate, around the nozzle and the exhaust...
  • Page 303 32-200050 Cooling Water System 19.1.6 Monitoring The temperatures mentioned in chapter 01., section 01.2, should not be exceeded. Pressure gauges on the instrument panel indicate HT and LT pressures after the pumps. The pressures depend on the speed and the installation. Guidance values, see chapter 01., section 01.2.

  • Page 304: Water Pump

    Cooling Water System 32-200050 Mechanical cleaning A great deal of the deposits consists of loose sludge and solid particles which can be brushed and rinsed off with water. On places where the accessibility is good, e.g. cylinder liners, mechanical cleaning of considerably harder deposits is efficient. In some cases it is advisable to combine chemical cleaning with a subsequent mechanical cleaning as the deposits may have dissolved during the chemical treatment without having come...
  • Page 305 32-200050 Cooling Water System The water side of the pump is provided with a mechanical shaft seal. The ring (4) rotates along with the shaft and seals against it with the O-ring. The spring presses the rotating ring against a fixed ring (3) which seals against the housing with the O-ring (7).
  • Page 306 Cooling Water System 32-200050 4 When reassembling the impeller, tighten the screw to torque, see chapter 07. 5 Check that the O-ring (2) and non-return valve O-rings between pump and engine pump cover are intact and in posi- tion when re-installing the volute casing. Check that the volute casing is in position.
  • Page 307 32-200050 Cooling Water System 10 Oil the collar and press the bearing in by its inner ring with a suitable pipe. See Fig 19-3A. 11 Turn the shaft according to Fig 19-3B. 12 Oil the collar and press the bearing in by its inner ring with a suitable pipe.

  • Page 308: Temperature Control System

    Cooling Water System 32-200050 19 Tighten the screws to torque according to chapter 07. 20 Assemble the impeller and the mechanical seal cording to pos. a) and b) above. 21 Mount the pump on the engine. Mounting of gear wheel to water pump 13.
  • Page 309 32-200050 Cooling Water System LT thermostatic valve 1. Plug 2. Retainer ring 3. Washer 4. Springs 5. Control cylinder 6. Control piston 7. Element holder 8. Thermostat element 9. Retainer ring 10. Guiding pin 11. End flange 12. Screw 13. Adjusting screw Fig 19-5 4019029601 19.4.2.1 Maintenance...
  • Page 310 Cooling Water System 32-200050 8 Check the element by heating it slowly in water. Check at which temperatures the element starts opening and is fully open. The correct values can be found on the thermostatic element or in chapter 01.; the lower value for the water temperature is the opening temperature, the higher for the fully open valve.
  • Page 311 32-200050 Cooling Water System 19.4.3 HT thermostatic valve The HT thermostatic valve is integrated in the pump cover at the free end of the engine. It is equipped with positive three-way valve action in which the water is positively made to flow in the direction required.
  • Page 312 Cooling Water System 32-200050 The HT thermostatic valve is provided with four elements (in-line engine) and six elements (V-engine). Since flow is diverted either to by-pass or heat exchanger, failure of an element would cause no change in pressure drop. The contents of the elements has an almost infinite force when heated and is positively sealed.
  • Page 313 32-200050 Cooling Water System 4 Check the element by heating it slowly in water. Check at which temperatures the element starts opening and is fully open. The correct values can be found on the thermostatic element or in chapter 01.; the lower value for the water tem- perature is the opening temperature, the higher for the fully open valve.
  • Page 314 Cooling Water System 32-200050 19 - 14 WÄRTSILÄ 32...

