Wartsila Me Operations Manual

OPERATIONS MANUAL
NO. 995
DIESEL ENGINE TYPE
WARTSILA VASA
Engine type
Engine specification No.
Manufacturers serial numbers
Vessel
8R22MD
15135
3000 3003
RRM 23
This manual must always be available for the for engine operation crew.
Copying or submission of the manuals contents to the third parties is not
allowed.
WARTSILA DIESEL
Wartsila Vasa Factory
P.O. box 244, SF-65101 Vaasa 10, Finland
Tel.: 961-111 433, Telex 74250 wva sf
TABLE OF CONTENTS:
00.
CONTENTS, GENERAL, DEFINITIONS
Contents of Operation Manual

General
Definitions
01.
MAIN CHARACTERISTICS, OPERATIONAL SPECIFICATION AND ENGINE

ARRANGEMENT
Main characteristics
Recommended operational specification
Reference conditions
Engine arrangement
02.
FUEL OIL, LUBE OIL, COOLING WATER, NOZZLE COOLING OIL
Fuel oil
-
general
fuel oil treatment
recommended limits for fuel oil quality specification
comments on the fuel oil quality specification
measures when running on heavy fuel
general recommendations
Lube oil
-
specification of the circulated lube oil

circulation lube oil types allowed for use in Wartsila Vasa 22HF, HE main
engines
-
lube oil maintenance and condition inspection
regulator lube oil
turbocharger lube oil
Cooling water
-
general
additives
treatment
list of most frequently used cooling water additives
nozzle cooling oil
03.
START, SHUT-DOWN, OPERATION, STARTING AFTER A LONG SHUTDOWN, STARTING AFTER DISMANTLING, OPERATION CONTROL AFTER
OVERHAUL, ENGINE BREAK-IN
Start
-
manual start
remote and automatic start
Shut-down
-
manual shut-down
remote shut-down
automatic shut-down
general
Maintenance during operation

-
after every two days or every 50 running hours
after every two weeks or every 250 running hours
after one month or every 500 running hours
due to PMS
general
Starting after a long shut-down

-
manual start
Starting after dismantling

Operation control after overhaul
Engine break-in
04.
PREVENTIVE MAINTENANCE SCHEDULE
General
Period:
Every second day regardless whether the engine ran or not
Period:
Every week regardless whether the engine ran or not
Period:
Every 50 running hours
Period:
Period:
Period:
Period:
Period:
Period:
Period:
Period:
05.
HAND TOOLS
Hand tools for cylinder heads

Hand tools for piston
Hand tools for piston rod
Hand tools for main bearing
Hand tools for cylinder liner
Hand tools for fuel instruments
Hand tools for bolt tensioning
Nut wrenches
Various hand tools
Hand tools for turbocharger
Hand tools for engines with flywheel shield bearings
Hand tools for V-shape engine
Hand tools for inline engine
Hand tools for 4-cylinder engine
Combination tools
06.
SETTINGS, AIR GAPS AND WEAR LIMITS
Settings
Air gaps and wear limits
07.
TORQUE AND THREADED CONNECTION REQUIREMENTS
Stud, bolt and nut torques

Locking fluid application
Hydraulic torque of threaded connections
-
threaded connections hydraulic torque pressure
topping-up and checking hydraulic accessories set and bleeding-off air
undoing hydraulically torqued threaded connections
hydraulic tightening of threaded connections
08.
TROUBLESHOOTING, EMERGENCY OPERATIONS
Failures, possible causes

-
crankshaft does not rotate during start
crankshaft rotates with air but no combustion in engine cylinders
intermittent combustions in engine cylinders, combustions are completely

absent in some cylinders
-
engine runs intermittently
slaps or detonations in engine
dark exhaust gas
white-blue exhaust gas
abnormal high exhaust gas temperature of all cylinders
abnormal high exhaust gas temperature of any cylinder
abnormal low exhaust gas temperature of any cylinder
very uneven exhaust gas temperature
low lube oil pressure or no lube oil pressure
high lube oil pressure
high lube oil temperature
abnormal high discharge cooling water temperature, big difference in

suction and discharge cooling water temperatures
nozzle temperature adjusting lube oil temperature is higher or lower than

rated, big or small temperature difference in the system
-
water in lube oil
water in air receiver
engine RPM falls down at continuous or increased load
engine stops
engine does not stop though the shutdown handle is in stop position or a
remote shutdown signal is activated

-
engine overruns and does not shut down in spite of tripped limit switch
Emergency operation
-
running with faulty air cooler (s)
running wit faulty turbocharger (s)
running with broken cams
running with uninstalled piston and rod
torsional oscillations and other vibrations
09.
ENGINE SPECIFIC INFORMATION
Test reports, measurement chart forms

Fuel oil specification
Other specifications
Special devices
10.
ENGINE BLOCK WITH CYLINDERS, BEARINGS, CYLINDER LINERS AND

CRANKCASE
Description
Main bearing shell removal
Bearing shell and snap ring inspection
Installation of shells and main bearing snap rings
Removal and installation of additional flywheel shield bearing
Removal and installation of cylinder liner
Camshaft bearing sleeve inspection
Camshaft bearing sleeve removal
Camshaft bearing sleeve installation
11.
CRANK GEAR: CRANKSHAFT, CONNECTING ROD, PISTON
Description
Crankshaft package removal
Axial deflection check

Connecting rod and piston removal
Piston and connecting rod maintenance
Installation of connecting rod and piston
12.
CYLINDER HEAD WITH VALVES
Description
Removal of cylinder head assembly
Installation of cylinder head
Valve air gap adjustment
Inlet and outlet valve maintenance
-
valve removal
inspection and repair of valves and seats
engine valve removal
Cylinder head maintenance general information

13.
CAM SHAFT DRIVE
Description
Removal of camshaft drive
Camshaft drive assembly
14.
VALVE MECHANISM AND CAMSHAFT
Description of valve mechanism

Actuator arm disassembly and assembly
Cam follower disassembly and assembly
Description of camshaft
Camshaft section removal
Camshaft section installation
15.
TURBOCHARGER AND AIR COOLING
Description
Operation
Turbocharger maintenance
Troubleshooting
Part numbers
Appendixes
16.
FUEL INJECTION SYSTEM
Description
High pressure fuel pump, description
Removal and installation of high pressure fuel pump
Fuel injection start inspection
High pressure fuel pump disassembly
High pressure fuel pump assembly
High pressure fuel tube
Nozzle, description
Nozzle removal
Nozzle installation
Nozzle overhaul
Changing high pressure fuel pump piston stroke starting moment
17
FUEL SYSTEM
General
Description
Maintenance
Bleeding-off pressure
Pressure regulating valve adjustment
-
pump valve adjustment
setting pressure regulating valve
setting pressure regulating valves
Electric driven fuel pump

-
fuel charging pump (engine driven)
Fuel prefilter
-
description
cleaning
Fuel filter
-
description
replacing filter elements and cleaning filter
16.
Description
High pressure fuel pump, description
High pressure fuel pump assembly
Nozzle, description
Nozzle removal
Nozzle installation
Nozzle overhaul
17
FUEL SYSTEM AND NOZZLE TEMPERATURE REGULATING SYSTEM

FOR HEAVY FUEL APPLICATION
Fuel system
-
general
description
bleeding-off air
pressure regulating valve adjustment
fuel charging pump
fuel filter
Nozzle temperature regulating system

-
description
maintenance
18.
LUBE OIL SYSTEM
General description
General maintenance
Lube oil pump
-
description
disassembly
inspection
assembly
Lube oil pressure regulating valve and safety valve

-
description
maintenance
Lube oil cooler

-
description
general maintenance
lube oil end cleaning
water end cleaning
Thermostatic valve
-
description
maintenance
Main lube oil filter

-
description
replacing filter elements and cleaning filter
Centrifugal filter
-
description
cleaning
Lube oil primary circulating pump

-
description
general maintenance
disassembly
assembly
19.
COOLING WATER SYSTEM
Description
-
general
high temperature loop
low temperature loop
bleeding-off air from the system and systems pressure
preheating
instrumentation
Maintenance
-
general
water cavity cleaning
Water pump
-
general
maintenance
Temperature regulating system

-
general
temperature regulating valve
pressure regulating valve
20.
GAS DISCHARGE SYSTEM
Description
Expansion joint replacement
Isolated casing suspension
21.
STARTING AIR SYSTEM
Description
Main starting valve
-
description
maintenance
Air distributor
-
description
maintenance
Starting valve in cylinder head

-
description
maintenance
Air cylinder and pipelines

Starting air system with pneumatic starter
-
description
maintenance
22.
CONTROL GEAR
Description
Maintenance
Testing and adjustment
-
shutdown handle in stop position
regulator in stop position
mechanical limit switch
electro-pneumatic limit switch
starting fuel injection limit switch
load indicator
RPM regulator
-
general
hydraulic actuator drive
regulator removal
regulator installation
Mechanical limit switch

-
description
RPM limit setting check
RPM limit setting adjustment
maintenance
Electro-pneumatic limit switch

-
description
checking and adjusting stop position settings
RPM limit setting check
RPM limit setting adjustment
maintenance
Starting fuel injection limit switch

-
general
checking and adjusting limit settings
function test
maintenance
23.
INSTRUMENTATION
Engine instrumentation
-
instrumentation panel
temperature gauges
combined differential pressure switches and automatic alarm system

instruments
discrete action instruments
remote measuring instruments
RPM measuring gear including control relay instruments

MAIN CHARACTERISTICS, OPERATIONAL SPECIFICATION AND
ENGINE ARRANGEMENT
START, SHUT-DOWN, OPERATION, STARTING AFTER A LONG
SHUT-DOWN, STARTING AFTER DISMANTLING, OPERATION
CONTROL AFTER OVERHAUL, ENGINE BREAK-IN
PREVENTIVE MAINTENANCE SCHEDULE
HAND TOOLS
ENGINE BLOCK WITH CYLINDERS, BEARINGS, CYLINDER LINERS
AND CRANKCASE
CAM SHAFT DRIVE
VALVE MECHANISM AND CAMSHAFT
FUEL SYSTEM
LUBE OIL SYSTEM
STARTING AIR SYSTEM
CONTROL GEAR
INSTRUMENTATION
00.
00.1
Contents of Operation Manual
1.
2.
3.
4.
This Operation Manual contains information and provisions required for

operating and maintenance of the diesel engine. The general overview
information is not included. Consequently, it is assumed that the maintenance
crew has a good knowledge of diesel engine maintenance.
JSC Wartsila reserves the right to add minor changes and improvements
related to the design enhancement of the diesel engine without adding
corresponding changes in this Operation Manual.
The diesel engines are equipped as specified in the purchase package. No
claims are accepted based on this Operation Manual as it includes the parts
and components that may be not included in the purchase package.
The diesel engine layout is specified in details as according to the serial
number stamped at the manufacturers name plate.
Please, indicate engine type, manufacturers serial number and engine
specification every time sending the related correspondence or placing an
order for spare parts and components.
5.
6.
00.2
1.
2.
3.
4.
5.
6.
Spare parts catalogue is attached as an addendum to this Operations Manual.

