Page 1 Document ID Installation Vasa R22 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.
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.
Page 3 22-9601 Contents, Instructions, Terminology 00. Contents, Instructions, Terminology 00.1 Contents of the Instruction Book This Manual contains data and instructions for operation and maintenance of the engine. Basic general knowledge has not been entered. Consequently, it is assumed that the engine operation and maintenance staff is well informed of the care of diesel engines.
Page 4 Contents, Instructions, Terminology 22-9601 00.3 Terminology The most important terms used in this manual are defined as follows: Operating side. The longitudinal side of the engine where the operating devices are located (start and stop, instrument panel, speed governor). Rear side. The longitudinal side of the engine opposite the oper- ating side.
Page 5 22-9601 Contents, Instructions, Terminology graduation of the flywheel. During a complete working cycle, comprising in a four-stroke engine two crankshaft rotations, the piston reaches TDC twice: a) For the first time when the exhaust stroke of the previous working cycle ends and the suction stroke of the following one begins.
Page 6 Contents, Instructions, Terminology 22-9601 High temperature cooling water circuit (HT-circuit). The cooling water for the engine block, cylinder head and turbocharger. Low temperature cooling water circuit (LT-circuit). The cooling water for the charge air cooler and the lubricating oil cooler. 00 - 4 VASA 22...
Page 7 200145 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 8 Appendix A Risk Reduction 200145 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 Explosion or fire if flammable gas/vapour is leak- ing into the insulation box. Touching of moving parts Warning light when turning device engaged.
Page 9 200145 Risk Reduction Appendix A 00A.1.1.3 Hazards that may be due to different leakages, break- down or improper assembly of component Fuel or gas pipe will burst and spray fuel / gas, • • • • • • • • Leakage of: —...
Page 10 Appendix A Risk Reduction 200145 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 equip- ment, Contact with electricity during maintenance work if power not •...
Page 11 200147 Welding Precautions Appendix B 00B. Welding Precautions 00B.1 Precautions General 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.1.1 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 12 Appendix B Welding Precautions 200147 Sparkles can also be a problem after they have cooled down, i.e. causing short circuits, sealing problems etc. 00B.2 Precaution checklists 00B.2.1 Checklists General The checklists (preferable glued to a plastic plate) in this chapter should be put into the engines cabinet for respective system type.
Page 13 200147 Welding Precautions Appendix B 00B.2.5 WECS 7000/8000 checklist The following precautions must be paid attention to before welding in the vicinity of a WECS 7000 or 8000 control system: • Deactive the system by disconnecting all external connectors (X1...X6). •...
Page 14 Appendix B Welding Precautions 200147 00 - 4...
Page 15 22-9601 Main Data, Operating Data and General Design 01. Main Data, Operating Data and General Design 01.1 Identification The VASA 22 engines have been designed to use different fuels and a large speed range. Engines with the capability to use fuels with a viscosity lower than are designated “HF”...
Page 16 Main Data, Operating Data and General Design 22-9601 Lubricating oil volume in the engine Engine type 4R22 6R22 8R22 8V22 12V22 16V22 4R22/26 6R22/26 8R22/26 Oil volume c. litres Oil volume between max. and min. marks c. litres/mm Anticorrosive oil c. litres Cooling water volume in the engine, c.
Page 17 22-9601 Main Data, Operating Data and General Design Other pressures (bar) Firing pressure See test records Opening pressure of safety valve on lube oil pump 6...8 Visual indicator and elec- tronic transducer for high pressure drop over lube oil fil- ter and fuel filter 1.2...1.8 See section 20.4, 8- and 16-cylinder engines...
Page 18 Main Data, Operating Data and General Design 22-9601 Other pressures (bar) Firing pressure See test records Opening pressure of safety 6...8 valve on lube oil pump Visual indicator and elec- 1.2...1.8 tronic transducer for high pressure drop over lube oil fil- ter and fuel filter See section 20.4, 8-cylinder engines Depending on speed and installation...
Page 19 22-9601 Main Data, Operating Data and General Design The cylinder liners are of wet type and made of special cast iron and honed to an optimal finish. The main bearings are fully interchangeable trimetal or bi- metal which can be removed by lowering the main bearing cap. The crankshaft is forged in one piece and is balanced by counter weights as required.
Page 20 Main Data, Operating Data and General Design 22-9601 The starting system. The air supply into the cylinders is con- trolled by the starting air distributor run by the camshaft. The four-cylinder engine are normally be provided with an air driven starting motor. Cross-section of Wärtsilä...
Page 21 22-9601 Fuel, Lubricating Oil, Cooling Water 02. Fuel, Lubricating Oil, Cooling Water 02.1 Fuel 02.1.1 General The engine is designed to operate on heavy fuel (residual fuel) with a maximum viscosity of 55 cSt/100°C (approx. 730 cSt/50°C, approx. 7200 sec. RI/100°F) and will operate satisfactorily on blended (intermediate) fuels of lower viscosity, as well as on distillate fuel.
Page 22 Fuel, Lubricating Oil, Cooling Water 22-9601 Rated capacity of the centrifuge may be used provided the fuel viscosity is less than 12 cSt at centrifuging temperature. Marine Gas Oil viscosity is normally less than 12 cSt at 15°C. 02.1.2.2 Heating See diagram, Fig 02-1.
Page 23 22-9601 Fuel, Lubricating Oil, Cooling Water Example: Known viscosity 60 cSt at 50°C (K). The following can be read along the dotted line: viscosity at 80°C = 20 cSt, tempera- ture at fuel injection pumps 74-87°C, centrifuging temperature 86°C, minimum storage tank temperature 28°C. Conversion from varies current and obsolete viscosity units to centistokes can be made in the diagram, Fig 02-2.
Page 24 Fuel, Lubricating Oil, Cooling Water 22-9601 02.1.2.3 Viscosity control An automatic viscosity controller, or a viscosimeter, at least, should be installed in order to keep the correct viscosity of the fuel before the fuel enters the engine fuel system. 02.1.3 Maximum limits of fuel characteristics The diesel engine Wärtsilä...
Page 25 22-9601 Fuel, Lubricating Oil, Cooling Water With a density of more than 0.991 g/ml at 15°C, water, in particular and to some extent solid matter can no longer be removed with certainty by a centrifuge. Centrifuging systems that are claimed to be able to clean fuel oils with densities up to 1.010 g/ml at 15°C are available.
Page 26 Fuel, Lubricating Oil, Cooling Water 22-9601 Ignition quality is not defined, nor limited, in marine residual fuel standards. The same applies to ISO-F-DMC marine distillate fuel. The ignition quality of these fuels cannot — for a variety of reasons — be determined by methods used for pure distillates, i.e.
Page 27 22-9601 Fuel, Lubricating Oil, Cooling Water Nomogram for deriving CII and CCAI VISCOSITY DENSITY CCAI cSt (mm 2 /s) (kg/m 3 at 15°C) 50°C at 100°C 1000 1020 1040 1000 Fig 02-3 2202579426 What do the values mean? Straight run residues show CCAI values in the 770 to 840 range and are very good igniters.
Page 28 Fuel, Lubricating Oil, Cooling Water 22-9601 To avoid difficulties with poor ignition quality fuels the following should be noted: • sufficient preheating of the engine at start, • proper function of inverse cooling system, • proper function of injection system, in particular injection nozzle condition.
Page 29 22-9601 Fuel, Lubricating Oil, Cooling Water at no load for more than 3 minutes before loading, as well as idling more than 3 minutes before stopping is unnecessary and should be avoided. 02.1.6 General advice To avoid stability and incompatibility problems (precipitation of heavy components in the fuel), avoid if possible blending of fuels from different bunker stations, unless the fuels are known to be compatible.
Page 30 Fuel, Lubricating Oil, Cooling Water 22-9601 02.2 Lubricating oil 02.2.1 System oil characteristics Viscosity. Viscosity class SAE 30 or SAE 40. SAE 40 is preferred. Alkalinity. The required lubricating oil alkalinity is tied to the fuel specified for the engine, which is shown in the table below. Fuel standards and lubricating oil requirements Category Fuel standard...
Page 31 22-9601 Fuel, Lubricating Oil, Cooling Water 02.2.2 Lubricating oil qualities Approved system oils - all fuel categories - for Wärtsilä Vasa 22, 22/26 engines Designation (brand name) of Fuel Lubricating oil supplier Visc. lubricating oil supplier categ. Adnoc-Fod Marine Engine Oil X324 SAE 30 A, B, C Marine Engine Oil X424...
Page 32 Fuel, Lubricating Oil, Cooling Water 22-9601 Approved system oils - all fuel categories - for Wärtsilä Vasa 22, 22/26 engines Designation (brand name) of Fuel Lubricating oil supplier Visc. lubricating oil supplier categ. Elf Lub Marine Aurelia XT 3055 SAE 30 A, B, C Aurelia XT 4055 SAE 40...
Page 33 22-9601 Fuel, Lubricating Oil, Cooling Water Approved system oils - all fuel categories - for Wärtsilä Vasa 22, 22/26 engines Designation (brand name) of Fuel Lubricating oil supplier Visc. lubricating oil supplier categ. Teboil Teboil Ward S 30 T SAE 30 SAE 30 A, B, C Teboil Ward S 30 T SAE 40...
Page 34 Fuel, Lubricating Oil, Cooling Water 22-9601 During the first year of operation it is advisable to take sam- ples of the lubricating oil after about 250, 500 and 1000 oper- ating hours. The sample should be sent to the oil supplier for analysis.
Page 35 22-9601 Fuel, Lubricating Oil, Cooling Water Fast and great changes may indicate abnormal operation of the engine or of a system. Compensate for oil consumption by adding maximum 10 % new oil at a time. Adding larger quantities can disturb the balance of the used oil causing, for example, precipitation of insolubles.
Page 36 Fuel, Lubricating Oil, Cooling Water 22-9601 Caution! If turbine oil is used in the governor, take care not to mix it with engine lubricating oil. Only a small quantity may cause heavy foaming. 02.2.5 Lubricating oils for ABB-VTR turbochargers with ball and roller bearings See the Instruction Book for the turbocharger, attached.
Page 37 22-9601 Fuel, Lubricating Oil, Cooling Water Mineral oils: oil change interval 500 h Viscosity (cSt) Viscosity Manufacturer Brand name Index (VI) 40°C 100°C Indian Oil Corp. Servoprime 68 64-72 8.15 Servoprime 76 74-80 9.13 Servopress 68 64-72 Servosystem HLP 68 64-72 Kuwait Petroleum Van Gogh 68...
Page 38 Fuel, Lubricating Oil, Cooling Water 22-9601 Caution! The pump should be regreased after one hour of operation when the pump is new or has been overhauled. The following grease is recommended: Klüber Unisilikon L50/2. The pump is to be regreased only under running conditions! 02.2.7 Lubricating grease for the electric driven prelubricating pump For further information about the pump see chapter 18.
Page 39 22-9601 Fuel, Lubricating Oil, Cooling Water 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 have a hardness below 10 d H, a chloride content of less than 80 mg/l and a pH value above 7.