  • Page 315: Exhaust System

    32-200045 Exhaust System 20. Exhaust System 20.1 Exhaust manifold 20.1.1 General description The exhaust manifold is fitted between the cylinder head and the Data and dimension Multiduct turbocharger. The manifold consists of the multiducts (3) and the Material: Nodular cast iron exhaust pipes (2) with expansion bellows (1).
  • Page 316 Exhaust System 32-200045 The complete exhaust system is enclosed by an insulation box built up of sandwich steel sheet. Caution! The surface of the insulation box is hot. The exhaust gas temperatures can be checked after each exhaust valve. Sensors for remote measuring of the temperatures after each exhaust valves as well as before and after the turbocharger are mounted.
  • Page 317 32-200202-01 Starting Air System 21. Starting Air System 21.1 Description The engine is started with compressed air of max. 30 bar. Minimum pressure required is 15 bar. The pressure before the main starting valve (4) is indicated on the Local Display Unit (LDU) (1). The inlet air pipe from the starting air receiver is provided with a non-return valve (2) and a drain valve (3) before the main starting valve (4).
  • Page 318 Starting Air System 32-200202-01 As a precaution the engine cannot be started when the turning gear is engaged. Starting air to the distributor is led through a blocking valve (9), mechanically blocked when the turning gear is engaged, thus preventing start. The starting air system is equipped with the safety valve (19), which protect the system and the components in possible fault situations.
  • Page 319 32-200202-01 Starting Air System 21.2.2 Maintenance 1 Remove the main starting valve from the engine. 2 Remove the hexagon socket head screws and remove the pilot valve assembly. 3 Remove the pilot valve piston (22). 4 Clean the pilot valve of any dirt which may block the small air passages and holes.
  • Page 320 Starting Air System 32-200202-01 21.3.2 Maintenance Normally, the starting air distributor does not need maintenance. If it has to be opened for control and cleaning, remove the complete distributor from the engine. Certain pistons can be checked in situ. 1 Remove the end plate (11). Loosen all pipes from the distributor.
  • Page 321 32-200202-01 Starting Air System Caution! Do the testing with control air pipes and starting air pipe disconnected, otherwise the engine may start. 21.4 Starting valve 21.4.1 Description The valve consists of a valve spindle (34) with a spring-loaded operating piston (33) mounted in a separate housing. Starting valve 30.

  • Page 322: Pneumatic System

    Starting Air System 32-200202-01 8 Check that the O-ring (35) of the valve housing are in- tact. Lubricate with oil. 9 Check that the steel sealing (36) is intact and in position, when mounting the valve into the cylinder head. 10 Tighten the valve to torque stated in chapter 07.
  • Page 323 32-200202-01 Starting Air System The push button of the solenoid valve can be used as a local mechanical stop. Note! When the engine is running, the air supply to the engine must always be open. Pneumatic system 2. Non return valve 3.
  • Page 324 Starting Air System 32-200202-01 21.6.3 Maintenance of pneumatic components Solenoid valve (43 and 44, Fig 21-4). In case of disturbance in the electric function of the valve, test the valve by pushing the button (1), see Fig 21-5. Should there be a mechanical malfunc- tion, open the valve using a special tool.
  • Page 325 32-200202-01 Starting Air System 21.7 Slow turning device As additional equipment the engine can be provided with a system for slow rotation of the engine before starting, with intention to protect the engine if there is water, oil or fuel in a cylinder, at remote starting.
  • Page 326 Starting Air System 32-200202-01 a pressure regulator (22), non-return valve (48), slow turning valve (21) and a throttle valve (49). At remote starting the slow turning valve (21), which is control- led by the solenoid valve (47), is activated for a time necessary to rotate the engine two revolutions.
  • Page 327 32-200636-01 Control Mechanism 22. Control Mechanism 22.1 Description During normal operation the engine speed is controlled by a governor (1) which regulates the injected fuel quantity to corre- spond with the load and engine speed. The regulation movement is transferred to the control shaft (10) through a adjustable link rod (2).

  • Page 328: Check And Adjustment

    Control Mechanism 32-200636-01 The system should work with minimal friction. Regularly clean and lubricate racks, bearings (also self-lubricating bearings (8)) and ball joints with lubricating oil. The system should be as free from clearances as possible. Check clearances of all connections. Total clearance may cor- respond to max.
  • Page 329 32-200636-01 Control Mechanism Control mechanism 1. Governor VIEW B 2. Adjustable link rod 3. Lever for governor 4. Screw 5. Spring 6. Lever for injection pump 7. Spring 8. Bearing housing 9. Lever VIEW A 10. Control shaft 11. Load limiter 12.
  • Page 330 Control Mechanism 32-200636-01 22.3.3 Electro-pneumatic overspeed trip device 22.3.3.1 Maintenance For maintenance schedule, see chapter 04. Removal 1 Remove the valve from the injection pump. 2 Remove the piston (2) by tapping the cylinder (3) against a piece of wood. If the piston is stuck, press it out by connecting a grease gun with a suitable adapter to the air supply of the cylinder.