This catalogue includes cross sections or side views of all parts and
components.
The Operational Manual has the following numbering:
Sub-section, for example, 00.1
Page numbers, for example, 00-1 (possible additional pages have
letters as well, for example, 00-1A, B, C, etc.)
Hand tools with designation are given in Section 05. The text has only
tool designations.
General
Prior to take any actions, it is necessary to study carefully the corresponding
sections of this Operation Manual.
Keep records for each engine in individual machine log book.
Any maintenance activity must be carried out with keeping cleanness and
order in the engine room.
Prior to disassemble any system, please, make sure that the systems are
dried or the pressure is relieved. After dismantling, close without delay lube oil,
fuel oil and airports with adhesive tape, covers, clean fabric or similar material.
When replacing any worn or damaged part having mark indicating the cylinder
or bearing number, please, mark the new part with the same number at the
same place. Any replacement must be recorded in the engine log book with a
clear description of the reason for the replacement.
After re-assembly, please, make sure that all bolts and nuts are tight and lock
wired if required.
00.3
Definitions
The main terms mentioned in the Operation Manual are given below:
Control end: Longitudinal diesel engine side where controls are installed (start and
stop controls, instrumentation panel, RPM regulator).
Side opposite to control end: Longitudinal diesel engine side situated on the opposite
to control end.
Power end: Butt end of the diesel engine where the flywheel is installed.
Side opposite to power end: Butt end of the diesel engine opposite to power end.
Cylinder numeration: according to recommendation #932 of ISO and standard DIN
6265 the numeration of cylinders starts from the power end. For V-shape diesel
engines, the left side cylinders looking from the power end are named as A1, A2, etc.
the right end side cylinders are named as B1, B2, etc. See the picture below.
Bearing numeration: Bearing numeration starts from the power end. The journal
thrust main bearing is designated as #1. If the diesel engine is equipped with
additional main bearing (flywheel shield bearing) such bearing is designated as #0.
The camshaft journal thrust bearing is designated as #0.
Right-hand engine: If one looks from the drive end and the crankshaft rotates
clockwise the diesel engine is called a right-hand engine.
Left-hand engine: If one looks from the drive end and the crankshaft rotates
counterclockwise the diesel engine is called a left-hand engine.
Bottom dead center: abbreviated as BDC is a lower point where the piston stroke in
the cylinder changes its direction.
Top dead center: abbreviated as TDC is an upper point where the piston stroke in the
cylinder changes its direction. TDC for each cylinder is marked with TDC sign as
according to the calibration of the flywheel.
Top dead center at the combustion moment: Within the full working cycle of a fourstroke engine when the crankshaft makes two revolutions, the piston gets to TDC
twice:
a.
The first cycle takes place when the blow-off stroke of the previous cycle ends
and the suction stroke of the following cycle starts. The outlet valves as well as
inlet valves at this moment are partially open and blowing takes place. When
rotating the crankshaft back and forth close to TDC both inlet and outlet valves
are moving this indicates that the crankshaft is close to the position which
can be called TDC at blowing moment.
b.
The second cycle takes place after the compression stroke and before the
working stroke. Just before TDC, the fuel injection takes place (when the
engine is running) and such TDC can be called TDC at combustion moment.
At this moment, all valves are closed and will not move if the crankshaft is
rotated. Carefully watching at the camshaft and high pressure fuel pump one
can see that the pump cam follower is at the raising side of the fuel cam.
01.
MAIN CHARACTERISTICS, OPERATIONAL SPECIFICATION AND

ENGINE ARRANGEMENT
01.1
Main characteristics
Cylinder diameter:
Piston stroke:
Cylinder working volume
220 mm
240 mm
9.12 ltr
Combustion sequence:
Engine type
Right-hand engine
Left-hand engine
4R22
134-2
124
6R22
153624
142635
8R22
13748625
12V22
A1 B1 A5 B5 A3 B3
A6 B6 A2 B2 A4 B4
A1 B4 A4 B2 A2 B6
A6 B3 A3 B5 A5 B1
16V22
A1 B1 A3 B3 A7 B7
A4 B4 A8 B8 A6 B6
B2 B2 A5 B5
A1 B5 A5 B2 A2 B6
A6 B8 A8 B4 A4 B7
A7 B3 A3 B1
Usually, the diesel engines are made of right-hand rotation.

Engine lube oil volume:
4R22
6R22
8R22
Lube oil volume,

liters
320
450
Lube oil volume

between maximum
and minimum
marks, liters
60
Anti corrosion oil,

liters
Engine type
12V22
16V22
580
670
870
100
125
150
195
65
90
110
130
160
4R22
6R22
8R22
12V22
16V22
90
120
160
240
320
Engine water volume:

Engine type
Cooling water
volume, liters
01.2
Recommended operational specification of main engine according to

specification No. 4V92A95 running on diesel fuel
These recommendations are applicable for a normal operation at the rated RPM:
1. Temperature (O C)
- lube oil at engine inlet
- lube oil at crankcase by
- high temperature water at engine outlet
- high temperature water at engine inlet by
- high temperature water above the water in turbocharger
- low temperature water at engine inlet, fresh water
- low temperature water at engine inlet, sea water
- air charge in receive
- exhaust gas at cylinder outlet
- cooling water heating
2. Pressures (Bar)
- lube oil at engine inlet at:
900 rpm
1000 rpm
1100 rpm
1200 rpm
- high temperature water at engine outlet
- low temperature water at engine inlet
- fuel oil at engine inlet, pump with electric motor
- fuel oil at engine inlet, suspension pump
- starting air
- purging air
3. Other pressures (Bar)
Combustion pressure
Lube oil pump safety valve opening pressure
Combined differential pressure switch tripping and lube oil
and fuel oil filter differential pressure electric transducer
pressure
Rated value
Limit
settings
values for
alarm
(safety)
system
62 70
10 13 higher
78 86
5 8 lower
8 12
25 38
25 32
40 60
See test
certificate
70
80
3.5
4.0
4.5
4.5
1.8 4.5
1.8 4.5
4.0
4.0
max. 30
See test
certificate
2.0 (1.5)
See test
certificate
68
1.2 1.8
90 (95)
75
50 higher
1.5
2.0
2.0
18
Allowed
differential
pressure min.
max. 10 Bar
01-3
01.3
Reference conditions
The basic environmental conditions are as follows:

Ambient air pressure
Ambient temperature
Humidity
Cooling water temperature in air cooler
- fresh water
- sea water
1.013 bar
45O C
60%
38 O C
32 O C
Of the diesel engine is used in the environment that differs from the aforementioned
one this is be indicated in the document package. Otherwise, the percentage of the
power reduction may be calculated as follows:
(a + b + c) %
where,
a=
0.5% per each O C of the ambient air temperature above + 45 O C
b=
1.0% per each 100 meters above 300m above the sea MSL
c=
fresh water: 0.4% per each O C of cooling water in air cooler above +38 O C
sea water: 0.4% per each O C of cooling water in air cooler above +32 O C.
01.4
Engine arrangement
The diesel engine is a four-stroke engine with gas turbine charger, intermediate air
cooling and direct fuel injection.
Engine cylinder block being an integrated engine body part is a solid mold. The main
bearings are designed as suspension bearings. Main bearing seat is supported with
two hydraulically tightened studs and two horizontal side bolts. Camshaft bearing
seats are molded together with the block. The air receiver as well as cooling water
and lube oil manifolds are molded as integrated part of the block. Crankcase and
camshaft hatch covers are made of mild steel alloy and installed at the engine
cylinder head with O-rings. The crankcase is welded.
Main bearings are steel, triple coated, fully interchangeable and may be removed
with seats release.
Crankshaft is solid-forged and balanced with counterweights as required.
Connecting rods are hot-formed. The lower connecting rod head is diagonally cut and
its coupled surfaces are teeth-shaped. The main bearing has a staged shape in order
to provide a bigger support area at the lower part of the bearing.
Pistons are made of cast iron with ball graphite and lube oil cooled. The cooling lube
oil enters the cooling cavity through the connecting rod, piston pin and drilled ports
and leaves through the drilled ports designed to achieve the optimum agitating effect.
Piston skirt is lubricated under pressure. Two upper grooves of piston rings are
reinforced. The piston ring set consists of three compression rings (two of them are
upper chromed rings) and one chromed spring-loaded oil ring installed above piston
pin level.
Cylinder head is made of high tensile strength cast iron and fixed with four
hydraulically tightened studs. Two inlet and two outlet valves are totally identical and
their seats are covered with stellite alloy. Valve rods are chromed. Valve seat rings
are made of the special cast iron and inserted into slots that are effectively water
cooled. The valve gear is lubricated under pressure and protected with a casing.
Camshaft consists of put together piston individual sections with cams integrally
forged with the shaft. The camshaft bearings are installed directly within the cylinder
head.
High pressure fuel pumps are installed at the upper level of cylinder head and have
followers situated in the pump body.
Nozzles are fully inserted into the cylinder head and the high pressure fuel tube is
connected to nozzles from one side through a reducing pipe. Thus the fuel oil can
never mix with the lube oil.
Gas turbocharger is installed one for each cylinder row and situated at the side
opposite to control end.
Air coolers have removable tubing loops. V-engines are equipped with to similar air
coolers.
Fuel oil system consists of a fuel charging pump and a double filter with three-way
valve.
Lube oil system consists of a gear-type pump, double-type lube oil filter, cooler with
thermostatic valve, centrifugal bypass filter and lube oil charging pump with electric
motor. All of them are installed atop the diesel engine.
Starting air system. Air charge to the cylinders is controlled by the air distributor
driven by the camshaft. The four-cylinder engine is started with the help of a
pneumatic starter.
02.
02.1
General
The diesel engine is designed for running on heavy fuel (black oil) with the maximum
viscosity 380 centistokes at 50O C (3500 c by Redwood viscosimeter #1 at 100 O F)
but it works satisfactory as well on mixed (medium viscous) fuel oils the with lower
viscosity and on the distillate diesel fuel. The maximum values of the fuel viscosity for
a given diesel engine are indicated in the document package included in the engine
supply scope. Nevertheless, it is recommended to avoid using mixed brands of fuel
oils (black oil and distillate diesel fuel) with the viscosity from 10 to 30 centistokes at
50O C (from 65 to 200 c by Redwood viscosimeter #1 at 100O F) having 30 to 60% of
the distillate diesel fuel in order to prevent sedimentation of heavy components of the
mixture that may cause filter contamination and heavy sludge accumulation after
centrifuge purifiers. When problems occur due to the filter contamination, the need to
use different brands of fuel oils may be considered based on the method specified in
ASTMD 2781 or other similar standards.
02.1.1
Fuel oil treatment
a.
Purification
The heavy fuel (residual heavy fractions of the cracking process and their mixes with
distillate diesel fuel) must be cleaned with an effective centrifugal purifier prior to
access the day tank. Before the purification, the fuel oil is to be preheated. The
recommended temperature of preheating related to the fuel viscosity is given in the
table below.
Make sure that a correct gravity wheel is selected. Never exceed the recommended
speed of the fuel pass through the purifier as the speed is selected with relation to
the viscosity and the density of the given fuel. The lower the fuel pass speed the
higher the purification efficiency.
Fuel oil
Max. viscosity (cSt at 50O C)

30
40
60
80
180
240
380
Recommended fuel oil speed passing

through purifier (% of maximum
capacity)
65
60
45
40
30
25
20
Recommended preheating
temperature (O C)
73
80
86
88
98
98
98
FUEL VISCOSITY V/S TEMPERATURE DIAGRAM

REQUIRED TO PREHEAT THE FUEL OIL.
1.
2.
3.
4.
5.
6.
7.
Approximate pour point viscosity.