Page 40 Fuel, Lubricating Oil, Cooling Water 22-9601 02.3.3 Treatment When changing the additive or when entering 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. If, against our recommendations, an emulsion oil has been used, the complete system must be absolutely cleaned from oil and greasy deposits.
Page 41 22-9601 Fuel, Lubricating Oil, Cooling Water Approved cooling water treatment products Supplier Product designation Drew Ameroid Marine Division Maxicard Ashland Chemical Company DEWT-NC powder One Drew Plaza Liquidewt Boonton, NJ 07005, USA Vecom CWT Diesel QC-2 Grace Dearborn Ltd. Dearborn 547 Widnes, Chesire W A8 8UD United Kingdom Houseman Ltd...
Page 42 Fuel, Lubricating Oil, Cooling Water 22-9601 02 - 22 VASA 22...
Page 43 200111 Environmental Hazards Appendix 02A 02A. Environmental Hazards 02A.1 General Fuel oils, lubricating oils and cooling water additives are environmen- tally 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 and...
Page 44 Appendix 02A Environmental Hazards 200111 02A.2.2 Personal protection equipment • Respiratory organs protection: Oil mist: Use respirator, com- bined particle and gas filter. Evaporated fumes (hydrogen sul- phide, etc.): Use respirator, inorganic gas filter. • Hands protection: Strong, heat and hydrocarbon resistant gloves (nitrile rubber for example).
Page 45 200111 Environmental Hazards Appendix 02A 02A.3.1 Handling • Ensure adequate ventilation if there is a risk of release of vapours, mists or aerosols. Do not breathe vapours, fumes or mist. • Keep away from flammable materials and oxidants. • Keep away from food and drinks. Do not eat, drink or smoke while handling.
Page 46 Appendix 02A Environmental Hazards 200111 Note! Complete safety data sheets for the specific products used at your installation should be available from the lubricating oil manufac- turer or your local dealer. 02A.4 Cooling water additives, nitrite based The products are toxic if swallowed. Concentrated product may cause serious toxic symptoms, pain giddiness and headache.
Page 47 200111 Environmental Hazards Appendix 02A • Eye contact: Rinse immediately with plenty of clean water and seek medical advice. If possible, keep rinsing until eye specialist has been reached. • Ingestion: Rinse mouth with water. Drink milk, fruit juice or water.
Page 48 Appendix 02A Environmental Hazards 200111 Use for example the ready made "Oil Analyse Application" form, see Instruction Manual attachments . Observe personal safety precautions when taking and handling fuel oil and lubricating oil samples. Avoid breathing oil fumes and mist, use respirator if necessary.
Page 49 22-9632 Start, Stop and Operation 03. Start, Stop and Operation 03.1 Start 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 50 Start, Stop and Operation 22-9632 6 Check that the stop lever is in work position, open the starting air valve, shut the blow-off valve when there is no more condensate. 7 Push the start button until the engine starts firing. If the engine does not start after 2 - 3 seconds the reason should be checked.
Page 51 22-9632 Start, Stop and Operation 10 seconds. If this attempt also fails, the program relay will connect the alarm circuit. On engines equipped with pneumatic starting motors the period between the starting attempts should be long enough to guarantee that the flywheel has stopped. 4 When the engine has reached a predetermined speed, an auxiliary relay energized by the remote tacho transmitter cuts off the starting circuit, and the starting air solenoid valve...
Page 52 Start, Stop and Operation 22-9632 03.2.3 Automatic stop When the shut-down solenoid is energized from the automatic shut-down system due to some disturbance, the engine will stop as in remote stop. Before this an alarm device will normally initiate an alarm signal indicating the reason for the shut-down. When the engine stops because of overspeed, the mechanical overspeed trip device and the electro-pneumatic overspeed trip device may have tripped.
Page 53 22-9632 Start, Stop and Operation it is favourable to have a charge air temperature as high as possible. 2 Check the indicator for pressure drop over fuel filters. When the pressure drop over the filters increases, the pressure in the system decreases. Very low pressure (less than 0.5 bar) reduces the engine performance and may cause uneven load distribution between the cylinders (risk of breakdown!).
Page 54 Start, Stop and Operation 22-9632 3 Check the indicator for pressure drop over the lubricat- ing oil filters. Too large pressure drop indicates clogged filter cartridges, which results in reduced oil filtration when the by-pass valve is open. Reduced oil filtration results in in- creased wear.
Page 55 22-9632 Start, Stop and Operation 2 Check the cylinder pressures. At the same time, note the load of the engine (the position of the load indicator or the injection pump racks offers an accurate measure of the engine load). Note! Measurement of cylinder pressures without simultaneous no- tation of the engine load is practically worthless.
Page 56 Start, Stop and Operation 22-9632 4 Operation at loads below 20 % of rated output should be limited to maximum 100 hours continuously when operating on heavy fuel by loading the engine above 70 % of rated load for one hour before continuing the low load operation or shut- ting down the engine.
Page 57 22-9632 Start, Stop and Operation 2 The speed governor control lever being in maximum position and the stop lever in work position, release the over- speed trip manually. Check that all injection pump racks move to a value less than 4 mm. 3 If the injection pumps, camshaft or its driving mechan- ism have been touched, check the injection timing.
Page 58 Start, Stop and Operation 22-9632 4 After overhauling, the following instructions are espe- cially important: • check pressure and temperature gauges, • check the automatic alarm and stop devices, • check the pressure drop over the fuel filter and lubricating oil filter, •...
Page 59 22-9632 Start, Stop and Operation Running-in programme Engine After piston overhaul 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 03-2 2203519426 VASA 22...
Page 60 Start, Stop and Operation 22-9632 03 - 12 VASA 22...
Page 61 22-9845/III Maintenance Schedule 04. Maintenance Schedule 04.1 General The maintenance necessary for the engine depends on the oper- ating conditions in the main. The periods stated in this schedule are guidance values, only, but must not be exceeded during the guarantee period.
Page 62 Maintenance Schedule 22-9845/III 04.1.1 How to select application and fuel quality There are two different types of applications defined: • Average load is above 75 % of nominal engine output. • Average load is below 75 % of nominal engine output. Four types of fuel are defined: •...
Page 63 22-9845/III Maintenance Schedule 04.4 Interval: 50 operating hours Air cooler(s) 15.2.1 Check draining of air cooler(s) Check that the draining pipe is open, check if any leakage. 03.3.1 Cooling system Check water level in cooling system Check the water level in the expansion tank(s) and/or the static pressure in the engine cooling circuits.
Page 64 Maintenance Schedule 22-9845/III 04.5 Interval: 250 operating hours Centrifugal filter 18.9 Clean centrifugal filter(s) Clean more often if necessary. Remember to open the 03.3.2 valve before the filter after cleaning. Control mechanism 22.2 Maintenance of control mechanism Check for free movement, clean and lubricate. Fuel Overhaul interval HFO 2...
Page 65 22-9845/III Maintenance Schedule 04.8 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 23.1.4 Functional check of automation Check function of the alarm and automatic stop devices. 01.3, 01.4 Electrical fuel feed pump Lubricate electrical fuel feed pump...
Page 66 Maintenance Schedule 22-9845/III 04.9 Interval: Interval: 2000 operating hours Charge air cooler(s) 15.2 Check water side 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. Injection valves 16.5 Inspect injection valves...
Page 67 22-9845/III Maintenance Schedule 04.10 Interval: 4000 operating hours Air cooler(s) 15.2 Clean the charge air cooler(s) Clean and pressure test. Look carefully for corrosion. Every second time the ultra sonic wash is recommended. Camshaft 14.2 Inspect contact faces of camshaft Check the contact faces of the cams and tappet rollers.
Page 68 Maintenance Schedule 22-9845/III 04.11 Interval: 8000 operating hours Balancing shaft gear 11.3 Inspect balancing shaft gear and bearing bushes 4R22, 4R22/26 Replace parts if necessary. 11.4 Camshaft driving gear Inspect camshaft driving gear Replace parts if necessary. Governor driving gear Inspect governor driving gear 22.4 Replace parts if necessary.
Page 69 22-9845/III Maintenance Schedule Overhaul interval Fuel Average load > 75 % Average load < 75 % HFO 2 8 000 10 000 HFO 1 12 000 14 000 16 000 20 000 04.12 Interval: See table above Connecting rods Inspect big end bearing 11.2 Replace big end bearing if necessary.
Page 70 Maintenance Schedule 22-9845/III 04.13 Interval: 16000 operating hours Centrifugal filter for lubricating oil Basic service Fuel feed pump 17.5 Inspect fuel feed pump. General overhaul and replace gaskets. 06.2 Governor drive 22.4 Check the governor drive bearing Check governor driving shaft bearing clearance in situ. 06.2 Turning device 03.1...
Page 71 22-9845/III Maintenance Schedule 04.16 Interval: 24000 operating hours Balancing shaft 11.3 Inspect balancing shaft bearing 4R22, 4R22/26 Take one bush out for inspection. If in bad condition check the other too. Replace if necessary. Coupling Check the flexible coupling Flexible coupling Dismantle and check flexible coupling acc.
Page 72 Maintenance Schedule 22-9845/III 04 - 12 MD, HF...
Page 73 22-200222 Maintenance Tools 05.Maintenance Tools 05.1 General Maintenance of a engine requires some special tools developed 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 74 Maintenance Tools 22-200222 Main Bearings Code Description Drawing No. 803001 Bit, hexagon socket screw 22 with 1" square drive 4V80L0001 822001 Torque multipler X - 4 4V82L0001 832003 Lifting tool for main bearing shell 1V83C0119 851001 Turning tool for main bearing shell 4V85B0007 851002 Turning tool for main bearing shell...
Page 75 22-200222 Maintenance Tools Cylinder Liner Code Description Drawing No. 836001 Extracting & lifting tool for cylinder liner 841009 Honing tool for cylinder liner 1V-T22088 841010 Drilling machine for honing tool 4V84B0136 842025 Honing stones 25x25x250, coarse, including holder 842026 Honing stones 25x25x250, fine, including holder VASA 22 05 - 3...
Page 76 Maintenance Tools 22-200222 Connecting Rod, V-Engine Code Description Drawing No. 803011 Stud remover M30x2 4V80G0018 807011 Long Socket wrench 27x12,5L DIN3124 835003 Protecting sleeve for connecting rod, upper 2V83F0071 835004 Protecting sleeve for connecting rod, lower 3V83F0068 860000 High pressure pump (1000 bar) 4V86A0038 861025 Pin for tightening of nuts...
Page 77 22-200222 Maintenance Tools Connecting Rod, L- Engine Code Description Drawing No. 803011 Stud remover M30x2 4V80D0018 807011 Long socket wrench 27x12.5L DIN3124 860000 High pressure pump (1000 bar) 4V86A0038 861025 Pin for tightening of nuts 4V86B0011 861027 Hydraulic cylinder 3V86B0060 861032 Distance piece 3V86B0071...