  • Page 331: Speed Governor

    32-200636-01 Control Mechanism 22.4 Speed governor 22.4.1 General The engine can be equipped with various governor alternatives Data and dimensions depending on the kind of application. Concerning the governor Governor: itself, see the attached governor instruction book. Mechanical-hydraulic type Weight: ~ 65 kg 22.4.2 Hydraulic governor drive The governor is driven by a separate drive unit, which, in turn,...
  • Page 332 Control Mechanism 32-200636-01 2 Turn the governor terminal shaft to the stop position, see Fig 22-3 (in clockwise direction seen from the driving end). 3 Mount the terminal shaft lever (3) as follows, see Fig 22-3. Mount the governor electrical- and pipe connections. 4 Lock the fastening screw and mark the position of the terminal shaft lever with a mark on the shaft corresponding to that of the lever.
  • Page 333 32-200636-01 Control Mechanism 22.5 Electro-pneumatic overspeed trip device 22.5.1 Description (Fig 22-2) The overspeed trip device is electronically controlled. Air of max. 30 bar is used as operating medium. The tripping speed is 15 % above the nominal speed. The three-way solenoid valve (44), Fig 21-4, gets the stop signal for overspeed from the engine automation system.
  • Page 334 Control Mechanism 32-200636-01 Caution! Do not increase the engine speed above the 920 RPM in any circumstances. The tripping speed should be 15 % above the nominal speed, see chapter 06., section 06.1. Caution! Special attention should be paid to the testing of tripping speed as an inadequate carefulness may result in a disastrous overspeeding of the engine.
  • Page 335 32-200115/II Instrumentation and Automation 23. Instrumentation and Automation 23.1 General All engines are equipped with the Wärtsilä Engine Control Sys- tem - WECS 2000. WECS is used for monitoring and control of the engine. It is developed for use on the diesel engines and designed for the harsh environment of the engine.
  • Page 336 Instrumentation and Automation 32-200115/II WECS cabinet 1. Local Display Unit 2. Main Control Unit 3. Relay Module 4. Local Control Panel 5. Connectors 6. Isolation relays 7. Protection diodes 8. Fuses 9. Filters 10. Amplifier 11. Converter 12. Converter 13. Terminals ENGINE BLOCK GROUNDING SCREW Fig 23-2...

  • Page 337: Functional Description

    32-200115/II Instrumentation and Automation 23.2 Functional description 23.2.1 General In this chapter the functional tasks of the WECS are described. Speed measurement is separated from other measuring systems because of its special character. Safety task includes several functions like alarms, timings, start/shutdown control and fuel limiting.
  • Page 338 Instrumentation and Automation 32-200115/II 23.2.3.1 Starting There are some important properties to be noticed in the start system of the WECS: · Start conditions are all configurable so they may vary de- pending on the installation, · The engine will not start, if either local or remote reset button isn’t pressed after shutdown.
  • Page 339 32-200115/II Instrumentation and Automation The required safety shutdowns depend on the type of installa- tion. Shutdown conditions and limits are specified in the instal- lation specific documentation. Shutdown backup system Some shutdown functions of the WECS are backed up in the Relay Module, which is an independent hardwired system.
  • Page 340 Instrumentation and Automation 32-200115/II 23.2.4.2 Sensors for monitoring and alarm The following standard set of sensors for monitoring, alarm and safety are mounted on the engine. Code Name Type LS103A Fuel oil leakage, injection pipe LS106A Fuel oil leakage, clean fuel LS108A Fuel oil leakage, dirty fuel flywheel end PT101...