Fuel can be hardly pumped or cannot be pumped at all.
Maximum viscosity in fuel oil storage tank.
Maximum viscosity in fuel day tank.
Recommended purification temperature.
Minimum fuel storage and day tank temperature.
Recommended viscosity before high pressure fuel pump.
Viscosity by
Redwood #1
Centistokes
m2
(10-6 sec )
Example:
The fuel with 120 cSt at 50O C (A) must be preheated before the high
pressure fuel pump to 107 122 O C (B C), in the day tank it is to be
preheated minimum up to 47 O C (D), in the purifier up to 93 O C (E) and
in storage tank minimum up to 30 O C (F). The fuel oil cannot be
pumped at the temperature below 17O C (G). The fuel oil is 1000 C by
Redwood #1 viscosimeter at 100 O F (H).
For the distillate diesel fuel (maximum viscosity 14 cSt at 40 O C) (for example, Marine
Diesel Fuel), the recommended flow speed is 80% and the preheating temperature is
45O C.
Even in case of using pure distillate diesel fuel, it is recommended to purify the fuel
oil as the fuel is getting contaminated in the fuel tanks. The estimated capacity of the
fuel oil purifier may be used if the fuel viscosity is below 12 cSt at the purification
temperature. For example, the viscosity of Marine Gas Oil fuel is normally below 12
cSt at 15 O C.
b.
Preheating
See diagram above.

The maximum recommended viscosity of the fuel oil storage tanks (where the fuel is
bunkered) is 400 cSt. Due to the possibility of the wax accumulation the temperature
of the fuel oils with the viscosity below 120 cSt at 50 O C must be maintained at the
higher viscosity than it is required.
Fuel oil viscosity (cSt at 50 O C)
380
240
180
40 120
4.5 40
Below 4.5
Minimum fuel oil temperature in the

storage tank (O C)
50
42
38
30
24
6
The fuel oil having viscosity exceeding 5 cSt at 50 O C requires preheating before the
purification.
The maximum recommended viscosity in the day tank is 140 cSt. Due to the
possibility of the wax accumulation the temperature of the fuel oils with the viscosity
below 50 cSt at 50 O C must be maintained at the higher viscosity than it is required.
Minimum fuel oil temperature in the

day tank (O C)
67
60
55
47
40
30
24
6
Fuel oil viscosity (cSt at 50 O C)

380
240
180
120
80
40 50
4.5 40
Below 4.5
The fuel brands having viscosity exceeding 10 cSt at 50 O C must be preheated

before entering fuel oil system of the diesel engine. It is recommended to keep the
temperature of the last preheater at the entrance to the high pressure fuel pump in
order to compensate the heat loss between preheater and the diesel engine.
c.
Viscosity control
While running on fuels necessitating preheating, an automatic viscosity control device
must be installed to maintain the required viscosity at the entrance to the engines
fuel system.
02.1.2
Recommended maximum limits for fuel oil quality specification

Characteristics
Density at 15 O C
Kinematic viscosity at 80 O C
UOM
Heavy fuel
HF
0.9910
75.00
--380.00
Heavy fuel
HE
0.9910
28.00
--100.00
Heavy fuel
MD
0.9200
--14.00
11.00
Coke number by Conradson
kg/ltr
cSt
cSt
cSt
St by
Redwood # 1
% of weight
Coke number by Ramsbottom
% of weight
---
---
2.5
Water content
% of volume
1.0
0.5
0.3
Water content at engines

inlet
% of volume
0.2
0.2
0.2
Ash content
Sulfur content
Pour point
Vanadium content
Asphaltenes
Sodium salts content
Aluminum content
% of weight
% of weight
O
C
mg/kg
% of weight
mg/kg
mg/kg
0.15
5.00
30
500
8
50
30
0.10
3.50
24
250
8
50
30
0.05
5.00
6
100
----30
Kinematic viscosity at 100 O F
3500.00
800.00
70.00
20.0
12.0
---
02.1.3
Recommended minimum limits for fuel oil quality specification
Characteristics
Closed cup tester flash point
by Pensky-Martens
UOM
O
Heavy fuel
HF
60
Heavy fuel
HE
60
Heavy fuel
MD
60
Other characteristics apart from the viscosity are to comply with the British
Standard 100:1982, class M6 with additional limitations related to water
content at the engine inlet and asphaltene and sodium salt contents.
Other characteristics apart from the viscosity are to comply with the British
Standard 100:1982, class M4 with additional limitations related to water
content at the engine inlet and asphaltene and sodium salt contents.
According to the British Standard 100:1982, class M3 with additional

limitations related to water content at the engine inlet.
02.1.4 Comments on the fuel oil quality specification

a...
The viscosity is not taken into account for the assessment of the fuel oil quality
but it can be used to determine type of systems to preheat and treat the fuel oil
which must be taken into consideration while assessing the cost effect of the
whole power plant. The engines fuel system running on heavy fuel is designed
for the maximum fuel oil viscosity 380 cSt at 50 (3500 st by Redwood 1 at
100 F) and for the engines running of diesel fuel the maximum viscosity is 14
cSt at 40 (70 st by Redwood 1 at 100 F).
b.
When the fuel oil density exceeds 0.990 sg it is harder to remove water with
purification as well as it is difficult to a certain degree to remove solid particles.
c.
High sulfur content increases the possibility of corrosion and excessive wear
especially at the low load and may contribute to sediment accumulation at the
high temperatures.
d.
High ash content causes the abrasive wear and may result in high-temperature
corrosion and promotes sediment deposition. The most harmful parts are
vanadium and sodium salts.
e.
High vanadium content causes high-temperature corrosion at the outlet valves

especially while combined with the high content of sodium salts. The corrosion
increases under the effect of high temperatures (at the increased engine power).
f.
Sodium salts combined with the high vanadium content provoke hightemperature corrosion at the outlet valves. Fuel brands having about 40% of
sodium salts compared to vanadium content are considered as the most
harmful. Sodium salts also cause contamination of the turbochargers turbine at
the high load.
g.
High coke number by Conradson may cause the sediment deposition in

combustion chamber and gas exhaust system especially at low power mode.
h.
High asphaltene content may cause the sediment deposition in combustion

chamber and gas exhaust system. Under certain conditions, the asphaltenes
may deposit and clog filters and/or cause sedimentations in the fuel oil system.
The sedimented asphaltenes may cause a lot of sludge during the purification.
i.
Heavy fuels may contain a lot of water (up to 1%). The water may also originate
in fuel oil storage tanks. In order to avoid problems with running high pressure
fuel system the water content must be reduced to the value not exceeding 0.2%
with the purification.
j.
Volatility, inflammability. Heavy fuel oils may have very low cetane ratio or low
volatility (high sublimation curve). This may become a cause of failure when
running at low load mode.
02.1.5
Measures when running on heavy fuel
A diesel engine is designed to run on heavy fuel with quality characteristics given in
the table in Section 3 in all operational conditions.
But the poor quality of the fuel oil affects significantly the wear, service life and
maintenance of parts and components of the engine.
In order to achieve the maximum cost efficiency of the diesel engine operation it is
recommended to take the following measures:
a.
to limit the maximum continuous power as much as operationally possible if it

is known or assumed that the vanadium content in the fuel is high (exceeding
200mln-1) and especially if sodium salt content at the same time is about 40%
related to vanadium content.
b.
to limit operations at the low load as much as operationally possible if it is

known or assumed that the sulfur content in the fuel is high (exceeding 3%),
coke number exceeds 12% and/or asphaltene content is above 8%.
A continuous engine run at the load below 20% must be limited to 100 hours with
loading the engine to 70% of its rated capacity for one hour prior to continue running
at the low load again.
Running engine idle (while mover if off for main engine, when generator has no
load diesel generator) must be limited as much as possible. Engine preheating at
no-load longer than 2-3 minutes is not required and such preheating is to be avoided
as well as idle operation longer than 2-3 minutes before the shutdown
02.1.6
General recommendations
In order to prevent problems caused by the incompatibility of fuels (sedimentation of

the heavy particles of the fuel) it is necessary not to allow mixing fuel oils received
from different bunkering stations if such fuel oils are not accepted as compatible.
If the fuels compatibility and stability may be a source of problems you must never
add distillate fuel oil it potentially results in the increase of the sedimentation. Adding
the fuel additives with effective thinning properties may be tolerable until the next
bunkering.
The quality characteristics of the fuels made of mixed with residual sinking fractions
of such modern crude oil refining processes as catalytic cracking and viscracking
(lowering viscosity with light cracking) may correspond to certain recommended
limitations specified in the Section 3.
"Modern" brands of the heavy fuel compared to conventional brands made of mixed
with residual sinking fractions left after the petroleum refining at the atmospheric
pressure have less inflammability and the efficiency of the combustion.
Heavy fuel brands made of mixed residual sinking fractions of catalytic cracking may
contain very abrasive catalytic particles (silicon and aluminum oxides). If they are not
removed before they entered the fuel system they may cause the complete wear of
the high pressure fuel pumps and injectors within several hours.
Running on heavy fuel brands made of mixed residual sinking fractions of the
cracking process may cause problems which can be avoided if the following
measures are taken:
sufficient number of fuel oil purifiers available onboard. The best results may
causes the smallest number of malfunctions are achieved when using two
purifiers connected in sequence. The first purifier serves for cleaning purposes
and the second one is used for the sedimentation. The other option suggests
connecting two purifiers in parallel but this option impose an increased
requirement for the selection of the impeller and for the constant regulation of
the flow and temperature in order to achieve the optimum results. The volume
of the fuel oil passing through the purifier must not exceed the volumes of the
fuel used by diesel engines by more than 10 %.
-
sufficient number of preheaters to maintain the temperature recommended for