Page 78 Maintenance Tools 22-200222 Piston Code Description Drawing No. 832002 Lifting tool 3V83C0064 832008 Mouting tool when using antipolishing ring 3V74L0037 836007 Dismantling tool for antipolishing ring 3V10T1366 843002 Clamp tool for piston rings 2V84D0010 843003 Piston ring pliers 4V84L0018 843004 Pliers for retaining rings 4V84L0016 843005...
Page 79 22-200222 Maintenance Tools Cylinder Head Code Description Drawing No. 808001 T-wrench for indicator valve 4V80K0006 832005 Lifting tool for cylinder head 3V83C0082 832006 Service trestle for cylinder head 1V-T20524 834002 Fitting tool for exhaust valve seat ring 837016 Extractor for push rod protection pipe 3V83H0097 837019 Extractor for inlet valve seat ring...
Page 80 Maintenance Tools 22-200222 Injection Equipment Code Description Drawing 806005 Special socket wrench 19 for flange nuts 3V80G0022 806009 Crowfoot wrench 27 for injection pipes 4V80L0002 806010 Adapter A10x12.5 DIN 3123 807004 Long socket wrench 22x12.5L for connecting pie DIN 3124 807010 Long socket wrench 30x12.5L for nozzle nut DIN 3124...
Page 81 22-200222 Maintenance Tools Turbocharger Code Description Drawing 865001 Maintance tools VASA 22* 865002 Blanking tool for turbocharger* *) State engine number, turbocharger type and serial number/HT number when ordering VASA 22 05 - 9...
Page 82 Maintenance Tools 22-200222 Tightening Tools Code Description Drawing 806006 Special key for hexagon socket screw 8 4V80G0021 808002 Speed brace B12.5x500 with 1/2" square drive DIN3122 808003 Ratcheat handle 12.5x300 with 1/2" square drive DIN3122 808005 Extension bar B12.5x125 with 1/2" square drive DIN3123 820008 Torgue wrench 20-100 Nm...
Page 83 22-200222 Maintenance Tools Miscellaneous Tools Code Descriptions Drawing No. 483001 Turning tool 3V48D0038 803012 Wrench combinatin for dismantling elctric motor 4V80D0016 809001 Tool locker 4V80L0003 832004 Eye bolt for charge air cooler insert DIN 580 834001 Mounting & removing tool for camchaft bearing buch 3V83L0039 837012 Extractor for gear wheels...
Page 84 Maintenance Tools 22-200222 Additional Tools for Engines with Shield Bearing Code Description DrawingNo. 820010 Change key for torque wrench 24 mm 4V92K0208 851004 Turning tool for shield bearing shell 4V85B0010 861022 Distance sleeve fo shield bearing 4v86B0065 861030 Hydraulic cylinder for shield bearing 861141 Pin for tightening of nuts 4V86B0034...
Page 85 22-200222 Maintenance Tools Additional Tool for 4R22 and 8V22 Code Description DrawingNo. 332001 Guiding pin 4V33C0028 803013 Bit, hexagon socket screw 14 with 3/4" square drive 4V80L0001 807912 Socket wrench for balancing shafts 30X20 DIN 3124 808008 Extension lever for balancing shaft 3/4" 4V80K0012 VASA 22 05 - 13...
Page 86 Maintenance Tools 22-200222 High Pressure Pump Code Description DrawingNo. 860000 High pressure pump (1000 bar) 4V86A0038 860150 Manometer 4V51L0085 861016 Quick coupling, female 4V86A0035 861017 Quick coupling, male 4V86A0040 861035 Flexible hose 600 mm 4V86A0013 861036 Flexible hose 3000 mm 4V86A0030 861166 Fexible hose 600 mm, including quick couplings...
Page 87 22-9601 Adjustments, Clearances and Wear limits 06/II 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 Inlet valve opens Exhaust valve closes Exhaust valve opens Inlet valve closes...
Page 88 06/II Adjustments, Clearances and Wear limits 22-9601 06.2 Clearances and wear limits (at 20°C) Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) Main bearing clearance 0.180-0.268 (also flywheel bearing) Journal diameter 200.000 199.975 Journal circularity 0.015 Journal taper 0.015/100...
Page 89 22-9601 Adjustments, Clearances and Wear limits 06/II Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) Piston ring gap (clamped ø220) Compression rings 0.65-0.95 2.05 Oil scraper rings 0.80-1.05 Piston ring height: Compression ring 1 3.99 3.978 0.120-0.152...
Page 90 06/II Adjustments, Clearances and Wear limits 22-9601 Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) 14 Valve tappet, diameter 54.97 54.94 Guide diameter 55.03 55.00 Diameter clearance 0.03-0.09 0.15 Tappet roller bore diameter 30.021 30.000 Bush diameter, outer 29.960...
Page 91 22-9601 Adjustments, Clearances and Wear limits 06/II Drawing dimension (mm) Normal Wear limit Part, measuring point clearance (mm) Max. Min. (mm) 22 Driving shaft for governor 20.000 19.979 Bearing for driving shaft 20.053 20.020 Bearing clearance 0.020-0.07 0.15 Axial clearance 0.10-0.15 Backlash for driving gear 0.10-0.20...
Page 92 06/II Adjustments, Clearances and Wear limits 22-9601 06-6 VASA 22...
Page 93 22-200640 Tightening Torques and Instructions for Screw Connections 07. Tightening Torques and Instructions for Screw Connections 07.1 Tightening torques for screws and nuts Note! See section 07.3 for hydraulically tightened connections! The position number in the tables below refers to corresponding figures A to J, which are located in the engine according to Fig 07-1.
Page 94 Tightening Torques and Instructions for Screw Connections 22-200640 A: Flywheel Fig 07-2 2207569143 Screw connection Torque Screw connection Torque Pos. VASA 22 (Nm) VASA 22/26 (Nm) 120 ± 5 120 ± 5 1. Split gear screws, Split gear screws, Apply Loctite 242 on threads, see Apply Loctite 242 on threads, see section 07.2 section 07.2...
Page 95 22-200640 Tightening Torques and Instructions for Screw Connections *) NOTE! The flywheel of the Vasa 22 engine can be fitted in two different ways depending on installation specification: 1. With 20 pcs of M24 screws (12.9) bolted directly to the crankshaft without nuts and fitted bolts.
Page 96 Tightening Torques and Instructions for Screw Connections 22-200640 C: Camshaft and control mechanism Fig 07-4 2207589143 Pos. Screw connection Torque (Nm) 80 ± 5 1. Camshaft flange connection screws, (M10 12.9) Torque wrench setting with tool 4V80G21. The screws are treated with locking compound and can be used three times the locking effect being intact, then replace.
Page 97 22-200640 Tightening Torques and Instructions for Screw Connections D: Cylinder head Fig 07-5 2207599143 Pos. Screw connection Torque (Nm) 85 ± 5 1. Rocker arm bearing bracket, fastening nuts. When reassembling stud bolts, apply Loctite 270 on threads. 50 ± 5 2.
Page 98 Tightening Torques and Instructions for Screw Connections 22-200640 E: Injection pump BOSCH LÓRANGE LÓRANGE LÓRANGE PFR1CY210... PYO-G056 PYO-G063 PYO-G070 Fig 07-6 2207609143 Torque (Nm) Pos. Screw connection Bosch L’Orange L’Orange L’Orange PFR1CY210 PYO-G056 PYO-G063 PYO-G070 30 ± 5 1. Hexagon socket screw. 70 ±...
Page 99 22-200640 Tightening Torques and Instructions for Screw Connections F: Fuel injection valve For tightening order, see section 16.5 LÓRANGE DUAP Fig 07-7 2207619143 Torque (Nm) Pos. Screw connection L’Orange Duap 50 ± 5 50 ± 5 1. Injection valve fastening nuts. 110 ±...
Page 100 Tightening Torques and Instructions for Screw Connections 22-200640 G, H: Engine driven pumps Alternative 1 Alternative 2 Fig 07-8 220771 Pos. Screw connection Torque (Nm) 1. Fastening screws for lubricating oil 75 ± 5 pump driving gear (connection with four Inbus Plus fastening screws, M10x45 12.9 210 ±...
Page 101 22-200640 Tightening Torques and Instructions for Screw Connections I: Free end of crankshaft Fig 07-9 2207639143 Pos. Screw connection Torque (Nm) 600 ± 20 1. Screws of pump driving gear at free end of crankshaft, ( Use the torque multiplier X-4. M20 12.9).
Page 102 Tightening Torques and Instructions for Screw Connections 22-200640 K: Side screws for main bearings Fig 07-11 220767 Pos. Screw connection Torque (Nm) 1200 ± 20 1. Side screws for main bearings. Use the torque multiplier X-4. 07 - 10 VASA 22...
Page 103 22-200640 Tightening Torques and Instructions for Screw Connections We recommend the use of torque measuring tools also when tightening other screws and nuts. The following torques apply to screws of the strength class 8.8; when oiled with lubricating oil or treated with Loctite.
Page 104 Tightening Torques and Instructions for Screw Connections 22-200640 07.3 Hydraulically Tightened Connections 07.3.1 Tightening pressures for hydraulically tightened connections Hydraulically tightened connections Fig 07-12 2207659143 Max. hydr. pressure (bar) Tightening Hydraulic Pos. Screw connection torques of cylinder tightening loosening studs (Nm) number Cylinder head screws, M42.
Page 105 22-200640 Tightening Torques and Instructions for Screw Connections 07.3.2 Filling, venting and control of the hydraulic tool The hydraulic tool set consists of a high pressure hand pump with integrated oil container, hoses fitted with quick-couplings and non-return valves, cylinders and a pressure gauge mounted on the hand pump but not connected to the pressure side of the pump.
Page 106 Tightening Torques and Instructions for Screw Connections 22-200640 3 Lift the pump above the cylinders and keep it in the po- sition where the plastic plug (2) is topmost. Remove the plug and filling screw located inside the plug. 4 Press the spout of the filling bottle into the filling hole and squeeze the bottle to make the oil enter.
Page 107 22-200640 Tightening Torques and Instructions for Screw Connections 07.3.4 Reassembling hydraulically tightened screw connections 1 Screw on nuts and attach distance sleeves. Screw on cyl- inders 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 108 Tightening Torques and Instructions for Screw Connections 22-200640 Hydraulic extractor cylinder Hydraulic oil Fig 07-14 2207539205 The effective area of the piston is 14.42 cm which gives the following relation between pressure and force. Relation between pressure and force for hydraulic extractor Max pressure 2000 4000...
Page 109 22-9601 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. See chapter, Trouble section...
Page 110 Operating Troubles, Emergency Operation 22-9601 d) Injection pump faulty (plunger or tappet sticking; delivery valve spring broken, delivery valve sticking). e) Injection valve faulty; nozzle holes clogged. f) Piston rings ruined; too low compression pressure. 11.2 g) 8...16-cylinder engines. It may be troublesome to make these fire on all cylinders when idling, due to the small quantity of fuel required.
Page 111 22-9601 Operating Troubles, Emergency Operation Exhaust gas temperature of all cylinders abnormally high a) Engine badly overloaded (check injection pump rack positions). Test Records b) See point 6c. c) Charge air temperature too high. Test Rec., 01.3 - charge air cooler clogged on water side or dirty on air side 15.2 - water temperature to air cooler too high, water quantity insufficient 01.3...