  • Page 341: Functional Testing

    32-200115/II Instrumentation and Automation Even if the above mentioned sensors are considered as standard the amount and type of sensors can in special cases vary, depend- ing on the needs for various installations. The actual set of sensors and other electrical equipment mounted on the engine, as well as alarm, load reduction and shutdown set points, can be found in the installation specific documentation.
  • Page 342 Instrumentation and Automation 32-200115/II 23.3.1.2 Testing of the overspeed trip by using a signal generator 1 Connect the signal generator (848113) to both speed sensors one at a time. The signal generator is connected to the pins signal and gnd of the speed sensor. See the Fig 23-26 for connec- tions.
  • Page 343 32-200115/II Instrumentation and Automation Table 23-2 Frequency corresponding to speed No planetary gear Planetary gear 750 rpm (nominal speed) 300 Hz 263 Hz 863 rpm (15% overspeed 345 Hz 302 Hz limit, DCU/SMU) 885 rpm (18% overspeed 354 Hz 310 Hz limit, RM) 23.3.2 Testing of pressure transducers 23.3.2.1 Pressure transducers...
  • Page 344 Instrumentation and Automation 32-200115/II 4 Adjust calibrator settings. 5 Read the transducers measuring values at least at two points (e.g. the lowest and the highest points of the entire range) and check with the transducers specifications. 6 Adjust or replace the transducers if necessary. 7 Open the valve when the transducers is checked.
  • Page 345 32-200115/II Instrumentation and Automation 3 Check the switch by observing at which pressure the mi- cro switch breaks. Correct pressure is stated in the engine specifications and printed on the switch itself. 4 Adjust or replace the switch if necessary. 5 In case of erroneous function also check connection and wiring.
  • Page 346 Instrumentation and Automation 32-200115/II 23.4 Instrumentation The local control instrumentation is placed on the WECS cabinet and consists of: · Local start button, (green) · Local stop button, (red) · Local reset button / shutdown indication, (blue) · Local / remote start mode selector (start blocking for local / remote operation) ·...
  • Page 347 32-200115/II Instrumentation and Automation 23.4.0.1 Local Display Unit The Local Display Unit (LDU) replaces the traditional pressure gauge panel, the thermometers and other instruments. The operator is able to give all necessary commands with the buttons existing on the LDU frame. The LDU reads information from the MCU using MODBUS.
  • Page 348 Instrumentation and Automation 32-200115/II · stop/shutdown override information (in the lower right cor- ner of the page) THE HISTORY PAGE The history page shows the latest events of the engine, e.g. engine being started, alarms, shutdowns, etc., with a short description. The description includes time of event, type of event, sensor code and sensor description.
  • Page 349 32-200115/II Instrumentation and Automation Control buttons of the LDU WÄRTSILÄ Main Page MAIN Cyl. HELP ENTER -+80 HISTORY Engine speed Fuel rack pos. 12 rpm DOWN - S A Mode : Mode : EMERGENCY EMERGENCY SHIFT Fig 23-6 402312200111 THE KEY BUTTONS The MAIN key takes you to the main page.
  • Page 350 Instrumentation and Automation 32-200115/II 23.4.1 WEnCoM-functions The WEnCoM is divided into two parts: the safety functions included in the WECS and the trend diagrams implemented in the external system. The external system in this meaning is any control, alarm or monitoring system connected to the WECS. The temperature measuring of the cylinder liners, main bearings and the exhaust gas valves, the checking against alarm power reduc- tion and shutdown levels and the needed mathematical opera-...
  • Page 351 32-200115/II Instrumentation and Automation 23.4.1.2 Main bearings The temperature of the main bearing is monitored with the sensor in direct contact with the bearing shell, see Fig 23-8. Alarm, power reduction or shutdown is generated if the values exceed specified limits.
  • Page 352 Instrumentation and Automation 32-200115/II Exhaust gas temperature sensor Fig 23-9 080209C9503 The following measured and calculated values are generated for each cylinder as separate data and are recommended to be used in the external system for trend diagrams: · Exhaust gas valve 1 temperature, ·...