the purification and injection of the fuel oil. When purifying the fuel oils with
high viscosity having density approximately 0.990 it is very important that the
temperature fluctuations are to be as low as possible (2 before purifier).
sufficient preheating of diesel engines and fuel system before the start up.
02.2
02.2.1
Lube oil
Specification of the circulated lube oil
Viscosity. The circulated lube oil must have the viscosity corresponding to class SAE
30. Lube oils with viscosity class SAE 40 may be used as well and for certain brands
of the lube oil such viscosity class is even recommended.
Quality. The circulated lube oil must be as per its characteristics suitable for the
vessel middle speed four-stroke engines with a high level of turbine air charging
which burn sulfurous and high-sulfurous fuel oils. The lube oil must have the high
thermal stability and contain the additives that have to following features:
to increase the lube oil resistivity to oxidation;
-
to increase corrosion-resistant features of the lube oil;
to prevent sedimentation deposition inside the diesel engine;
to increase the capacity of the oil film to bear the mechanic load;
to neutralize the acid residuals of burning and oxidization.
The lube oil must have the high hydrophobic properties and capacity to keep the
active features of the additives.
The lube oils of vessel engines there are no general standards. Whatever is referred
to the content of the additives in the lube oil and diesel engines operational process,
the recommendations of standards MIL-L-2104 or API Service CD that they must
to comply with are the ones that may be applied.
Alkalinity. The lube oil alkalinity must be within the range from 25 to 40 mg of KOH/g
a little bit higher at the high sulfur content in the fuel.
02.2.2
Specification of the circulated lube oils allowed to be used in diesel engines

of type "Wartsila" Vaasa 22HF, , MD
Lube oil supplier
Name (brand) of lube oil
Energol IC-HF 303, 304
Castrol
MXD 303, 304
Esso
Tro-Mar SR 30, SR 40, SRX 40
Elf
Aurelia 3030, 3040, XT 3040, 4040
Gulf
Veritas Select 30, 40
Mobiloil
Mobilgard 324, 424, 342, 442
Nynas
Aurelia 3030, 4030, XT 3040, 4040
Olje-Energi
Goth Oil 325
Shell
Argina T Oil 30, 40, X Oil 40
Teboil
Teboil Ward S30T SAE 30, 40
Texaco
Taro DP 30, 40
Compagnie Francaise de Raffinage
Total HMA SAE 30
Note: The use of the lube oils not included n the table above requires the engine
manufacturers approval in order to confirm the warranty issued for the given diesel
engine.
The lube oils marked with "" are approved based on the results of the engine tests
and the other lube oils are approved based on the basic analysis and
recommendations of lube oil suppliers. Never mix the different lube oil brands prior to
receive the approval of a lube oil supplier and during the warranty period the engines
manufacturer approval is required as well.
The use of lube oils with the alkalinity from 35 to 40 mg KOH/g is recommended in
case of the sulfur content in fuel oil 4% and above but at the same moment it is not
allowed in auxiliary engines at the low sulfur content in the fuel oil if the main engine
requires the use of the lube oil with the alkalinity exceeding 30 mg H/g.
02.2.3
a.
Lube oil maintenance and condition inspection
The circulated lube oil purification is recommended for the removal of the water
and unsoluble particles. It is not allowed to add water during the purification
(flushing). The lube oil is to be preheated up to 80 - 85 . In order to achieve
an effective purification, it is necessary to use only approximately 20% of the
rated capacity of the purifier. In order to achieve the optimum efficiency, the
purifiers capacity must be sufficient for the purification of the whole volume of
the lube oil 4-5 times in 24 hours while applying 20% of purifiers maximum
capacity. The impeller must be selected based of the lube oils weight at 80
(usually lube oil suppliers recommend at 15 ).
Warning:
b.
The failures of the automatic self-cleaning purifiers may at certain

circumstances highly increase the water content in the lube oil (for
example, faulty regulating valve).
It is recommended to take samples for the lube oil analysis during the first year
of the operation approximately after 250, 500 and 1000 running hours. The
samples are to be forwarded to the lube supplier for the analysis. The
corresponding periods between replacements may be identified based on the
results of such analysis. After that, the lube oil samples may be sent for the
analysis after each 500 running hours.
In order to make sure that the lube oil sample corresponds to the circulated
lube oil same, it is necessary to take it into a clean bottle 0.75 1 liter through
the valve specially designed for this purpose. This valve is installed at the lube
oil tube straight after the filter. The lube oil sample must be taken before the
next lube oil topping-up and not after. Prior to take the sample, the bottle is to
be flushed with the lube oil to be analyzed.
In order to achieve a perfect assessment of the circulated lube it is desired to
add the following information accompanying the lube oil samples: description of
the power plant, manufacturers serial number of the engine, lube oil brand,
engine running hours, running hours on this given lube oil and other potential
notes. The lube oil sample having only the power plant description and engines
serial number is nearly useless.
The lube oil condition is assessed as per the following features comparing the
results of the analysis with the rated values (typical analysis) of the fresh lube
oil of the given brand.
-
Viscosity must not exceed the rated value more than by 25% at 100.
Maximum allowed lube oil viscosity SAE 30 - 140 cSt at 40 and 15 cSt
at 100.
Maximum allowed lube oil viscosity SAE 40 - 212 cSt at 40 and 19 CSt
at 100.
Maximum allowed viscosity is 70 sSt at 40 and 9 sSt at 100 .
Flash temperature must not fall more than 50 below the rated value.
The minimum allowed flash temperature (at open tester cap) is 170 . At
the temperature 150 there is a possibility of the combustion in the
crankcase.
Water content must not exceed 0.2%. When the water content is 0.5%, it is
necessary to take purification measures or replace the lube oil.
Alkalinity, minimum 15 mg KOH/g.

Allowed content of the unsoluble mechanic particles depends on the
different factors. It is necessary to respect the recommendations on the
lube oil supplier. The content of 2- 3% of the unsoluble in n-peptane
mechanicls particles anyhow requires some measures.
Generaly, one may say that any changes of the lube oil analysis values are
the correctest base of the lube oil quality othen than the absolute values of the
characteristics. The drastic and big changes may be the sign of the abnormal
operation of the diesel engine or the system.
The lube oil consumption must be compensated with addition not more than
10% of the fresh lube oil per time. When adding a big volume of the lube oil,
the balance of the working lube oil may be offset, for example, with deposition
of the unsoluable mechanical particles.
c.
The volume of the added lube oil must be measured and recorded. The
valuable information may be received by analyzing lube oil consumption. The
constant increase of the lube oil consumption may be explained by worsening
conditions of piston rings, pistons and cylinder liners. The drastic increase of
the lube oil consumption is a reason to remove pistons if the other reasons of
the consumption have not been identified.
d.
A draft schedule of the lube oil replenishing is shown in Section 04, subsection 04.7. The time between lube oil replenishing depends particularly on
operational condition of the diesel engine, fuel oil quality, purification efficiency
and general lube oil consumption. When using effective purification and big
systems (with dry crankcase) usually it is allowed to have very long time
between lube oil replenishing.
When replacing lube oil, the following operational sequence is to be carried
out:
1.
Drain the lube oil from the system while the oil is still hot. Make sure
that the lube oil filters and coolers are drained as well.
2.
Clean lube oil cavities including filters and camshaft crankcase. Install
new filter elements.
3.
Fill the crankcase with a small volume of the fresh lube oil and pump it
through the system with charging pump. Drain the lube oil.
4.
Top up with the required volume of the lube oil.
Lube oil samples taken regularly and analyzed by the lube oil supplier give the
possibility to record the analysis results related to the running hours with this
given lube oil. This is a reliable method to determine the periods required
between the lube oil replenishing.
Send or ask lube oil supplier to send lube oil analysis report copies to the
engine manufacturer which will assist with assessing the condition of this lube
oil.
02.2.4
Regulator lube oil
See regulator operation manual (section 22). Usually, the lube oil with viscosity class
SAE 30 fits for purpose and frequently it is allowed to use the same lube oil as in the
system of the diesel engine or turbocharger. The period between lube oil replacing is
1000 running hours.
Warning: If the regulator is lubricated with turbine lube oil it is not allowed to mix it
with the engines lube oil. Even a small volume of the different lube oil may result in
heavy foaming.
02.2.5
Turbocharger lube oil
See turbocharger operation manual (section 15). The mineral lube oil with the
viscosity of 52 87 cSt at 40 is used preferably turbing lube oil. . The period
between lube oil replacing is 1000 running hours.
Warning: It is not allowed to mix the turbine lube oil with the engines lube oil. Even a
small volume of the different lube oil may result in heavy foaming.
02.3
Cooling water
02.3.1
General
In order to prevent corrosion, scale depositions and other foreign substances in the
circulation system of the cooling water it is necessary to put additives.
Prior to put additives in the cooling water it must be transparent and have the lowest
possible hardness (not more than 10 German degrees, 1 dH = 10 mg /ltr and 10
German degrees correspond approximately to 3.6 mg-equivalent/ltr), the chloride
content must be below 80 mg/ltr as well hydrogen ion exponent must exceed 7.
The best results are achieved with the application of additives and sufficiently
distillated water received, for example, from a water maker.
Warning: The distillated water without additives absorbs carbon dioxide from the
atmosphere resulting in the high possibility of corrosion buildup.
02-13
The sea water may cause corrosion buildup and depositions even if it entered the
system in a small volume.
The rain water contains a lot of oxygen and carbon dioxide resulting in the high
possibility of corrosion buildup. Thus, the rain water is not acceptable as cooling
water.
02.3.2
Additives
It is necessary to use the additives of the well-established and reliable suppliers. The
instruction suppliers must be followed.
Note: It is not recommended to use (single) emmulstion oils, phospfates and borates.
The table in section 02, sub-section 02.3.4, the properties of the most common
cooling water additives are specified.
The sub-section 02.3.4 of section 02 contains a list of the cooling water treatment
products.
In very critical situations when the mixed cooling water additives are not available it is
necessary to treat the water with sodium nitrite (NaN02) with the ration of 5 kg/m3. In
order to have the hydrogen ion exponent approximately 9 if required it is
necessary to add caustic soda (NaOH).
Note: Sodium nitrite is poisonous.
02.3.3
Treatment
When changing additives or adding additives into a system where untreated water
was used previously, the whole system must be (chemicaly) cleaned and flushed with
the new treated water prior to top up. If in spite of our recommendations the emulsion
oil was used the whole system must be absolutely cleaned removing all depositions
of the oil and grease.
The evaporated water must be compensated with untreated water if the untreated
water is used the additives content may gradually excessively increase. In order to
compensate leakage or other losses it is necessary to use the treated water.
While carrying out operations requiring draining cooling system try to re-use the
drained treated water.
02.3.3
List of most frequently used cooling water additives
Additive
Advantages
Disadvantages
- content assessment is
possible with the help
of special
instrumentation
- susceptible to erode
Zink layer and soft
soldered surfaces;
- poisonous: lethal dose
is 3 4 g of solid
nitrite
Application
Sodium
nitrite
- high efficiency
- low active quantity:
0.5% of its weight;
- inexpensive
- acceptable for use