Page 112 Operating Troubles, Emergency Operation 22-9601 01.3 Too high lubricating oil temperature a) Faulty thermometer. b) Insufficient cooling water flow through oil cooler (faulty pump, air in system, 19.1 valve closed), too high raw water temperature. 01.3 c) Oil cooler clogged, deposits on tubes. 18.5 d) Faulty thermostat valve.
Page 113 22-9601 Operating Troubles, Emergency Operation b) An overspeeding engine is hard to stop. Therefore, check regularly the 22.3 adjustment of the control mechanism (the injection pump rack positions) 1) the stop lever being in stop position or the overspeed trip device being tripped and the speed governor at maximum fuel admission.
Page 114 Operating Troubles, Emergency Operation 22-9601 When operating the engine without turbochargers, the engine output must be limited so that the normal full load exhaust temperatures are not exceeded. Available load from the engine with blocked turbocharger (s) is about 20 % of full load. 08.2.3 Operation with defective cams If the camshaft piece with damaged cams cannot be removed and replaced by a new one, the engine can be kept running by the...
Page 115 22-9601 Operating Troubles, Emergency Operation 08.2.4 Operation with removed piston and connecting rod If damage on piston, connecting rod or big end bearing cannot be repaired, the following can be done to allow emergency operation: 1 Remove the piston and the connecting rod. 2 Cover lubricating oil bore in crank pin with a suitable hose clip, and secure.
Page 116 Operating Troubles, Emergency Operation 22-9601 08 - 8 VASA 22...
Page 117 22-9601 Engine Block with Bearings and Cylinder Liners, Oil Sump 10. Engine Block with Bearings and Cylinder Liners, Oil Sump 10.1 General description 10.1.1 Engine block and bearings The engine block is cast in one piece of cast iron. The distributing duct for the cooling water as well as the air receiver are incorporated in the engine block.
Page 118 Engine Block with Bearings and Cylinder Liners, Oil Sump 22-9601 pipe for crankshaft bearings, are incorporated in the oil sump. An oil dipstick is located in one of the crankcase covers. The oil dipstick indicates the maximum and minimum limits between which the oil level may vary.
Page 119 22-9601 Engine Block with Bearings and Cylinder Liners, Oil Sump Note! For V-engines, equipped with torsional vibration damper Hasse & Wrede ASK 1728, two extra distance sleeves are delivered. These two sleeves are to be used on the main bearing closest to the torsional vibration damper only. The DISMANTLING 1.
Page 120 Engine Block with Bearings and Cylinder Liners, Oil Sump 22-9601 Use of turning tool for bearing shell 1. Upper main bearing shell 2. Turning tool for main bearing (851 001, R22 and 851 002, V22) Fig 10-3 2210549434 8 Cover the two crankshaft journal oil holes with tape. At least every third main bearing must be in place at the same time to support the crankshaft.
Page 121 22-9601 Engine Block with Bearings and Cylinder Liners, Oil Sump 10.2.3 Installing main bearings 1 Clean the main bearing bore, caps, shells and crankshaft journal very carefully. 2 Take off the protecting tape from the crankshaft oil holes and lubricate the journal with pure engine oil. 3 Lubricate the upper shell bearing surface (not rear side).
Page 122 Engine Block with Bearings and Cylinder Liners, Oil Sump 22-9601 Note! The thrust washers are marked according to Fig 10-4 (operat- ing side of the engine) Marking of the thrust washers of the crankshaft Fig 10-4 2210599204 14 Tighten the nuts by the pin (2) until face-to-face contact. The pressure should be kept constant all the time.
Page 123 22-9601 Engine Block with Bearings and Cylinder Liners, Oil Sump 1 Remove the end cover. 2 Unscrew the four screws fastening the bottom of the bearing housing to the engine block. 3 Remove the guiding pins. 4 Loosen the nuts of the two vertical screws by the hydrau- lic tool.
Page 124 Engine Block with Bearings and Cylinder Liners, Oil Sump 22-9601 10.4 Cylinder liner 10.4.1 Maintenance of cylinder liner Honing of cylinder liner bore Always hone the cylinder liner when new piston rings are mounted. Normally a light honing is sufficient. If the honing is done when the cylinder liner is on its place in the engine block, the crankshaft under the cylinder liner concerned must be covered by plastic film.
Page 125 22-9601 Engine Block with Bearings and Cylinder Liners, Oil Sump Removing and lifting of cylinder liner 1. Screw (4V83G29) 2. Nut (4V83G31) Fig 10-5 2210569435 10.4.3 Mounting of cylinder liner If more than one cylinder liner have been removed, check that the liners are installed in the same cylinders as before the overhaul.
Page 126 Engine Block with Bearings and Cylinder Liners, Oil Sump 22-9601 Machining of engine block for new type of cylinder liner 265) Contraction edge Engine block Cylinder liner Fig 10-6 2210609204 3 Lubricate the O-rings and sealing faces with Molykote Paste G or soft soap. 4 Mount the lifting device.
Page 127 22-9601 Crank Mechanism 11. Crank Mechanism: Crankshaft, Connecting Rod, Piston 11.1 Crankshaft 11.1.1 Description The crankshaft is forged in one piece. The first main bearing, seen from the driving end, is provided with thrust washers and guides the crankshaft axially. On V-engines all crank webs are provided with counterweights;...
Page 128 Crank Mechanism 22-9601 1 Turn the crank of the first cylinder near the bottom dead center. 2 Apply the crankshaft indicator between the two crank webs into the center marks provided for this purpose. 3 The clearance between the micrometer and connecting rod should be as small as possible.
Page 129 22-9601 Crank Mechanism Before re-aligning the engine and the driven machinery, check the main bearing shell thickness. Engines with a torsional elastic coupling Engines with a torsional elastic coupling connected to the fly- wheel have a larger difference at the crank web next to the DISMANTLING flywheel owing to the crankshaft deflection.
Page 130 Crank Mechanism 22-9601 11.2 Connecting rod and piston 11.2.1 Description The connecting rod is drop forged and precision serrated in the mating face. The big end bearing is a trimetal bearing of the same design as the main bearings. Lubricating oil is fed through the main bearings and bores in the crankshaft.
Page 131 22-9601 Crank Mechanism 5 Lift the distance sleeves, 861033 for in-line engines and 861026 for V-engines, on to the connecting rod screws, Fig 11-2. 6 Screw on the hydraulic tools; for in-line engines the hy- draulic tool 861027 with the distance piece 861032, for V-engines the hydraulic tool 861027.
Page 132 Crank Mechanism 22-9601 11 Lift the piston a little to remove the upper big end bearing shell (3), this applies only to in-line engines. On V-engines, mount the protecting rails 835003 and 835004 in position above the connecting rod serration. 12 When lifting the piston, take care not to damage the crank pin and the cylinder liner wall.
Page 133 22-9601 Crank Mechanism clearance of the rings in their grooves, see chapter 06., section 06.2, pos. 11. Especially the two chromium-plated topmost piston rings should be examined. If the chromium-plating is worn through, the ring should immediately be replaced by a new one. Note! If the cylinder liner is new or honed, all rings are to be replaced by new ones.
Page 134 Crank Mechanism 22-9601 5 Check the gap clearance by fitting the rings into a new cylinder liner before installing new piston rings. Check also the vertical clearance in the ring grooves (chapter 06., section 06.2, pos. 11). When installing the rings, use the piston ring pliers. The ring joints should be located 120°...
Page 135 22-9601 Crank Mechanism 16 Connect the hoses, and proceed with tightening of con- necting rod nuts. 11.3 Balancing mechanism for 4-cylinder engines The four-cylinder in-line engine is equipped with two balancing shafts (3) which rotate at a speed twice the crankshaft speed. The shafts are driven by the crankshaft (1) through an intermediate gear (2).
Page 136 Crank Mechanism 22-9601 11.3.1 Removal of balancing shaft bearing bushes 1 Turn the engine into a position where the balancing shaft eccentrics point downwards. 2 Loosen the screws (6) , from the shaft the bearings of which is to be removed. 3 Loosen the screws (7) and remove the upper bearing shells (8).
Page 137 22-9601 Crank Mechanism 6 Re-install the shaft piece (3), clean the threads of the fas- tening screws (10) thoroughly and apply Loctite 242 to them. 7 Put the axial washer (13) to end of the shaft 8 Tighten the screws (10) to the stated torque and put the locking wire (14) to the screws.
Page 138 Crank Mechanism 22-9601 4R22 balancing arrangement (Phase 1) Fig 11-4 221156A9205 2 Push the intermediate gear in position when the crank- shaft is turned with cylinder 1 in TDC (top dead centre) and the balancing shafts with the guiding pins upwards, see Fig 11-5.
Page 139 22-9601 Crank Mechanism 11.4 Balancing mechanism for 8V22 en- gines The eight-cylinder V-engine has four balancing wheels rotating at a speed twice the crankshaft speed. Each wheel is driven by the crankshaft through an intermediate gear. The bearing ar- rangement is similar to the one used in the camshaft intermediate gear.
Page 140 Crank Mechanism 22-9601 5 Turn the crankshaft 30° clockwise from the top dead cen- tre of cylinder no. Al (in this position the crank pin of cylinder 1 points straight upwards). 6 Re-install the end cover with help of the guiding pins. Check that the hose seal against the underneath surface of the end cover comes to its place properly and that the under edge of the pump cover comes 0.15 ...
Page 141: Table Of Contents
22-9601 Crank Mechanism Balancing mechanism for 8V22 View C 1. Screw 2. Screw 3. Screw 4. Flange 5. Shaft 6. Bearing bush 7. Distance bush 8. Screw 9. Nut 10. Counter weight 11. Counter weight 12. Gear wheel 13. Bush 14.
Page 142 Crank Mechanism 22-9601 11.4.4 Dismantling (at the flywheel end) 1 Check the axial clearance, section 06.2 pos. 23 B. 2 Unscrew the screw (15) and remove the flange (16). 3 Unscrew the screw (21) and remove the shaft (19). The whole package counterweights - gear wheel can now be re- moved.
Page 143 22-9601 Crank Mechanism Diagram for 8V22 balancing system Fig 11-7 2211539545 VASA 22 11 - 17...
Page 144 Crank Mechanism 22-9601 11 - 18 VASA 22...
Page 145 22-9601 Cylinder Head with Valves 12. Cylinder Head with Valves 12.1 General description The cylinder heads are cast of special quality grey iron. Each head includes two inlet valves (10), two exhaust valves (9), a centrally located fuel injection valve (4), a starting valve (13) and an indicator valve (12).The cylinder heads are individually tightened to the engine block with four studs and hydraulically tightened nuts.
Page 146 Cylinder Head with Valves 22-9601 components being in contact with combustion gases. Efficient cooling and a rigid design is best achieved with the “double deck” design in which the flame plate is relatively thin and the mechani- cal load is transferred to the strong intermediate deck. The most sensitive areas of the cylinder head are cooled by drilled cooling channels optimized to distribute the water flow evenly around valves and the centrally located fuel injector.