  • Page 353: Main Control Unit

    32-200115/II Instrumentation and Automation 23.5 Hardware 23.5.1 General This section covers the whole range of WECS hardware units, summarizing their technical and physical properties. Enclosure and frame characteristics like dimensions are also described. Most PCB’s are illustrated with a layout figure and a block diagram including I/O description.
  • Page 354 Instrumentation and Automation 32-200115/II 23.5.2.1 Frame The aluminum Frame provides a compact housing for the inter- connection of the MCU boards and cable ground terminations. The MCU Frame has provision for an optional Interface Board. 23.5.2.2 Mother Board The DMB50 Mother Board is mainly a busboard having no electrical functions of its own.
  • Page 355 32-200115/II Instrumentation and Automation 23.5.2.3 DC/DC Converter The DPS50 DC/DC Converter is a multifunction switcher power supply board for the MCU. It carries four independent supplies and circuits for control and BIT purposes. DPS50 DC/DC Converter 1 2 3 4 ERROR FULL +18V...
  • Page 356 Instrumentation and Automation 32-200115/II Block diagram of the DC/DC Converter Isolated Power On/Off primary switcher +DC IN -DC IN +12V 0.6A Control logic EEPROM Step-up switcher On/Off +18V 0.4A control ² C BUS SHUTDOWN Step-down switcher On/Off +5V 1.2A RESET control Inverting switcher On/Off...
  • Page 357 32-200115/II Instrumentation and Automation 23.5.2.4 Processor Board The Processor Board coordinates with the MCU software all the functions of the individual MCU Boards. It also provides memory for storage of program code, parameter files and system database. The functional blocks of the Processor Board are shown in Fig 23-15. Layout of the Processor Board RESET RESET...
  • Page 358 Instrumentation and Automation 32-200115/II 23.5.2.5 Memory Unit The DMM50 Memory Unit enables the use of removable PC Cards for program and configuration upgrading. Memory Unit layout DMM 50 STATUS DMM 50 Fig 23-16 080302Y9503 LED indicators The PC Card drives A and B have both a LED for indicating their activity.
  • Page 359 32-200115/II Instrumentation and Automation 23.5.2.6 LAN Board The LAN Board provides the MCU with additional serial ports. It is also accommodated with special modules for linking the MCU to CAN and RS-485 networks, like MODBUS. LAN Board Layout DML 50 DML 50 Fig 23-17 080302X9516...
  • Page 360 Instrumentation and Automation 32-200115/II The LAN Board front panel LED’s: · The green LED flashes approximately once every 10 seconds. (If the interval is longer, the program has excess load), · The red LED should be OFF. If the LED is ON, reset the MCU.
  • Page 361 32-200115/II Instrumentation and Automation Block Diagram of the Interface Board +12 VDC 8 bit I/O PicoBus Buffer and Filter control Analog I/O Filter Control Analog I/O Filter Electronics: DMB50 Memories Controllers Analog I/O A/DC Filter etc. Analog I/O Filter Fig 23-20 030302C9525 WÄRTSILÄ...

  • Page 362: Distribution Unit

    Instrumentation and Automation 32-200115/II 23.5.3 Distribution Unit The Distribution Unit can either be a Sensor Multiplexer Unit (SMU) including an SMU Board or a Distributed Control Unit (DCU) including both an SMU Board and a DCU Board. SMU and DCU VAISALA POWER VAISALA...
  • Page 363 32-200115/II Instrumentation and Automation 23.5.3.1 SMU board The SMU Board is rather flexible in application and offers a variety of possible configurations. Various types of sensors can be connected to it: · 4-20 mA current loop · current transducer · voltage transducer ·...
  • Page 364 Instrumentation and Automation 32-200115/II SMU Board block diagram RS-232C Driver/ port Receiver RS-232C Interface RS-485 Driver/ port Receiver RS-485 Board Control 2 freq. Electronics: inputs Memories Controllers A/DC D/AC 8-bit etc. digital DC + Power Supply DC - analog channels Fig 23-23 030304B9525 23-30...
  • Page 365 32-200115/II Instrumentation and Automation 23.5.3.2 DCU Board The DCU is a combination of two processor based boards. The 16-bit processor of the DCU Board acts as a host for the SMU and handles all of the outside communications. There are three com- munication channels available in the unit besides of the SMU serial channel, which is no more visible to the user.
  • Page 366 Instrumentation and Automation 32-200115/II DCU Board block diagram PCMCIA Driver Buffer Control Electronics: RS-232C Interface Memories Controllers RS-485 etc. Board DC + Power Supply DC - Fig 23-25 030304C9525 Operationally the DCU board provides a distributed database over the CAN-bus. A PC Card is used to transfer new application definitions from the associated configuration tool to the DCU system.
  • Page 367 32-200115/II Instrumentation and Automation 23.5.4 Sensors 23.5.4.1 Speed sensors Engine speed sensor The rotation speed of the engine is measured with two touch free inductive PNP-type proximity switches. The sensor is supplied with a 10 - 30 V DC supply voltage (normally 15 V DC in the WECS).
  • Page 368 Instrumentation and Automation 32-200115/II ABB turbocharger speed sensor The turbocharger speed sensor is a magnetic type and it does not require any supply voltage. The sensor is mounted eccentrically in the turbochargers bearing space cover. In a lubricating wheel on the shaft there are six embedded magnets, which are each generating a pulse in the sensor when passing the sensing head.
  • Page 369 32-200115/II Instrumentation and Automation EGT turbocharger speed sensor The speed sensor of the EGT turbocharger functions like the speed sensor of the ABB turbocharger except that it gives either two or six pulses during each revolution of the TC shaft. The metal housing of the sensor has 5/8"...