except for heat
exchangers with air
cooling with a lot of
soft soldered area
Nitrite +
borate
- no high possibility of
corrosion deposition
due to excessive or
insufficient dosing;
- non-harmful for skin;
- allowed to be used in
industrial water
makers
Sodium
chromate
or
Potassium
chromate
- high efficiency
- low active quantity:
0.5% of its weight;
- moderate price;
- easy to assess the
content (colour
comparison with the
test solution);
- easy available at the
market
- at the low content, the - acceptable for use as

possibility of pitting
additives in cases when
increases;
toxicity is allowed.
- harmful for skin;
Careful handling and
- poisonous: lethal dose
close control are
is approximately 1 g;
required when used.
- use in industrial water
makers is prohibited
Sodium
silicate
- non-poisonous;
- safe for use
- not effective at water

- limited application
flow speed exceeding
2 m/sec;
- very expensive brands;
- at the low content, the
possibility of pitting
increases
02-15
Examples of cooling water treatment products
Supplier
Burmah-Castrol Marine
Burmah House
Pipers Way
Wiltshire SN3 1 RE, UK
DIA-PROSIM
107 Rue Edith Cavell
94400 Vitry, France
Drew Chemical Corp., Marine Division
522 Fifth Avenue
New York, N.Y. 10036, USA
Name
Castrol solvex WT2
RD 11 M
Drew Ameroid
DEWT-NC powder
Maxigard
Gamlen Chemical Company (UK) Ltd

Wallingford Road, Uxbridge,
Middlesex UK
Gamlen Gamcor NB
Houseman Hegro Ltd

The Priory, Burham
Slough SL 1 7LS, UK
Cooltreat 101 Cooltreat 102
Magnus Maritec International Inc. 150 Roosevelt Place,

P.O.Box 150 Palisades Park, New Jersey 07650, USA
NCL Diesel Water treatment
Nalfloc Ltd, Marine Department

P.O.Box 11, Northwich,
Cheshire CW 8 4DX, UK
Nalfleet 9-121 powder Nalfleet

9-131 liquid
Nalco Chemical Co, Marine Department

100 Morris Avenue, Springfield New Jersey 07081, USA
Nalco 39 powder Nalco 39-L

liquid
Perolin Co Ltd
50 Mount Street
London WLY 5 RE, UK
Perolin Formet
Water System
Treatment No. 326 and
No. 326-L
Perolin Inhibitin
Cooling water treatment (no
nitrite content)
Rochem Ships Equipment A/S

P.O.Box 2645, St Haunshaugen Oslo 1, Norway
Rochem Rocor NB
Rochem Rocor NB liquid
USSR
Industrial sodium nitrite GOST

19906-74
OKP 214322 0220
See sub-section 02.3.2
02-16
Note: Request your additives supplier for instructions of water treatment process,
dosing and content assessment. Most of the suppliers provide content test kits along
with the delivery package.
02.4
Nozzle cooling oil
For nozzle cooling, the same lube oil that is used in the engines lube oil system must
be applied. (This applies only to diesel engines running on heavy fuel types 22HF
and 22.)
03.
START, SHUT-DOWN, OPERATION, STARTING AFTER A LONG

SHUT-DOWN, STARTING AFTER DISMANTLING, OPERATION
CONTROL AFTER OVERHAUL, ENGINE BREAK-IN
03.1
Start
The following items are to be checked prior to start up the engine:

-
sufficient level of the lube oil
fuel system is in operational condition (preheating and pressure are

sufficient, preheating of high pressure fuel pump is provided with the
preliminary fuel oil circulation),
nozzle temperature regulating system is in the operational condition (the

level in the expansion tank, preheating and pressure are sufficient, nozzle
preheating is provided with the preliminary fuel oil circulation)1)
fresh water and sea water systems are in operational condition (pressure
in systems is sufficient and engine preheating is provided with the
preliminary preheated fresh water circulation),
lube oil level in regulator and turbochargers is sufficient, starting air

pressure exceeds 15 bars (usually pressure approximately 11 bars is
already sufficient for the engine start-up),
starting air system is free of condensate,
drain tube of air cooler housing is open, no drains.
03.1.1 Manual start

.
Run the lube oil charging pump until the pressure gauge indicates the
pressure approximately 0.5 Bar.
b.
The engines with a direct drive to the propulsion: Prior to start-up put the
regulator at the idle speed and disconnect the engine from the propeller shaft
or the blades of the controllable pitch propeller to the neutral position.
c.
Always, when there is enough time before the engine start, check the
crankshaft with two revolutions with open control valves. Thus, a hydraulic
impact is prevented.
d.
Disconnect shaft barring gear.
____________________________________________________________________
1)
Applied only to diesel engines type 22HF and 22 running on heavy fuel.
e.
Check the automatic alarm device and protection device are in the starting
positions (section 23.).
f.
Check that the stop handle is in Run position, open starting air valve, close
relief valve when the condensate is completely removed.
g.
Put starting handle in Start position or press starting button until the fuel
combustions in the engine cylinders. If the engine does not start up after 2 3
seconds it is necessary to find out the reason.
h.
Do not re-start engines equipped with pneumatic starters before stopping

flywheel.
i.
Check without a delay after the engine start that the pressure and temperature
are within the allowed limits.
j.
Check that the automatic alarm system and protection system devices are in
Run position.
03.1.2 Remote and automatic start

If the engine is not running for more than one week the first start must be taken
manually as described in Item 1.
The engines with automatic start function must be subject to a test start once a
week.
a.
When starting engine with remote control it is necessary to start at first lube oil
charging pump. Usually, there is a lamp indicating that the pump is running. If
the engine was not running for more than two hours it may be re-started when
the lube oil pressure gauge indicates approximately 0.5 Bar.
The lube oil charging pump of engines with automatic control runs
continuously providing constant readiness for the start-up. The pump must be
checked for operation at least once in two days.
b.
Press starting button of the engine with remote control. At this, the solenoid
valve installed at the engine receives the power supply and opens the access
to the starting air for the engine. The starting button must be pressed for 1 - 2
se only which is sufficient for the engine start-up. The remote tachometer or a
signal lamp (which is on while the engine is running) warn about the start-up.
Some ship engines have the remote control designed in such a way that
pressing start button causes the start-up of the lube oil charging pump at first
and only when the lube oil pressure increases (approximately to 0.5 Bar) the
engine starts up automatically as described in Iten c.
c.
In diesel engines with automatic start, the solenoid control is performed with
the program relay. Normal program: As soon as the program relay receives
the starting pulse the solenoid receives the power supply for 2 4 seconds. At
this time, the solenoid valve opens starting the diesel engine. If the engine
does not start the following start is carried out in 20 seconds and at this time
the solenoid receives the power supply for 10 seconds. If the start-up failed
the program relay activates the alarm system. For the engines equipped with
pneumatic starters the period between start-ups must be sufficient to assure
that the flywheel has stopped.
d.
When the engine reaches the predetermined speed the auxiliary relay receives
the power supply from the RPM transducer and breaks the starting circuit. At
this moment, the starting air solenoid valve closes. Simultaneously, the power
supply of the lube oil charging pump is disconnected thus preventing pumps
running when the diesel engine works. In some power plants, the lube oil
charging pump continues running at low RPM values in order to keep lube oil
pressure with the lube oil pump driven by engine. After some time (10 30
sec), automatic alarm, protection and remote speed regulating systems
automatically switch on.
03.2
Shutdown
03.2.1
Manual shutdown
a.
Before the shutdown, the engine must run 2 3 minutes idle.
b.
Stop the engine with putting the stop handle to stop position. The time of the
rpm decrease until the complete stop of the engine provides a good
opportunity to detect possible malfunctions hearing the abnormal noise.
03.2.2
Remote shutdown
a.
Same action as in item 03.2.1 .
b.
Press remote shutdown button. The switching solenoid installed in the

regulator receives power supply after that for some time and fuel oil racks of
the high pressure fuel pump shift to stop position. The dwell time of the
solenoid is set in such a way (20 50 sec) that the solenoid is switched on
until the engine shuts down. At this time, the engine cannot be restarted. After
a certain period of time, the switching solenoid returns to its original position.
c.
When the engine stops and the RPM value falls below a predetermined value,
the automatic alarm, protection and RPM remote regulating systems switch off
and the indicator lamp warning about running engine goes off. In the engines
equipped with automatic lube oil charging pumps, such pump starts
immediately.
03.2.3
Automatic shutdown
In case of a malfunction, the switching solenoid receives the power supply form the
emergency protection system and at this time the engine shutdown takes place the
same way as during the remote shutdown. Usually before the engine shutdown, the
alarm transducers send a signal indicating the reason of the engine shutdown.
If the engine shuts down due to the engine racing there are the chances that
mechanical and electro-pneumatic limit switches tripped at each high pressure fuel oil
pump.
03.2.4
General
The engine may always be stopped manually (with stop handle) independently from
the remote control or automatic control systems.
When carrying out works on or inside the engine, it is necessary to make sure that
the automatic starting device and lube oil charging pump are shut down. Block the
engines starting air inlet with the shutoff valve installed before the solenoid.
Put the stopping handle at the STOP position.
If it is required to stop the engine for long time the indicator valves must be closed.
Also, it is recommended to close the exhaust pipe.
The lube oil system of the stopped engine must be topped up with the lube oil every
second day with the help of the lube oil charging pump. At the same time the
crankshaft must be rotated to a new position. These measures reduce the possibility
of the WEAR CORROSION at the shaft journals and bearings when the stopped
engine is exposed to vibrations.
In order to make sure that all works well it is necessary to the engine once a week.
03.3
Maintenance during operation
03.3.1
After every two days or every 50 running hours
a.
Compare the reading of all tachometers and pressure gages and the engine
load. The temperature values to a greater or lesser extent depend upon the
engine load. The charging air pressure depends upon the engine load; the
lube oil, fresh water and sea water (suspended pumps) pressure depends
upon the RPM.
That is why it is necessary to compare the received readings with the
corresponding curves and the values recorded at the corresponding load and
RPM in the commissioning test reports. The recommended values are given in
section 01.
If the exhaust gas differential temperature in some cylinders exceeds 80