Page 147 22-9601 Cylinder Head with Valves 4 Remove the injection pipe. 5 Loosen the oil pipe and the starting air pipe. 6 Remove the rocker arm bracket (1) and the push rods (14) as well as the caps of the cylinder head screws. Pull up the sleeve on the leakage pipe.
Page 148 Cylinder Head with Valves 22-9601 apply LOCTITE 270 on the threads. Then screw in the studs completely in the cylinder head. Mount the push rod protecting pipes and fit the push rods and the rocker arm bracket. Tighten the nuts to the torque stated in chapter 07., section 07.1.
Page 149 22-9601 Cylinder Head with Valves 5 Insert a feeler gauge corresponding to the valve clear- ance (see chapter 06.) between the pressure surface of the yoke and the shoe of the rocker arm. Tighten the adjusting screw until the feeler gauge can be somewhat moved to and fro. Tighten the locking nut while fixing the adjusting screw.
Page 150 Cylinder Head with Valves 22-9601 Valve seat rings are fitted in the cylinder head for both inlet and exhaust valves. The exhaust valve seat rings are cooled and hence provided with two O-rings. 12.3.2 Dismantling the valves 1 Fit the tool assembly 846010 according to Fig 12-3. 2 Depress the springs by turning the device clockwise.
Page 151 22-9601 Cylinder Head with Valves Control of the burning off on valve Burn-off area Fig 12-4 2212568932 3 Check the sealing faces at the valves and the sealing rings. For this purpose it is recommended to apply a thin layer of fine lapping compound to the valve seat and rub the valve slightly against the seat a few times by hand.
Page 152 Cylinder Head with Valves 22-9601 2 Apply a thin layer of lapping compound to the sealing surface of the valve; No 1 for coarse lapping, No 3 for fine lapping. 3 Rotate the valve to and fro towards the seat with the nut speeder.
Page 153 22-9601 Cylinder Head with Valves Also a flat bar of the dimensions 10x30 mm can be used. 2 Press or knock out the ring through the valve guide with an arbor. 12.3.7 Fitting a new inlet valve seat ring 1 Check the bore diameter in the cylinder head, see sec- tion 06.2, pos.
Page 154 Cylinder Head with Valves 22-9601 12.3.9 Reassembling of the engine valves 1 Check the valve springs for cracks and wear marks on the coils. If any, replace the springs by new ones. 2 Put the new seal rings in the valve guides. 3 Lubricate the valve stems with engine oil.
Page 155 22-9601 Cylinder Head with Valves Use the right T-handle wrench to open and close the indicator valve. Open and close indicator valve Always use the special The cock moves upward handle when closing ! when closing clockwise Fig 12-5 2212558932 VASA 22 12 - 11...
Page 156 Cylinder Head with Valves 22-9601 12 - 12 VASA 22...
Page 157 22-9601 Camshaft Driving Gear 13. Camshaft Driving Gear 13.1 General description The camshaft is driven by the crankshaft (1), Fig 13-1, through a gearing. The gear (2) on the crankshaft is split and fixed to a flange on the crankshaft with axial screws (4). These screws as well as the fastening screws of the gear are locked with Loctite 242.
Page 158 Camshaft Driving Gear 22-9601 13.2.2 Basic adjustment of valve timing The basic adjustment of the valve and injection timing is done by changing the relative position between the intermediate wheels (5) and (6). If the position is changed, the position of the camshaft is changed in relation to the crankshaft.
Page 159: Screw
22-9601 Camshaft Driving Gear Camshaft driving gear VIEW A 1. Crankshaft 2. Split gear wheel 4. Axial screws 5. Intermediate wheel 6. Intermediate wheel 7. Nut 8. Screw 10.Screw 11.Bearing pin 12.Intermediate bush 13.Screw 14.Flange 15.Screw 16.Locking wire 18.Camshaft gear 19.Screw 20.Bearing piece 21.Screw...
Page 160 Camshaft Driving Gear 22-9601 7 Turn the crankshaft until the flywheel hole (diameter 60 mm) at the inside of the rim is in front of the intermediate wheel bearing pin (Not 22/26 engines). 8 Press out the bearing pin. (11) 9 The intermediate wheel can now be lifted out, for in- stance by means of a rope sling.
Page 161 22-9601 Camshaft Driving Gear Place the bearing pin (11) into the intermediate gear and the bush (12). 4 Coat the screw (13) with Loctite 242 (screw it in by hand). 5 Fit the flange (14) together with a new O-ring and tighten the screw (15).
Page 162: Gear Wheel
Camshaft Driving Gear 22-9601 13.3 Split gear 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. 13.3.1 Removing of the split gear wheel After the gearing is removed according to section 13.2.2, the split gear wheel (2) can be removed from the crankshaft, Fig 13-1.
Page 163 22-9601 Camshaft Driving Gear 10 Mount the end cover half. Measuring split gear wheel Ø 10 Fig 13-3 2213529445 VASA 22 13 - 7...
Page 164 Camshaft Driving Gear 22-9601 13 - 8 VASA 22...
Page 165: Screw
22-9601 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 valve tappets (11) of the piston type moving in a common guide block casing (7), tubular push rods (4) with ball joints, drop forged rocker arms (3) pivoted in a rocker arm bearing bracket (13) and a yoke (14) guided by a yoke pin in the cylinder head, (Fig 14-1).
Page 166 Valve Mechanism and Camshaft 22-9601 14.1.2 Function The movement of the valve tappets is governed by the cam profile. The valve tappets transfer the movement through push rods to the rocker arms. The rocker arms operate the inlet and exhaust valves through a yoke.
Page 167 22-9601 Valve Mechanism and Camshaft 6 Inspect and measure the details for wear (section 06.2). 7 Oil the details with lubricating oil before reassembling. 8 Measure the axial clearance of the rocker arms after assembling, minimum 0.15 mm, see chapter 06. 14.1.3.2 Dismantling and assembling the valve tappets 1 Remove the rocker arm bracket (13) first.
Page 168: Screw
Valve Mechanism and Camshaft 22-9601 The bearing surfaces of the journals are induction hardened. The camshaft is driven by the crankshaft through a gearing at the driving end of the engine. At this end the camshaft is equipped with an overspeed trip device (7) and a helical gear (8) for driving of the speed governor.
Page 169 22-9601 Valve Mechanism and Camshaft 14.2.3 Mounting of camshaft piece 1 Clean and degrease the flange connection surfaces and the threaded holes. 2 Fit the fixing pins (4) and retainer rings with the longer part of the pin in the bearing journal. 3 Mount the camshaft piece (1) on the fixing pin and cen- tering at either end.
Page 170 Valve Mechanism and Camshaft 22-9601 5 Check the uncovered part of the bearing bush by means of a mirror. All camshaft bearing bushes towards the free end of the engine, seen from the bearing concerned, can be checked when the camshaft is in this position. 14.3.2 Removing of the camshaft bearing bush 1 Remove the camshaft cover, injection pump,...
Page 171 22-9601 Valve Mechanism and Camshaft 14.3.3 Mounting of the camshaft bearing bush 1 Lubricate the new bearing bush lightly with clean en- gine oil at the outer surface and put it on the guide sleeve. 2 Assemble the mounting device 834001 according to Fig 14-4.
Page 172 Valve Mechanism and Camshaft 22-9601 14 - 8 VASA 22...
Page 173 22-200520 Turbocharging and Air Cooling 15. Turbocharging and Air Cooling 15.1 Turbocharger 15.1.1 General description The turbocharger utilizes the energy of the engine exhaust gas to feed more air to the engine, thereby offering advantages such as boosted engine power output and thriftier fuel consumption. The exhaust gas discharged from the cylinders of the engine are led through the exhaust manifold into the turbocharger and are accelerated in the turbine housing before the passing of the...
Page 174 Turbocharging and Air Cooling 22-200520 The air outlet housing of the turbocharger is connected to the air duct (2) of the engine through a piece of metal bellows (1), which allows thermal expansion of the air duct, see Fig 15-1. Caution! The surfaces of the turbocharger and the air duct are hot.
Page 175: Screw
22-200520 Turbocharging and Air Cooling temperature resistant lubricants are used for exhaust pipe screws. 15.1.3 Water cleaning of turbine During operation, especially when running on heavy fuel, impu- rities in the exhaust gases sticks to the turbine wheel and other components in the turbocharger exhaust side.
Page 176 Turbocharging and Air Cooling 22-200520 Water cleaning of the turbine 1. Inlet valve 2. Quick-coupling 3. Drain valve 4. Flow meter 5. Valve Fig 15-2 2215529212 Every gas inlet of the charger is equipped with a washing nozzle. The nozzles are all connected through valves to a common water connection equipped with a quick-coupling.
Page 177 22-200520 Turbocharging and Air Cooling 15.1.4 Cleaning procedure of turbine The flow meter enables accurate control of the amount water injected. Before cleaning the turbine, it is advisable to record the following parameters for later use to determine the efficiency of the cleaning;...
Page 178 Turbocharging and Air Cooling 22-200520 15.1.5 Cleaning procedure of compressor The compressor can be cleaned during operation by injecting water. The method is suitable, provided contamination is not too far advanced. If the deposit is very heavy and hard, the compres- sor must be cleaned mechanically.
Page 179 22-200520 Turbocharging and Air Cooling Note! If injection is not successful, it must not be repeated before ten minutes. 1. Cover 2. Button 3. Knob 4. Air pipe 5. Water pipe Fig 15-3 2215609508 After injection, the engine should be run loaded for at least five minutes.
Page 180 Turbocharging and Air Cooling 22-200520 The exhaust gas temperatures after the cylinder heads must not exceed 500°C. If the engine is operated for longer periods with exhaust temperatures close to 500°C with the rotor removed there is a risk of piston seizure. This is due to the hot temperatures internally the piston (cooling gallery) causing the lubricating oil forming deposits in the cooling gallery.
Page 181 22-200520 Turbocharging and Air Cooling If water keeps on dripping or flowing from the draining pipe for a longer period (unless running all the time in conditions with very high humidity) the cooler insert may be leaky and must be dismantled and pressure tested. 2 At longer stops, the cooler should be either completely filled or completely emptied, as a half-filled cooler increases the risk of corrosion.
Page 182 Turbocharging and Air Cooling 22-200520 4 Clean the water side by detaching the headers (4) and (5), see Fig 15-1, from the cooler bundle and immersing the tube bundle into a chemical cleaning bath for at least 24 hours. Upon completion, follow the recommendations given for the air side.
Page 183 22-200520 Turbocharging and Air Cooling VTR Turbocharger 15 - 11...
Page 184 22-8604 Turbocharging and Air Cooling 15/III 15. Turbocharging and Air Cooling 15.1 Turbocharger 15.1.1 Description The turbochargers are of the axial turbine type. The insert type charge air cooler is mounted in a welded housing which, at the same time, serves as a bracket for the turbocharger. 12 and 16 cylinder V-engines have two identical cooler inserts in a common housing.