  • Page 370: Solenoid Valves

    Instrumentation and Automation 32-200115/II 23.5.5 Solenoid valves The solenoid valves used on the engines are 3-way type valves of make E. Seitz. They can, depending on the application, either be normally open or normally closed. The nominal operation voltage is 24 V DC, and the solenoids have a voltage tolerance of -15 % to +10 %.
  • Page 371 32-200115/II Instrumentation and Automation · local stop block, · overspeed shutdown block (backup), · emergency stop block, · WECS watchdog block, · stop/shutdown override block, · shutdown reset block, · short circuit block · stop block, · local start block, ·...
  • Page 372 Instrumentation and Automation 32-200115/II Table 23-5 LED’s of the Relay Module Color LED indication Lube oil shutdown Lube oil pressure switch has caused a shutdown and local hardwired reset button has not yet been pressed Lube oil shutdown yellow Lube oil shutdown is blocked during start/stop/standstill of an engine blocking Optional shutdown Optional shutdown switch has caused a shutdown, i.e.
  • Page 373 32-200115/II Instrumentation and Automation Table 23-7 Power supply LED’s of the Relay Module Color LED indication green U1 voltage (U6 and not stop related functions of the RM) is ON green U2 voltage (MCU and test instruments) is ON green U3 voltage (DCU chain 1) is ON green U4 voltage (DCU chain 2) is ON...
  • Page 374 Instrumentation and Automation 32-200115/II System software modes Self-test SERVICE APPLICATION mode mode Diagnostic utility Fig 23-30 1001A9520 Software structure of the WECS MODBUS MASTER MODBUS CALC INTERNAL SMU MEAS. ALARMS SCALE HOUR WENCOM COUNT CALC SCALE EXTERNAL SMU MEAS. SAFETY ALARMS FAST COMMUNICATIONS...