at the load above 25% it is necessary to find out the reason of such
difference.
The charging air temperature basically must be as low as possible at the
engine loads exceeding 60% but higher than the value when the
condensation starts. See section 03. At low charging air, cooling water and
lube oil temperatures, the temperature regulations increase automatically
corresponding to the load of the affected system. 2)
b.
Check the condition of the differential pressure indicating transducer in the fuel
oil filters. When the pressure differential in the filters increases the system
pressure decreases. Very low pressure (below 0.5 Bar) affects the engine
operation characteristics and may result in uneven load distribution between
cylinders (potential malfunctions). The excessive pressure differential may
result as well in the deformation of the filter elements (potential malfunctions of
high pressure fuel pump).
c.
Check the condition of the differential pressure indicating transducer in the

lube oil filters. The excessive pressure differential indicates that the bypass
valve is open resulting in the throughoutput decrease of the filter and
increased wear. Bleed off air from the filters if this does not help, replace filter
elements.
d.
Check lube oil level in the crankcase/lube oil tank. Inspect the viscosity and
visual condition of the lube oil. A simple way to check the water content in the
lube oil is as follows: put a drop of the lube oil on a hot surface (approximately
150 ), for example, on the closed heating element of the hot electric oven. If
the oil drop rests quite it does not contain water but if it sizzles that means that
the oil drop contains some water. The lube oil consumption must be
compensated with adding not more than 10% of the fresh lube oil at a time.
e.
Make sure that the air extraction from the fresh water system and the nozzle
temperature regulating system (through the expansion tank) is provided. 2)
Check that the leakage from the inspection hole of the fresh water and sea
water pumps is within the allowed limits (minor).
f.
Check the fuel leakage volume from the drain tubes and inspection hole of the
fuel oil charging pump.
g.
Make sure that the drain tube of the air coolers are open.
h.
Make sure that inspection holes of the lube oil cooler and fresh water cooler
are open.
i.
Clean the turbocharger compressor side with water sprey. See Turbocharger
Operation Manual, section 15.
2)
Applied only to diesel engines type 22HF and 22, running on heavy fuel.
j.
Drain water and sludge from the day tank as well as water from the starting air
cylinder.
k.
Ship diesel engines (engines with the direct drive to the propulsion shaft and
auxiliary engines): When the engine is not running, operate the lube oil
charging pump and rotate the crankshaft to a new position. This reduces the
chances to damage the camshaft and bearings due to the vibration.
03.3.2
After every two weeks or every 250 running hours
a.
Clean the centrifugal lube oil filters. If the depositions are more than 20 mm
reduce the time between cleaning in order to maintain the filtration efficiency.
Maximum allowed deposition thickness is 40 mm.
b.
Keep the fuel racks of the high pressure fuel pump clean (free from sticky
depositions), check the mobility of fuel oil system levers.
c.
Clean the turbocharger from the turbine end with water. If the engine is
running on very low quality fuel brands it may be necessary to reduce
significantly the time between cleaning. The big natrium salt content in the fuel
oil requires the periodic cleaning of the turbine. See section 15, sub-section
15.3 and turbocharger Operation Manual.)
03.3.3
After one month or every 500 running hours
a.
Check additives content in the fresh water.
b.
Check the pressure in cylinders. At the same time, record the engine loads
(position load indicator or fuel racks of the high pressure fuel pump indicates
accurately the engines load).
Note: Measuring cylinder pressure without simultaneous engines load recording

does not have any practical use.
c.
03.3.4
Check the load depending cooling system at the engines load below 30% of
the rated capacity. 3)
Due to preventive maintenance schedule (PMS)
a.
Record in the engine log book the following measures and the running hours
counters:
3)
Applied only to diesel engines type 22F and 22, running on heavy fuel.
03.3.5
taking samples of lube oil for the analysis (also record the duration of running
on this given lube oil). The lube oil analysis without the indication of the
running hours on it has a limited use (based on such analysis it is possible
only to identify the operational suitability of this lube oil);
lube oil replenishing;
cleaning of centrifugal lube oil filters;
replacements of lube oil and fuel oil filter elements;
replacements of the spare parts during the preventive maintenance according
to section 04.
General
a.
There is no automatic device for inspection or engine control that may replace
an experienced engineer. It is necessary to LOOK CLOSELY and LISTEN
CAREFULLY to the engine.
b.
"operational data" and "Maintenance report" blank sheets are provided for
each diesel engine. They must be thoroughly filled in.
c.
The continuous engine running at the loads below 20% of the rated capacity
must be limited to 100 hours on heavy fuel and run the engine not less than at
70% for one hour before continuing running at low load. The continuous
engine running at the loads below 10% of the rated capacity must be limited
as much as possible. Every 100 hours, the engines load must be at least 70%
for one hour before continuing running at low load.
Running on heavy fuel idle (with the generator without load) must be limited as
much as possible. Preheating the engine running idle longer than 2 3
minutes as well as running idle longer than 2 3 minutes before the shutdown
must be avoided.
03.4
Starting after a long shut-down (more than 8 hours)
03.4.1
Manual start
Check the following items:

lube oil level;
lube oil level in expansion tank of the nozzle temperature regulating
system;
fresh water level in the expansion tank;
sea water supply;
fuel oil level in the day tank (to avoid hard labour and time consuming
air bleeding-off from the fuel oil system due to the air captured by the
fuel charging pump);
4)
the starting air pressure must be at least 15 Bar;
the mobility of the fuel supply control levers and fuel racks of the high
pressure fuel pump. If any parts are jammed there is a possibility of the
engine racing.
b.
Take into consideration all items specified in section 03, sub-section 03.1. The
Item c is more important as longer the engine does not run.
c.
After starting engine, check the starting air distribution pipe does not heat at
none of the cylinders (gas leakage by starting valve).
d.
Bleed off air from the fuel oil and lube oil filters.
03.5
Starting after a long shut-down
Check the connections between RPM regulator, limit switch and high pressure
fuel pump (especially the position of the fuel racks of the high pressure fuel
pump) are correctly installed and not jammed and that all connections are
locked and the motion of the fuel racks of the high pressure fuel pump is free.
b.
When the RPM regulator lever is at the maximum fuel supply position and stop
handle at the Run position, do the manual tripping of the limit switch. Make
sure that the fuel racks of the high pressure fuel pump have the stroke at least
4 mm.
c.
If fuel oil pumps, camshaft or its driving gear were dismantled, check the fuel
injection moment.
d.
Make sure there is no leakage in the water cooling system especially in:
in lower part of cylinder liners;
lube oil cooler;
air cooler.
e.
Check the nozzle preheating system.5)
f.
Check/adjust air gaps in the valves. If the camshaft or its driving gear, check
the phases of the gas distribution of at least of one cylinder (of each cylinder
row of the V-shape engine). See the recommended values in section 06.
g.
Bleed off air from the fuel oil system if it was opened.
5)
h.
i.
Start
the
lube
oil
charging
pump.
Bleed
off
air
from the lube oil filters. Make sure that the lube oil exits through all bearings
and nozzle of the lube oil system, piston cooling channels, valve gear. Make
sure that the connections of pipes running inside or outside the engine do not
leak.
Rags or hand tools left in the crankcase, loose or not locked bolts or nuts (the
ones that must be locked), worn self-locking nuts MAY CAUSE the engine
break-down.
Thorough cleaning of lube oil cavities (crankcase oil pan and camshaft
crankcase cavities) protects lube oil pump and lube oil filter.
j.
Before starting read the instructions given in section 03, sub-sections 03.1 and
03.4.
03.6
Starting after dismantling
a.
During the first start-up, it is necessary to listen carefully to the unwanted

sounds and hammering. If it is suspected that there are any malfunctions it is
necessary to shut down the engine without delay and in case of normal
running the engine must be shut down in 5 minutes after having run idle at the
rated speed. Check the temperature at least of the main and crank pin
bearings as well as other bearings that were dismantled. If no malfunctions
were identified the engine may be restarted.
b.
Make sure that there is no gas, water, fuel, cooling or lube oil leakage. Be
especially careful to the fuel oil piping, high pressure fuel pump and nozzles.
Track the volume of leakage from the fuel drain piping.
c.
Make sure that the starting air distribution pipe does not overheat at any
cylinder (starting valve leakage). This may result in the fuel combustion.
d.
After dismantling the following instructions are very important to follow:

-
6)
Check pressure and temperature gauges;

Check automatic alarm and protection system instrumentation;
Check the pressure differential in the fuel and lube oil filters;
Check lube oil level in the crankcase/lube oil tank. Inspect the lube oil
condition.
Make sure that the air extraction for the fresh water system is provided;
Make sure that the air extraction for nozzle temperature regulating
system is provided; 6)
Check the volume of the drained fuel oil;
Check the inspection holes of the heat exchangers;
Check additives content in the fresh water;
Check pressure in cylinders;

Listen to the unwanted noise;
Check pressure in the crankcase;

Check starting air piping;
Bleed off air from filters.
03.7
Break-in
After the piston removal carry out the program A described below.
The piston rings took a new position and some time is required for their
breaking-in.
If the program was not carried out completely the full engine load is not
allowed earlier than in 4 hours.
b.
After the replacement of the piston rings, pistons or cylinder liners, after liner
honing finishing, the program B must be executed as close as possible as
described below.
If the program was not carried out completely the full engine load is not
allowed earlier than in 10 hours.
AVOID ENGINE BREAK-IN AT THE CONTINUOUS LOW LOAD!
The multiple change of the engine load is very important during the break-in.
Piston ring groove inclination depends upon the load and that is why the piston
rings adjust themselves to the cylinder liners differently depending upon the
load.
Break-in may be carried out running either on diesel fuel or heavy fuel using
the normal lube oil designed for the engine lubrication.
Engines
load, %
1. SHUT DOWN, CHECK THE TEMPERATURE OF THE CRANK PIN BEARINGS
After piston removal