Page 185 15/III Turbocharging and Air Cooling 22-8604 15.1.2 Turbocharger maintenance Normal overhauls can be carried out without removing the turbo- charger from the engine. When dismantling, remove the connection pipes for water. Loosen the exhaust inlet and outlet pipes. When reassembling, take care that all seals are intact. High temperature resistant lubricants are used for exhaust pipe screws.
Page 186 22-8604 Turbocharging and Air Cooling 15/III while the engine is running at reduced power, by a combination of scouring action and partial dissolving of the deposits. Under no circumstances the turbine should be allowed to run long enough to become very heavily coated with deposits. A fouled turbine can be recognized by abnormal exhaust gas tem-perature, charger speed and charge air pressure.
Page 187 15/III Turbocharging and Air Cooling 22-8604 2 Reduce engine load to between 10 and 20% of full load rating. 3 Open the valves (1), and check that they are not clogged. 4 Connect the water hose. 5 Open the drain valve (3) and check that it is clear of block-age.
Page 188 22-8604 Turbocharging and Air Cooling 15/III when the engine is stopped, drain the cooler completely. Open the air vent screw (3) to avoid vacuum when draining. Clean and pressure test the cooler at intervals according to section 04. or if the receiver temperature cannot be held within stipulated values at full load.
Page 189 15/III Turbocharging and Air Cooling 22-8604 15 - 6 VTR 161-251 Turbochargers...
Page 190 22-9601 Injection System 16. Injection System 16.1 General description This chapter deals with the high pressure side of the fuel system including injection pump, high pressure pipe and injection valve. The injection pumps are one-cylinder pumps with built-in roller tappets. The element is pressure lubricated and the drain fuel is led to a pipe system with atmospheric pressure outside the pump.
Page 191 Injection System 22-9601 fuel rack is connected to the regulating mechanism of the gover- nor. If the fuel rack is moved, the control sleeve in mesh with the rack is turned. Since the control sleeve acts on the plunger, the plunger turns with the control sleeve, thus the effective stroke changes and the injected fuel amount increases or decreases.
Page 192 22-9601 Injection System 16.3.1 Removal of injection pump It is recommended that the engine run a 5 minutes with light fuel before it is stopped for overhaul of injection pump. 1 Shut fuel supply to the engine before removing the injec- tion pump.
Page 193 Injection System 22-9601 5 Disengage the connection piece from the fuel control rack by removing the nut and pulling the screw aside. Put the nut on its place at once to avoid loosing any part. 6 Turn the crankshaft so that the pump tappet roller rests upon the base circle of the fuel cam.
Page 194 22-9601 Injection System high pressure side of the injection pump is shut by the edge of the element plunger, the so called “flowing position”. Control of fuel delivery start is necessary only if major compo- nents have been changed, e.g. injection pump, injection pump element or camshaft piece.
Page 195 Injection System 22-9601 2 Support the roller tappet by hand and open the fixing screw (21), Fig 16-1. 3 Remove the roller tappet. 4 Remove the spring retainer and element plunger. 5 Remove the spring and control sleeve. 6 Turn the pump into vertical position. 7 Open the screws (52) of the head piece crosswise and in steps of 30°.
Page 196 22-9601 Injection System 5 Fit the pump head piece into place and tighten the screws (52), Fig 16-1 by hand. Fit and tighten the screws (9) by hand. Note! The sealing surfaces must be absolutely clean. 6 Tighten the screws (9) and (52) crosswise to torque in three steps according to chapter 07., section 07.1 to ensure equal tightening of every screw.
Page 197 Injection System 22-9601 assembled. Always tighten the connections to correct torque. If necessary, the engine can be provided with alarm for a broken injection pipe. In that case the injection pipes are enclosed in a pipe, from which a drain pipe goes to a collecting vessel for the leak fuel lines.
Page 198 22-9601 Injection System 16.5.2 Removing injection valve 1 Remove the cylinder head cover and the cover of injec- tion pump box. 2 Remove the high pressure injection pipe and connec- tion piece. 3 Remove the fastening nuts of the injection valve. 4 Lift out the injection valve.
Page 199 Injection System 22-9601 Maximum lift of nozzle, removing of nozzle from holder Fig 16-3 2216529213 5 Clean the details. If possible, use a chemical carbon dis- solving solution. If there is none available, immerse the details in clean fuel oil, white spirit or similar to soak carbon. Then clean the details carefully by the tools 845006.
Page 200 22-9601 Injection System 10 Connect the injection valve to the test pump 864011. Pump to expel air. Shut the manometer valve and pump rapidly to blow dirt out of the nozzle orifices. Place a dry paper under the nozzle and give the pump a quick blow. Note fuel spray uniformity.
Page 201 Injection System 22-9601 4 Put new O-rings in the sealing flange of the high pressure connection piece (5). Place the flange on the connection piece and screw in the connection by hand, (be sure that the flange screws (6) is loose). Tighten the connection piece (5) to correct torque.
Page 202 22-9601 Fuel system 17. Fuel system 17.1 General description The engine is designed for continuous heavy fuel duty. Main engines as well as the auxiliary engines, can be started and stopped on heavy fuel. As the fuel treatment system before the engine can vary widely from one installation to another, this system is not described in detail in this book.
Page 203 Fuel system 22-9601 The electrically driven pump (9) delivers the correct flow to the engine through the duplex filter (8). The pressure control valve (11) maintains the correct pressure in the engine system. Both sides of the duplex filter shall be in operation at the same time to get maximum capacity of the filter cartridges.
Page 204 22-9601 Fuel system 17.3 Venting Open the air vent screws on the injection pumps (see chapter 16, Fig 16-1 pos. 42.) If the static pressure from the day tank is not sufficient, the fuel feed pump should be started. Vent the filter always after changing cartridges in the filter. If the engine is stopped and the feed pump is not running, the three-way valve of the filter can be directly changed over to both sides in operation and the air can be vented through the air vent...
Page 205 Fuel system 22-9601 17.4 Adjustment of pressure control valves Check the adjustment at intervals recommended in chapter 04. Adjust the valves at normal temperatures with an idling engine, i.e. the booster pump (9, Fig 17-1) running. All pressures mentioned in the instruction apply to the readings of the pressure gauge (5) in the instrument panel of the engine.
Page 206 22-9601 Fuel system the cock (7). At normal operation, both sides of the filter are used in parallel to provide maximum filtration. Fig 17-3A shows the valve in this position. When changing cartridges during operation one side can be closed. Fig 17-3B shows the position of the valve when the right side of the filter is closed.
Page 207 Fuel system 22-9601 17.6.2 Changing of filter cartridges Change cartridges regularly (see chapter 04.) and, if the pressure drop indicator gives alarm, as soon as possible. As the useful life of the cartridges is largely dependent on fuel quality, centrifuging and filtering before the engine, experience from the installation concerned will give the most suitable intervals between changes of cartridges.
Page 208 22-9601 Fuel system initial period of operation. At this time, there is a higher risk of damage from foreign debris in the fuel system. Installations of this kind (fuel feed pump in the external fuel system), generally heavy fuel installations, must be equipped with a fine fuel filter in the external system.
Page 209 Fuel system 22-9601 17 - 8 VASA 22...
Page 210 22-9601 Lubricating Oil System 18. Lubricating Oil System 18.1 General design The engine is provided with a lubricating oil pump (2) directly driven by the pump gear at the free end of the crankshaft. In some installations there is a separately driven standby pump in paral- lel.
Page 211 Lubricating Oil System 22-9601 The temperature can be checked from thermometers (19) before and after the oil cooler, i.e. the temperature after and before the engine. A temperature switch for high oil temperature is con- nected to the automatic alarm system (see chapter 23). The speed governor and turbochargers of VTR-type have their own oil systems, see separate instruction books.
Page 212 22-9601 Lubricating Oil System 10 % new oil at a time (see section 02.2). One side of the dipstick is graduated in centimetres. This scale can be used when checking the lubricating oil consumption. Change oil regularly at intervals determined by experience from the installation concerned, see chapter 04.
Page 213 Lubricating Oil System 22-9601 18.3.3 Inspection 1 Check all parts for wear (chapter 06., section 06.2) and replace worn parts. 2 Remove worn bearings from the housing by driving them out with a suitable mandrel, from the cover by machin- ing.
Page 214 22-9601 Lubricating Oil System Re-install the conical ring elements exactly as situated in Fig 18-3. The conical ring elements should fall easily in place and must not jam. 4 Re-install the friction ring elements (20). 5 Reinstall the washer (3) 6 Tighten the screws (4) a little and check that the gear wheel is in the right position.
Page 215 Lubricating Oil System 22-9601 The spring (16) is tensioned to balance this force at the required pressure. Thus the pressure is kept constant in the distributing pipe irrespective of the pressure in the pressure side of the pump and of the pressure drop in the system. By tensioning the spring (16) a higher oil pressure is obtained.
Page 216 22-9601 Lubricating Oil System 18.5.2 General maintenance 1 Clean and test the cooler by hydraulic pressure at in- tervals according to chapter 04. or if the lubricating oil tem- perature tends to rise abnormally. 2 Water side can be cleaned by removing water boxes without removing the cooler from the engine.
Page 217 Lubricating Oil System 22-9601 Lube oil cooler 1. End cover SECTION A-A 2. Tube stack 3. Jacket 4. Vent screw 5. O-ring 9. Bulb 10.Valve unit 11.Seat 12.Fix plate Fig 18-4 2218669543 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.
Page 218 22-9601 Lubricating Oil System Follow the manufacturer’s instructions to achieve the best results. 18.5.5 Cleaning of water side The cleaning should be carried out so that it does not damage the natural protective layer on the tubes. Use nylon brushes, metallic brushes can damage the natural protective layer.
Page 219 Lubricating Oil System 22-9601 It is preferable to change plates in bad condition too early, rather than too late. Water leakage to lubricating oil has serious consequences 3 When replacing plates, make sure that all plates are as- sembled in correct order. Change gaskets when necessary. Plate oil cooler MEASURE A = Q * 2.6 MM WHERE Q = NUMBER OF PLATES...
Page 220 22-9601 Lubricating Oil System Note! Rinse well. 18.6.5 Closing 1 Check that all sealing surfaces (surfaces in contact with media) of the heat exchanger are clean. 2 Check the threads of the tightening nuts. See that they are undamaged, cleaned and smeared with a thin film of lubricating paste.
Page 221 Lubricating Oil System 22-9601 Depending on the number of cylinders, the engine can be equipped with a thermostatic valve, that contains one or two valve units (10), Fig 18-6. Thermostatic valve for oil system 9. Bulb 10. Valve unit 11. Seat Fig 18-6 2218649509 18.7.2 Maintenance...
Page 222 22-9601 Lubricating Oil System 18.8 Lubricating oil main filter 18.8.1 Description This description applies to in-line engines. V-engines have two similar filters in parallel. The filter is a full-flow duplex filter, i.e. the whole oil flow passes through the filter(s). The flow can be adjusted by the three-way valve (9) to pass over one side or the other, or over both sides in parallel.