  • Page 375: Maintenance And Troubleshooting

    32-200115/II Instrumentation and Automation 23.7 Maintenance and Troubleshooting 23.7.1 General This section includes the information concerning controls and indicators needed in maintenance and troubleshooting. The Con- trols and indicators section is divided into paragraphs according to hardware. Because there are no moving parts in this system the mainte- nance procedures are simple nevertheless important to accom- plish.
  • Page 376 Instrumentation and Automation 32-200115/II Power ON/OFF switch DPS50 Power ON/OFF switch Fig 23-32 050302I9503 Position ON: Connects the external power source to the DC/DC Converter. Connects the 12 V system battery to the DC/DC Converter to enable battery charging or powering of the MCU from the battery. Position OFF: Disconnects both the external power source and the 12 V system battery from the DC/DC Converter.
  • Page 377 32-200115/II Instrumentation and Automation Error LED: The LED indicator has two states: ON CONTINUOUSLY - Indicates that power has been switched on 1 to 3 seconds ago but the MCU software has not started yet. The MCU software will turn off the LED once it has started. FLASHING - Indicates that there is an error in the charge process.
  • Page 378 Instrumentation and Automation 32-200115/II Controls and indicators of the MCU Processor LAN Board Board LED's LED's & controls Memory Unit LED's RESET STATUS STATUS RESET Interface Board LED DC/DC Converter STATUS STATUS LED's RESET G7/f1 STATUS G6/f0 RESET CTS0 RTS0 RXD0 ERROR TXD0...
  • Page 379 32-200115/II Instrumentation and Automation Status LED: The operation of the STATUS LED is controlled by the MCU software. Blinking of this LED indicates software operation and watchdog update. The STATUS LED also indicates the operation modes as follows. FLASHING One second intervals: This indicates that the self tests have been completed successfully and that the MCU is running in the APPLICATION mode.
  • Page 380 Instrumentation and Automation 32-200115/II 23.7.3 Distribution Unit 23.7.3.1 SMU There is a LED indicator on the SMU Board as shown in Fig 23-34. Status LED The status LED starts flashing at approximately one second interval when the board is connected to a power supply and the power is switched on.
  • Page 381 32-200115/II Instrumentation and Automation Power LED The POWER LED is continuously ON when the power is ON. Can LED The CAN LED blinking indicates that there is communication on the CAN link. Status LED The STATUS LED blinking indicates that the software is oper- ating.
  • Page 382 Instrumentation and Automation 32-200115/II 23.7.4 Relay Module 23.7.4.1 Indication LED’s The Relay Module has an indication LED for each functional block. The LED’s are shown in Fig 23-36. Their functions are described below: Indication LED’s of the Relay Module LUBE OIL SHUTDOWN STOP RELAY LUBE OIL SHUTDOWN LOCAL START BLOCKING...
  • Page 383 32-200115/II Instrumentation and Automation Local Stop LED Hardwired (normally local) stop button is being pressed; or it has been released less than 60 seconds ago. Overspeed Shutdown LED Overspeed has caused a shutdown and local hardwired reset button has not yet been pressed. The speed is measured with the backup speed pick-up.
  • Page 384 Instrumentation and Automation 32-200115/II Failure Alarm LED Failure signal of the Relay Module is active. In addition either one of the failure indication LED’s should be ON or one of the voltage LED’s should be OFF. Speed Switch 1 LED Speed of the engine is over speed limit 1.
  • Page 385 32-200115/II Instrumentation and Automation 23.7.4.3 Supply voltage LED’s All supply voltages have their own LED. These LED’s are shown in Fig 23-37 and their functions are described below: Power supply LED’s of the Relay Module BACKUP + 12 VDC Fig 23-37 080307U9503 U1 LED U1 voltage (U6 and not stop related functions of the RM) is ON.
  • Page 386 Instrumentation and Automation 32-200115/II 23.8 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 electrical contact surfaces.
  • Page 387 32-200115/II Instrumentation and Automation 23.9 Emergency operation of WECS2000 There are two functions in WECS supporting emergency opera- tion: · The blackout start function is used for automatically starting the engine after a blackout within the specified time delay. · The shutdown override function is used to exclude engine shutdowns during critical operation of the vessel.
  • Page 388 Instrumentation and Automation 32-200115/II Note! If there is an active shutdown or the stop sequence is active the blackout start will fail. Note! If a shutdown has not been reset the blackout start will fail. 23.9.2 Shutdown override OS736 All shutdowns except backup overspeed trip and emer- gency stop can be suppressed by activating the shutdown over- ride input to WECS.
  • Page 389 32-200115/II Instrumentation and Automation 23.9.3 Emergency start Would the electrical system fail the engine can be emergency started by operating the master starting valve CV321 manually. In emergency start the stop lever is used to control the accelera- tion. Note! The start is mechanically blocked, if the stop lever on the engine is in STOP position, or pneumatically blocked, if the turning gear is engaged.
  • Page 390 Instrumentation and Automation 32-200115/II 23.9.5 Overriding WECS or its parts In serious WECS problems the functionality of the system can be reduced into minimum by turning off the MCU. This can be done by pressing the MCU power switch into OFF position. After this action only minimum safety functionality of the Relay Module is available i.e.
  • Page 391 32-200115/II Instrumentation and Automation 23.9.6 Engines equipped with Woodward 721/723 speed governor The electronic speed governor receives a RUN/STOP control signal from WECS. If the shutdown sequence of the RM is active the output will be closed (or open if so configured) and the governor will receive a STOP signal and set the fuel rack to zero position.

  • Page 392: Error Codes

    Instrumentation and Automation 32-200115/II 23.10 Error Codes Whenever a measurement value is missing the data item status is set to OLD_VALUE. If the data item has never been updated, the status is set to DEFAULT_VALUE. In both cases an error code is updated to the data item.
  • Page 393 32-200115/II Instrumentation and Automation 23.11 Equipment nomenclature Main Control Unit MCU DMF50 Frame ....... . . Frame DMB50 Mother Board.
  • Page 394 Instrumentation and Automation 32-200115/II 23-60 WÄRTSILÄ 32...

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