After the replacement of the piston rings, pistons or cylinder liners, after
liner honing finishing
RUNNING HOURS
BREAK-IN PROGRAM
03-11
03-12
WATER CONDENSATION IN AIR COOLERS
WATER TEMPERATURE
AIR RELATIVE HUMIDITY
BEFORE THE TURBO
CHARGER
t bTC
Note:
P2 Charging air pressure

P1 Atmospheri c pressure
Example:
Air temperature
Relative humidity
P2
P1
Dew point
= 40O C
= 80%
=2
51 O C
That is the charging air temperature must

exceed 51 O C in order to prevent water
condensation
Dew point
Charging air ratio
P2
P1
04.
PREVENTIVE MAINTENANCE SCHEDULE OF THE ENGINES RUNNING

ON DIESEL FUEL (ACCORDING TO SPECIFICATION NO. 4V92G27 OR
BRITISH STANDARD BS 100: 1982 CLASS )
04.1
General
The need for the preventive maintenance of a diesel engine generally depends upon
the operation conditions. The time frames given in this schedule are approximate but
they must not be extended during the warranty period.
Use Maintenance report blank forms while doing the preventive maintenance. The
blank forms are included in each Operation Manual.
See as well Operational Manuals of the turbocharger and RPM regulator and
separate Operation Manuals of the equipment installed on your diesel engine and
recommendations given inl section 03.
04.2
Period: Every second day irrespectively if the engine worked or not
Component,
part, system
Action
Recommendations in
section, sub-section
Automatic
preliminary
lubrication
Check the operation
18.9, 03.2a, 23.1.4
Crankshaft
Ship engine: Rotate the crankshaft to

a new position at the not running
engine
03.3.1k
04.3
Period: Every week irrespectively if the engine worked or not
Component,
part, system
Action
Recommendations in
Starting-up
process
Test starts
03.1
04.4
Period: Every 50 running hours
Component,
part, system
Action
Recommendations in
Turbocharger
Clean compressor with water
15, 03.3.1i
Temperature and
pressure gauges,
load indicators
and other
instrumentation
Make p the report, record the

readings
03.3.1
Fuel oil filters
Rotate the handle of the corse mesh

fuel filter
17.3
Fuel oil and lube

oil filters
Check differential pressure indicating

transducer of the filter
17, 18, 23, 03.3.1b, c
Crankcase, speed
regulator,
turbocharger (s)
Check lube oil level, replenish the the 02.2.3c, 02.2.4, 02.2.5
losses
15, 18, 22
Fresh water
system
Check air bleeding-off the system
19.1.1, 03.3.1e
Fuel system
Check the volume of the lost fuel in

high pressure fuel pump and nozzles
17.2 03.3.1f
Air coolers
Make sure that the drain tube is

open. Make sure there is no leakage
15.3, 03.3.1g
Day tank
Drain water and sludge
Valve gear
Check air gaps in valves after each

50 running hours of the new or
overhauled engines
12.4
04.5
Component,
part, system
Action
Recommendations in
Centrifugal filter
Clean the filter
13, 03.3.2
Regulating gear
Check the mobility, clean, grease up
22, 03.3.2b, 03.5
04.6
Component,
part, system
Action
Recommendations in
Studs, bolts, nuts
Check the tightness of unlocked

bolts, studs and nuts
07
Valves
Check the mobility of inlet and outlet

valves in their guides. Check the air
gaps in the valves.
12.6, 06.1
Raw water
Check the additives content
02.3
Lube oil
In a new power plant or after shifting

to a new brand of the lube oil, take
lube oil sample for analysis
18.1, 02.2.3b
Pressure in
cylinders
Check the pressure
03.3.3 12.
Sea water filter
Clean the filter (The sea water filter is

not usually included in the engine
delivery package. The time between
19
filter cleaning depends upon the
type of the filter and the quality of
the sea water supply)
04.7
Component,
part, system
Lube oil filter
Fuel oil filter
Action
Check the filter elements, replace
them if required. (Usually filter
elements must be replaced when the
differential pressure indicating
transducer of the filter exceeds the
allowed limit value). Clean the mesh
filter element and filter housing.
If it is required to replace filter
elements with new ones (Usually
filter elements must be replaced
when the differential pressure
indicating transducer of the filter
exceeds the allowed limit value)
Clean the filter housing. Clean the
coarse mesh fuel filter in the fuel
supply tube.
Recommendations in
18
17
Automatic
controls
Check the operation of the automatic

alarm and protection system
23
Lube oil
In a new power plant or after shifting

to a new brand of the lube oil, take
lube oil sample for analysis
02.2.3b
Air filter
Clean the air filter (more frequent if

required)
15
Turbocharger
Replace lube oil
02.2.5, 15
04.8
Component,
part, system
Action
Recommendations in
Lube oil
Replace the lube oil of a new power

plant. Take lube oil samples for
analysis. If the analysis result is
positive and the lube oil supplier or
the engine manufacturer
recommends the time between the
lube oil replacement may be
extended by 500 running hours at a
time. After changing the lube oil, all
lube oil cavities must be cleaned.
02.2.3b, d
Nozzles
Check opening pressure. Dismantle

and clean the injectors. Check the
effective raise of the injector needle.
Check the springs.
Recommendation: Replace the
nozzle set with new or repaired ones.
16
Air coolers
Check and if required at first clean

the surface at the water end. If the
surface in clean enough and the
depositions are not critical, the time
frame between these is operations is
4000 running hours.
15, 19
Instrumentation
Check the pressure and temperature

gages. Replace the faulty gauges.
23.
Speed regulator
Replace the lube oil.
02.2.4, 22
Limit switches
Check tripping and RPM limit values.
22
04.9
Component,
part, system
Action
Recommendations in
Crankshaft
Check and record the deflections.

Check the axial the difference.
11, 06.2, item 10
Camshaft
Check the surface of the cam faces

and cam followers. Make sure that
the cam followers rotate.
14
Turbocharger
Clean the compressor and turbine

especially the guide gear. Make sure
that there are no depositions in the
water cavities and clean them if the
deposition thickness exceeds1 mm.
15
Heat exchangers
Clean and pressure test the fresh

water cooler, air cooler and lube oil
cooler. Inspect thoroughly and make
sure that there is nor signs of
corrosion.
15, 18, 19
Cylinder liners
Pull out a liner of one cylinder and

inspect the surface from the water
side. If the deposition thickness
exceeds1 mm, clean all liners and
improve the treatment of the cooling
water.
10.6, 02.3
Regulating gear
Make sure that there is no wear in all

connections between RPM regulator
and all high pressure fuel pumps.
22
Outlet manifold
Check nuts of the flange connections

and vertical studs inside the isolated
box as well
Page 20-51
04.10 Period: Every 8000 running hours1)

Component,
part, system
Action
Recommendations in
Cylinder heads
Dismantle and clean the lower part,

channels, inlet and outlet valves.
Inspect cooling cavities and clean them
if required. Polish the seat grooves of
the valve (manual lapping is sufficient).
Replace seal O-rings of the valve
guides. Replace seal O-rings of the
nozzles. Check the starting valves.
12, 16, 21
Pistons,
Piston rings,
piston pins
Remove, inspect and clean the pistons.

Inspect carefully the surfaces of the
piston rings.
Check the height of the ring grooves
(the elevation air gap between the ring
and the groove). Check the retaining
rings of the piston pins. Replace the
piston ring set (at each piston after
every 8000 or more hours). If during the
first removal of the piston the piston
11, 06.2
rings move freely in their rings the
working surfaces are perfect (shiny), the
layer of chromium at the working
surfaces is not worn and cylinder liners
face is in good condition, the time
between piston removals may
extended by 2000 hours at a time but
not more than up to 12000 running
hours. Note: See break-in programs in
section 03.
____________________________________________________________________
1)
If the time frames between piston removals are extended all preventive actions
taken every 8000 running hours are to be taken within the same time frames.
(continued)
04.10
Cylinder liners
Remove the liners of two cylinders,

inspect the surfaces from the water
side. If the deposition thickness
exceeds1 mm, clean all liners and water
cavities of the cylinder head. Replace
the seal O-ring in the lower part of the
liner during the first liner removal.
Measure the liner diameter. At the
locations where the signs of honing
finishing are seen the measurements
are not required as the depth of the
10, 06.2
honing signs is less than 0.01 mm.
If traces of wear, a lot of scratches or
shiny spots are seen the working
surface must be honed.
If time frames between piston removal
are 8000 running hours the liners must
be honed during every second removal
independently from the liner condition if
these time frames exceed 8000 running
hours the liners must be honed during
every time.
Connecting rods
Inspect the crank pin bearings and the

teeth of connecting rods connections.
11
Main bearings
Inspect the bearings shells
10
Pinion gears
Inspect all pinion gears. Check the air

gaps.
11, 13
Lube oil pump
Inspect the lube oil pump
18
High pressure fuel Check the air gaps in followers

pump
bearings. Check the charging valves.
16, 06
Thermostatic
valves
Clean, check
19, 17, 18.
Lube oil system
Blow tubes and elbows
18.
(continued)
04.10
Turbochargers
Replace bearings in turbocharger type

VTR
15
Fuel system
Clean day tank. Check fuel oil charging

pump.
17
Fresh water
system
Replace seal O-rings of the water drain

pipe.
19
Starting air
system
Clean starting air cylinders
21
Exhaust gas
manifold
Clean
04.11 Period: Every 16000 running hours1)

Component,
part, system
Action
Recommendations in
Connecting rods
Inspect main bearings. If time frames

between piston removal were extended
to 8000 running hours they must be
inspected every time when a piston is
removed.
11, 06
High pressure fuel

Check piston pairs
pump
16
Camshaft
Check bearings
10, 06
Camshaft drive
Check bearings of the intermediate

pinion gears
13, 06
Regulating gear
Check bearings of the regulator drive

shaft
06
(continued)
04.11
Spring dampener
type "Geislinger"
Dismantle and check
11
Liquid dampener
Take lube oil samples for analysis
11
Crankshaft
Check air gaps crank pin bearings

and frame bearings
11, 10, 06
Valve gear
Check the air gaps in the cam followers

and rocker actuators bearings
12. 14.
05-1
05.
MAINTENANCE HAND TOOLS
CYLINDER HEAD
Hydraulic tightening device
Lifting tool for cylinder head
Dismantling device for valves
Grinding device for valves
Extractor for injection valves
Grinding tool for injection valve

sleeve bottom
Handle for indicator valve
PART NUMBER
05-2
CYLINDER HEAD
Valve clearance feeler gauge
Circlip pliers
PISTON
Lifting tool
Tap M12
Clamp device for piston rings
Piston ring pliers Unistress
Circlip pliers
05-3
CONNECTING ROD
Hydraulic tightening device
Mounting device M33 for studs
Distance sleeves for tightening

device
MAIN BEARINGS
Distance sleeves for tightening
device
Lifting tool for main bearing cap
Hexagonal socket head M22 with

inner socket 1
Torque multiplier X - 4
05-4
MAIN BEARINGS
Turning tool for main bearing shell
V22HF
Turning tool for main bearing shell