Page 223 Lubricating Oil System 22-9601 insert (3) consisting of a pleated wire gauze around a perforated case. The wire gauze insert, with a mesh size of 60 µm, serves as a safety filter in case of failure or by-passing of the paper cartridge. The filters are provided with a bypass valve (7) over the paper cartridges which opens at a pressure drop of 2 - 3 bar (the pin comes out).
Page 224 22-9601 Lubricating Oil System 10 Check that the guide (4) slides into position. 11 Mount the plugs and the cover. Tighten the vent screw. 12 Move the three-way valve over to working position (Fig 18-7 C). 18.9 Centrifugal filter 18.9.1 Description A by-pass filter of the centrifugal type is provided as a complement to the main filter.
Page 225 Lubricating Oil System 22-9601 4 Remove sludge from the inside of the rotor cover and body by means of a wooden spatula or a suitably shaped piece of wood, and wipe clean. 5 Clean the separation cone. 6 Wash all details, for example in gas oil. Centrifugal filter 1.
Page 226 22-9601 Lubricating Oil System 10 Remove the cut-off valve plug (14) and cut-off valve assembly. Check that the spring and shuttle are undamaged and free to move. Change the plug seal, if necessary. 11 Reassemble the filter, checking that the rotor assembly is free to rotate, and then replace the filter body cover (4).
Page 227 Lubricating Oil System 22-9601 5 Remove the sealing ring (8). 6 Force the sealing unit (13) off the drive screw (2). Press- ing force may be relatively strong due to the rubber bellows. 7 Tap the stationary sealing ring (6) together with the O- ring out of the front plate by using a chisel.
Page 228 22-9601 Lubricating Oil System 18.10.4 Reassembly The reassembly is performed in the reversed order. 1 Remount the ball bearing in the front plate, the protec- tive washer turned outwards. Lock with the locking ring. 2 Oil the O-ring (7) , Fig 18-9. Insert the stationary sealing ring (6) in the front plate.
Page 229 Lubricating Oil System 22-9601 18-20 VASA 22...
Page 230 22-9601 Cooling Water System 19. Cooling Water System 19.1 General description 19.1.1 General The engine is cooled by a fresh water system, divided into a high temperature circuit (HT) and a low temperature circuit (LT). The fresh water is cooled in a separate central cooler. The LT circuit is provided with a temperature control valve which keeps the temperature in the circuit at a load dependent level.
Page 231 Cooling Water System 22-9601 19.1.2 HT circuit The HT circuit cools the cylinders, cylinder heads and turbo- charger(s). A centrifugal pump (9), direct driven by the engine, pumps the water through the HT circuit. From the pump the water flows to the distributing duct, cast in the engine block (in V-engines the water is distributed to the distributing ducts of each cylinder bank through ducts cast into the pump cover at the free end of the...
Page 232 22-9601 Cooling Water System 19.1.6 Monitoring Local thermometers • HT before and after engine • HT after turbocharger • LT before charge air cooler • LT before lube oil cooler • LT after lube oil cooler The temperatures mentioned in chapter 01., section 01.2 should be followed.
Page 233 Cooling Water System 22-9601 cylinder head cooling water spaces may be checked by opening the lower large plugs on the sides of the cylinder heads. The turbochargers can be checked through the covers of the water space and the coolers by removing the water boxes of the inlet water.
Page 234 22-9601 Cooling Water System are lubricated by splash oil entering through the opening (20). The radial seal (13) prevents the oil from leaking out and, at the same time, dirt and leak water from entering. Also the axial seal (14), sealing against the outside of the seal (13), assists in this. The gear wheel (24) is fastened to the shaft by conical ring elements (25).
Page 235 Cooling Water System 22-9601 19.3.2 Maintenance Check the pump at intervals according to the recommendations in chapter 04. or, if water and oil leakage occurs, immediately. Disassembling and assembling impeller 1 Remove the volute casing by loosening the nuts (17). 2 Remove the cotter pin and loosen the nut (1).
Page 236 22-9601 Cooling Water System 2 Disassemble the impeller and mechanical seal according to pos. a) and b) above. 3 Remove the rear plate (19) by undoing the screws (16). 4 Loosen the screws (21) and remove the cap (27). 5 Pull off the gear wheel without using any tool. If gear wheel does not come loose, a few strokes with a non-re- coiling hammer will help.
Page 237 Cooling Water System 22-9601 13 Press the bearing (11) by its inner ring with a suitable pipe. See Fig 19-3B. 14 Turn the bearing housing according to Fig 19-3C and oil the outer surfaces of the bearings. Press the shaft into the housing by both the inner and outer ring of the bearing (11) with a suitable pipe.
Page 238 22-9601 Cooling Water System 21 Tighten the screws to torque according to chapter 07. 22 Reinstall the seals (13) and (14), see pos. d) below. 23 Reinstall the rear plate (19) as well as the mechanical seal, impeller and volute casing according to pos. a) and b) above.
Page 239 Cooling Water System 22-9601 mum 30 bar. This pressure is reduced by the pressure reducing valve to a constant pressure of about 6 bar. The complete system is mounted on the engine. The switch (4) has a small hysteresis to make the system stable in the change-over area.
Page 240 22-9601 Cooling Water System pressure (14) beneath the position control piston (3). Thus the spring (12) forces the piston (3) to the right (high load - low temperature position). In this situation the low temperature thermostatic element controls the valve while the high tempera- ture thermostatic element is completely compressed.
Page 241 Cooling Water System 22-9601 the steps below. A mark (e.g. tape) on the indicator pin (18) for closed position of the valve (cooling cut off) will help in indicating the position of the valve. The movement of the valve is maximum 11 mm for normal control and maximum 30 mm when changing from low to high load.
Page 242 22-9601 Cooling Water System 3 The valve is jamming. Clean the valve. Too low temperature at high load 1 Defective thermostatic element(s) (the element(s) will not go back to cold position). 2 Jamming valve. Clean the valve. 3 The valve is not closing correctly. Check adjustment ac- cording to pos.
Page 243 Cooling Water System 22-9601 The temperatures can be altered only by changing the ele- ments inside the valve. 19.4.2.4 Changing of thermostatic element 1 Drain as much cooling water as necessary to empty the valve. 2 Shut off air supply. 3 Loosen the indicator pin (18) but do not remove it from the tap (17).
Page 244 22-9601 Cooling Water System 19.4.3 Check of change-over point 1 Raise the load slowly over the change-over point, normally at 35 % ± 2 % load (if no other value has been agreed with the manufacturer). Check the change-over from the move- ment of the screw (2), Fig 19-6, or from the electrical side (no current at high load).
Page 245 Cooling Water System 22-9601 No adjustments are ever required on the HT-thermostatic valve. The temperature is permanently set at the factory. The tempera- ture can be changed only by changing temperature element assemblies which is easily accomplished by unscrewing the hous- ing.
Page 246 22-9601 Cooling Water System The contents of the elements (9) has an almost infinite force when heated and is positively sealed. When the elements are heated, this force is transmitted to the piston thus moving the sliding valve towards the seat (11) to the by-pass closed position. This force is opposed by a high spring force, which moves the sliding valve to the heat exchanger closed position when the elements are cooled.
Page 247 Cooling Water System 22-9601 19 - 18 VASA 22...
Page 248 22-9601 Exhaust System 20. Exhaust System 20.1 Description The exhaust pipes are cast of special alloy nodular cast iron, with separate sections for each cylinder. Metal bellows of the multiply type absorb heat expansion be- tween the cylinder heads and the pipe system as well as between the turbocharger and the pipe system.
Page 249 Exhaust System 22-9601 20.2 Replacing expansion bellows 1 Remove the cover (4) of the insulation box to get access to the expansion bellows between the exhaust pipes and the cylinder head. 2 Remove the covers (6) to get access to the expansion bel- lows between the exhaust pipes and the turbocharger.
Page 250 22-9601 Exhaust System Exhaust gas profiles Cylinder Cylinder (C¡) (C¡) 100% 100% Clockwise rotating engine Counter-clockwise rotating engine Fig 20-2 2220529544 When estimating the function of a cylinder on the basis of the exhaust gas temperatures under normal conditions, the values recorded in the acceptance test should be used as reference values.
Page 251 Exhaust System 22-9601 The exhaust gas temperatures of cylinders 7 and 8 in a clockwise rotating engine and of cylinder 8 in a counter-clockwise rotating engine are usually 50-120°C higher than the mean temperature of the other cylinders. The temperature difference between the cylinders should not be balanced by readjusting the fuel pump racks, which causes un- even loading of the cylinders.
Page 252 22-9601 Starting Air System 21. Starting Air System 21.1 General description The engine is started with compressed air of maximum 30 bar. The minimum pressure required is about 11 bar depending on the cylinder number and the installation. A pressure gauge (15) indicates the pressure before the main starting valve.
Page 253 Starting Air System 22-9601 When the main starting valve opens, starting air passes partly through the flame arrester (16) and partly through the start blocking valve (23). The start blocking valve prevents the passage of control air if the cover to the turning opening at the flywheel is removed.
Page 254 22-9601 Starting Air System 21.2.2 Maintenance Normally, the main starting valve requires little maintenance. In case it is to be opened for inspection: 1 Remove the valve from the engine by loosening the starting air pipe, the pipe from the valve to the start blocking valve and the bracket with the starting lever.
Page 255 Starting Air System 22-9601 21.3.2 Maintenance Normally, the starting air distributor is only slightly worn. If it has to be opened for inspection and cleaning: 1 Take care not to damage the sliding surfaces of the piston and the distributor housing bores. 2 The pistons are individually matched and are not inter- changeable.
Page 256 22-9601 Starting Air System 21.5 Starting air vessel and piping The starting air system should be designed so that explosion is prevented. An oil and water separator should be included in the feed pipe between the compressor and the starting air vessel. At the bottom point of the piping there should be a drain valve.
Page 257 Starting Air System 22-9601 actuated by the solenoid valve (2), which is energized from the speed monitoring system. The pneumatic overspeed trip devices (13), described in detail in chapter 22., section 22.6, are controlled by the valve (14) which is actuated by the solenoid valve (4) on an electric signal from the speed monitoring system, whereby the engine stops.
Page 258 22-9601 Starting Air System 21.6.3 Check When starting, check that the automatic water draining works by watching whether water-mixed air flows out from the valve (9). Regularly check the pressure after the pressure control valve (5). Shut off valve (18), open valve (17) and read the pressure on the manometer panel (starting air manometer), Fig 21-3.
Page 259 Starting Air System 22-9601 21.7 Starting air system equipped with pneu- matic starting motor (4R22, 4R22/26) 21.7.1 Description In order to ensure automatic start irrespective of the crankshaft position, the four-cylinder engines are optionally equipped with a pneumatic starting motor, which turns the crankshaft through a gear ring on the flywheel until the speed necessary for start is reached.
Page 260 22-9601 Starting Air System 21.7.2 Maintenance It is very important to keep the system free from dirt and condensate to achieve troublefree function. See section 21.5. Vent the servo lubricator circuit when starting up a new motor or if, by mistake, the oil container went empty. If the servo lubricator circuit is not thoroughly vented the starting motor will get no lubrication and may be damaged.
Page 261 Starting Air System 22-9601 21-10 VASA 22...
Page 262 22-9601 Control Mechanism 22. Control Mechanism 22.1 Description During normal operation the engine speed is controlled by a speed governor (22), Fig 22-1, which regulates the injected fuel quantity to correspond to the load. The regulating movement is transferred to the control shaft (10) through a spring-loaded rod (20) which enables stop or limit functions to be transferred to the control shaft irrespective of the governor position.
Page 263 Control Mechanism 22-9601 Next to the governor there is a fixed mechanical limiter affecting the control shaft directly by means of the lever (18). 22.2 Maintenance Special attention should be paid to the function of the system as a defect in the system may result in a disastrous overspeed- ing of the engine or in the engine not being able to take load.
Page 264 22-9601 Control Mechanism • adjust the fuel rack position to 4 mm by adjusting the screws (5). Control mechanism 1. Fuel rack 4. Connection piece 5. Screw 6. Torsional spring 7. Follower 8. Control lever 9. Torsional spring 10. Control shaft 11.
Page 265 Control Mechanism 22-9601 Adjustment: • if the fuel rack positions are unequal, adjust first according to section 22.3.1 b), • adjust the spring-loaded rod so that the fuel rack position of 4 mm is obtained, • if changing the governor, see section 22.4. 22.3.3 Mechanical overspeed trip device Check of stop position •...
Page 266 22-9601 Control Mechanism 22.3.4 Electro-pneumatic overspeed trip device Check of stop position • set the stop lever in work position and the terminal shaft lever in maximum fuel position, • release the overspeed trip device manually, • check the fuel rack positions to be less than 5 mm. Adjustment of stop position •...
Page 267 Control Mechanism 22-9601 • check the fuel rack position. The suitable limitation depends on the installation, normally about 18 mm. Adjustment of limit position • connect pressure air to the nozzle (5), • loosen the fastening screw (3) of the limitation lever, •...
Page 268 22-9601 Control Mechanism 22.4 Speed governor 22.4.1 General The engine can be equipped with various governor alternatives depending on the kind of application. Concerning the governor in itself, see the governor instruction book. 22.4.2 Hydraulic governor drive The governor is driven by a separate drive unit which, in turn, is driven by the camshaft through helical gears.
Page 269 Control Mechanism 22-9601 Woodward R22/26 12V22 16V22 type Α Β Α Β Α Β Α Β ∠ ∠ ∠ ∠ ∠ ∠ ∠ ∠ 30° ± 5° 20° ± 5° UG10 20.1° 35.3° 80° ± 3.75° 80° ± 3.75° 45° ± 3.75° 45°...
Page 270 22-9601 Control Mechanism 22.5 Mechanical overspeed trip device 22.5.1 Description The overspeed trip device is of the centrifugal type. It will trip when the engine speed exceeds the speed mentioned in chapter 06., section 06.1. The tripping mechanism is fastened direct to the camshaft end.
Page 271 Control Mechanism 22-9601 Mechanical overspeed trip device Spring Weight Latch Spindle Spring Lever Lever Switch Plug 10. Control shaft 11. Screw In V-engine 12. Hole only 13. Screw 14. Adjusting nut 16. Screw 17. Spring 18. Cover 19. Housing 20. Spring cap Fig 22-6 2222529033 4 Lock the spring cap with the locking screw(nut).
Page 272 22-9601 Control Mechanism 22.5.4 Maintenance • remove the tripping mechanism by removing the screws (13) and (11), Fig 22-6, • remove the spindle (4) with piston and spring (5). Be very careful when removing the spring (5). Use the tool 837015.
Page 273 Control Mechanism 22-9601 In some installations (mostly main engines) the stop circuit is energized only during the time when the overspeed contact is closed (i.e. the slow down system). A parallel contact to the alarm system is used as an overspeed indicator. The solenoid valve can also be operated manually.
Page 274 22-9601 Control Mechanism 22.7 Starting fuel limiter 22.7.1 General Always when starting either automatically, remotely or manu- ally, a limiter automatically limits the injected fuel quantity. Always when the engine is not operating, the three-way solenoid valve (4), Fig 22-4, is energized connected to the air distributing pipe with the limiting cylinder.
Page 275 Control Mechanism 22-9601 2 Check that correct limitation is achieved during acceleration period. 3 The limitation is cut off when 100 RPM below the nominal speed delayed with two seconds. This can be checked by in- creasing the speed very slowly above the cutoff speed by turn- ing slowly the speed control knob of the governor.
Page 276 22-9601 Instrumentation and Automation 23. Instrumentation and Automation 23.1 Monitoring equipment mounted on the engine 23.1.1 Instrument panel The instrument panel is flexibly suspended on three rubber elements at the free end of the engine. The following instruments are included: Sensor code Manometer for: —...
Page 277 Instrumentation and Automation 22-9601 Monitoring equipment, Vasa 22 T401 T402 P301 E701 E705 S710 L202 P204 P403 P402 T601 P103 T202 P202 P203 P102 Fig 23-1 2223519428 23 - 2 VASA 22...
Page 278 22-9601 Instrumentation and Automation 23.1.3 Combined visual pressure drop indicators and alarm switches • for too high pressure drop across the lube oil filter (P204). The indicator/switch is mounted on each lube oil filter, • for too high pressure drop over the fuel filter when mounted on the engine (P103).
Page 279 Instrumentation and Automation 22-9601 replaced by a new one. Pressure and temperature switches can be checked during operation. Temperature switches: The switches are fitted into special pock- ets and can thus be lifted off for checking also during operation. The check should be carried out so that the sensor part of the switch is immersed in liquid, e.g.
Page 280 22-9601 Instrumentation and Automation 23.1.5 Transducers for remote measuring The engine is as standard supplied ready for connection of the following transducers: Temperatures: The connection points are located next to the respective local thermometers unless otherwise stated. • charge air in the air receiver, •...
Page 281 Instrumentation and Automation 22-9601 23.2.2 Theory of operation 23.2.2.1 Diesel engine speed The engine speed is sensed by means of a touchfree, inductive proximity switch mounted to count the cogs passing its sensing head when the engine is running. The frequency output from the sensor, proportional to the engine speed, is converted to a DC-voltage of 0 - 10 V.
Page 282 22-9601 Instrumentation and Automation measuring converter with relay function DEP255 for engine speed ........C2 3 Relay I 3 speed-controlled relay functions with optional delay .
Page 283 Instrumentation and Automation 22-9601 23.2.3.2 C2, n measuring converter with relay DEP255 function for the engine speed Theory of operation: The speed sensor is touchfree proximity switch attached against a cogwheel to count the cogs passing. The output from the sensor is a square-wave frequency propor- tional to the engine speed.
Page 284 22-9601 Instrumentation and Automation P502: switchpoint: the middle potentiometer P503: delay: at the right hand side of the card 1 Determine the n -card amplification: (rpm) = U [V DC] 2 Calculate corresponding output voltage at specified relay switching speed: (rpm) x U (V DC) [V DC] =...
Page 285 Instrumentation and Automation 22-9601 ......15 mA, short-circuit-proof Unlinearity: ........±0.1 % Temperature coefficient: .
Page 286 22-9601 Instrumentation and Automation 3 Adjust the channel potentiometer to calculated value of the TP voltage. By short-circuiting TP3 on the nDE-card ( C2 ) the possible delay of the relays can de determined. Respective trimpoten- tiometers are P604, P605, P606. Note! During the test the adjusted switchpoint of the relay can be adjusted to a value below the test voltage, if this is higher than...
Page 287 Instrumentation and Automation 22-9601 23.2.3.4 C4, TC-card: Measuring converter for one or two turbochargers Theory of operation: The sine wave signal of the turbocharger speed sensor is amplified and transmitted to a squarewave signal. This can be measured by frequency counter. The square wave frequency signal is converted to a speed- proportional voltage 0 - 10 V.
Page 288 22-9601 Instrumentation and Automation 23.2.3.5 C5 Relay II Theory of operation: The card consists of 3 voltage-controlled relays, each having one change-over contact. Any internal or external voltage between 0 and 10 V DC can be used as control. The switchpoints and delays are adjustable. LED indicates an activated relay.
Page 289 Instrumentation and Automation 22-9601 23.2.4 Engine Speed Sensor Theory of operation: The sensor is an inductive, touchfree poximity switch supplied with +12 V and 0 V DC. The third pin is a speed-proportional pulse train. The electronics of the sensor is resin-moulded into a tubular housing of nickel plated brass with external thread of 18x1.5 mm.
Page 290 22-9601 Instrumentation and Automation 23.2.5 Turbocharger Speed Sensor Theory of operation: This sensor is magnetic, therefore it does not require any voltage supply. The sensor head is splitted by a yoke causing a sinusoidal output voltage when a magnetic material passes its sensing head. The metal housing is threaded to 12 x 1.25 mm.
Page 291 Instrumentation and Automation 22-9601 23.2.6 Adjustments of the Despemes cards Adjustments of the Despemes cards Measured Card Remarks and Function Adj. Ind. normal set point Power supply Adjustment normally not needed. R21/R29 DC/DC Rot. speed of engine 1500 RPM=950 Hz=10 VDC P501 Tach.
Page 292 22-9601 Instrumentation and Automation Despemes box DIAGR. A VASA 22 C2, TP4, C3, TP1, 2, 3 Volts LED 1 TP 3 P601 P701 TP 1 P604 P711 P501 TP 1 TP 1 400 600 800 1000 1200 1400 TP 2 LED 2 DIAGR.
Page 293 Instrumentation and Automation 22-9601 23.2.7 Trouble shooting procedures 1. Power supply DC/DC START Supply Is the Switch the green LED terminals power on lighting? 30-? Replace the card Defective fuse? Replace the fuse Power supply ready for operation Fig 23-10 2223619512 Power supply Polarity Terminal...
Page 294 22-9601 Instrumentation and Automation 2. nDE-measuring converter with relay function START Output Power supply Test program 1 0...10V DC Relay activates Pulse input Test program 5 Replace (LED turns on) from the sensor the card at any speed? * or osc.? Output Replace 0...10V DC...
Page 295 Instrumentation and Automation 22-9601 3. Relay card START Analog output relays operate Test program 2 0...10V DC at any speed of the engine? from n Replace the card Check and adjust if necessary Relay card ready for operation Fig 23-12 2223639512 23 - 20 VASA 22...
Page 296 22-9601 Instrumentation and Automation 4. nTC-measuring converter with 2 channels START Analog Supply output Test program 1 voltage 0..10V DC? Replace Pulse output? the card Check and adjust if necessary Sine- wave voltage Check the censor from sensor? Replace the card -card ready for operation Fig 23-13...
Page 297 Instrumentation and Automation 22-9601 5. Engine speed sensor START Pulse- train, pro- portional to Test program 1 Voltage supply the engine speed on n /TP1 12 VDC Check the connec- between pins 1(+) and 3(-) on the tion line sensor conn. Adjust the sensor for symmetrical...

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Page 141: Table Of Contents

Page 159: Screw

Page 162: Gear Wheel

Page 165: Screw

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Page 175: Screw