R22HF
Turning tool for thrust bearing shell

V22HF
Turning tool for thrust bearing shell

R22HF
CYLINDER LINER
Extracting and lifting tool for
cylinder liner
05-5
INJECTION GEAR
Checking device for fuel injection
timing
Socket wrench 30 for nozzle nut
Socket wrench 22
Testing device for injection valve
Nozzle cleaning kit
Mounting tool for injection pump

tappet
05-6
INJECTION GEAR
Special socket wrench 19 for
flange nuts
Special open wrench for injection

pipe
TIGHTENING
Torque wrench
Speed brace with 1/2 inch square
Ratchet handle with 1/2 inch

square
05-7
TIGHTENING
Ratchet handle with 3/4 inch
square
Extension bars with 1/2 inch

square
Adapter with 1/2 inch female

square
Extension tube
Special key for camshaft flange

screws
05-8
WRENCHES
Ring wrenches
Double head
opened end
wrenches
Open ring spanner
Hexagonal socket
screw key
Hexagonal screw
bit with 1/2 in
square drive
Socket wrench
05-9
MISCELLANEOUS HAND TOOLS
Extractor for gear wheels, etc.
Mounting device for camshaft

bearing bushing
Dismantling device for centrifugal

filter
Screw driver
Eye bolt
Brushes for cleaning charge air

cooler
05-10
MISCELLANEOUS HAND TOOLS
Brushes for cleaning oil and water
coolers
Lever 22 x 550 mm
I-SHAPE ENGINES
Turning bar
Wrench for dismantling electric

motor
V-SHAPE ENGINES
Turning device
Protecting sleeve for connecting

rod
Protecting plug for connecting rod
05-11
SHIELD BEARING
Turning tool for shield bearing
shell
Distance sleeve
Reducing pieces
Elbow coupling
Pin for hydraulic tightening device
05-12
FOUR CYLINDER ENGINE

Hexagonal head tap 19/14
Socket wrench 19 with 3/4

square drive
Connection piece for ratchet

handle
COMBINATION TOOLS
Lateral tie bolt tool
Camshaft screws tool
06.
06.1
Setting information
Valve timing phases:

Inlet valve opens at 50 before TDC, closes at 40 after BDC.
Outlet valve opens at 50 before BDC, closes at 50 after TDC
Air gaps in valves at not preheated engine: inlet valves 0.4 mm
outlet valves 0.8 mm
Fuel injection moment at 15 before TDC
Position of the fuel racks at 100% load, heavy fuel 23.5 mm
diesel fuel
24.5 mm
Nozzle opening pressure 320 Bar
Speed limitation:
Rated speed
Maximum speed of the

mechanic limit switch
Maximum speed of the electropneumatic limit switch
15 rev/sec (900 rpm)
17.83 rev/sec (1070 rpm)
17.33 rev/sec (1040 rpm)
16.7 rev/sec (1000 rpm)
19.67 rev/sec (1180 rpm)
19.17 rev/sec (1150 rpm)
22.5 rev/sec (1350 rpm)
06.2
Item
10
Air gaps and wear limits (at 20O C)

Part, place of
measurement
Drawing size,
allowance, mm
Air gap in main bearing (also

in thrust bearing and
additional thrust bearing)
Normal air
gap, mm
Additional
air gap,
mm
0.18 0.27
Journal diameter
200
+ 0 - 0.029
Journal ellipticity
0.015
Journal taper
0015/100
Main bearing shell thickness
7.440 + 0... -0.015
Main bearing cage diameter
215
+ 0.029 ... -0
Diameter of installed bearing
200
+ 0.239...0180
7.38
Item
10
Part, place of
measurement
Drawing size,
allowance, mm
Axial air gap of thrust

bearing
Normal air
gap, mm
0.12 ... 0.25
100
- 0.160 ... 0.210
100
+ 0.035 ... -0
Additional
air gap, mm
0.5
Thrust bearing width

Corresponding width of
crankshaft journal
0.6 ... 0.13
Air gap in camshaft bearing
(as well as in thrust bearing)
80
+ 0 ... - 0.019
Diameter of camshaft spacer

3.970 + 0 ... - 0.015
3.91
Thickness of camshaft
bearing shell
88
+ 0.022 ... 0
80
+ 0.108 ... + 0.056
75
+ 0...- 0.019
90
+ 0 ... + 0.022
75
+ 0.056 ...+ 0.108
Air gap in camshaft bearing

(as well as in thrust bearing)
Diameter of installed
camshaft bearing
Diameter of camshaft spacer
at thrust bearing
Diameter of camshaft thrust
bearing cage
Diameter of installed
camshaft thrust bearing
0.14...0.31
Axial air gap of camshaft
thrust bearing
Width of camshaft thrust
bearing
R22 and V22, row A
V22, row B
58
64
- 0.16 ... 0.29

- 0.16 ... 0.29
Diameter of cylinder liner
220.08 + 0.046 ... 0
Ellipticity of cylinder liner
0.02
top 220.45
bottom 220.25
0.15
Item
11
Part, place of
measurement
Air gap in crank pin bearing
Drawing size,
allowance, mm
Diameter of crank pin

bearing journal
180
Ellipticity of crank pin

bearing journal
0.015
Taper of crank pin bearing

journal
0.015/100
Thickness of crank pin

bearings
4.940 + 0 ... 0.015
Diameter of crank pin

bearings cage
190
+ 0.029 ... 0
180
+ 0.203 ... + 0.144
Normal air
gap, mm
0.14 ... 0.23
+ 0 ... 0.025
Air gap in main bearing
0.09 ... 0.15
Diameter of piston pin
95
+ 0 ... 0.010
Ellipticity of piston pin
0.0025
Taper of piston pin
0.005
Diameter of main bearing

cage
115
+ 0.022 ... 0
Diameter of installed main

bearing
95
+ 0.142 ...+ 0.090
Axial deflection of
connecting rod in piston
0.55 ... 0.80
V22: Air gap between

connecting rods
0.18...1.94
Air gap between pin and

piston
Diameter of pin hole in
piston
Air gap in piston ring locks
(compressed, 220)
compression rings
0.005...0.025
95
+ 0.015 ...+ 0.005
0.65 ... 0.95

0.80 ... 1.05
Additional
air gap, mm
oil rings
Item
11
Part, place of
measurement
Vertical air gap between
grooves and piston rings
compression ring 1
compression ring 2
compression ring 3
oil ring
Height of piston ring grooves
grooves 1
grooves 2
grooves 3
grooves 4
Drawing size,
allowance, mm
0.12...0.15
0.07.-.0.10
0.07...0.10
0.04...0.07
0.35
0.35
0.35
0.35
0.14...0.22
219.87 + 0.02
Crankshaft oil thrower (drive

end)
axial deflection
radial air gap at crankshaft
flange circumference
12
Additional
air gap, mm
4.11 + 0.02... 0
4.06 + 0.02... 0
4.06 + 0.02... 0
6.03 + 0.02... 0
Air gap between piston and

cylinder liner at the bottom
part transversally
Corresponding diameter of
piston
Normal air
gap, mm
0.39...1.03
0.62...0.93
Diameter of valve guide
16
+ 0.095...+ 0.075
Diameter of valve stem
16
+ 0... 0.018
Air gap between stem and

guide
15.97
0.06...0.11
Axis misalignment of valve

seat with respect to valve
guide (maximum value)
0.10
Diameter of valve seat hole

in cylinder head
78
+ 0.019...0
0.20
13
Camshaft drive idler pinion

air gap in bearing
axial deflection
Item
13
Part, place of
measurement
Diameter of journal
0.03...0.09
0.15...0.35
60
60
+ 0.03 ... 0
Drawing size,
allowance, mm
-0.03...-0.06
Camshaft drive pinion,

air gap between:
crankshaft pinion and idler
pinion
idler pinion and camshaft
pinion
14
Normal air
gap, mm
Additional
air gap, mm
0.10...0.45
0.10...0.45
Common normal (meshing

line) of:
- crankshaft pinion
- big idler pinion
- small idler pinion
- camshaft pinion
99.75 0.024
146.003 0.027
99.842 0.024
130.694 0.024
Diameter of valve follower
55
-0.03...- 0.06
Diameter of valve guide
55
+0.03...-0
Diameter air gap
99.60
14
0.03...0.09
Diameter of valve follower

roller hole
30
+0.021...-0
Outside diameter of liner
30
-0.020...-0.033
Inside diameter of liner
22
+0.041...+0.020
Diameter of pin roller
22
-0.007...-0.020
Air gap between

roller and liner
liner and pin
50
+0.050...+0.025
Diameter of pin
50
+0...-0.016
Air gap in bearing

Diameter spreader guide
20
-0.040...-0.053
Diameter of spreader hole
20
+0.033...-0
0.15
21.95
0.02...0.05
0.03...0.06
Diameter of rocker actuator

bearing
Diameter air gap
0.20
0.50
0.10
0.13
49.95
0.03...0.07
0.25
0.04...0.09
0.15
Item
Part, place of
measurement
15
Needle stroke
16
High pressure fuel pump

cam follower:
Diameter of cam follower
roller
Drawing size,
allowance, mm
0.4
36
+ 0.025...0
Outside diameter of liner
36
- 0.050... 0.085
Inside diameter of liner
28
+ 0.065...+ 0.098
Diameter of pin roller
28
- 0.020... 0.052
0.05 ... 0.114
0.085-0.153
Fuel oil charging pump

Diameter of shaft
20
+0.009...-0.004
Diameter of bearing
20
+0.061...+0.040
Air gap in bearing
0.03...0.07
Axial deflection
0.02...0.10
Air gap in pumps drive

pinion gear
0.55. ..0.68
Length of common normal

(meshing line) of pump
pinion gear
Pump drive crankshaft
pinion gear:
of a pump with a standard
transmission ration = 70/48
and a pump with an
increased transmission
ration =73/45
Additional
air gap, mm
0.5
Air gap between

roller and sleeve
sleeve and pin
17
Normal air
gap, mm
0.15
53.68 0.022
53.50
115.348 0.024
115.19
115.159 0.024
115.00
Item
18
Part, place of
measurement
Drawing size,
allowance, mm
Lube oil pump V22:

Diameter of shaft
50
- 0.080...- 0.105
Diameter of bearing sleeve
50
+ 0039...- 0
Normal air
gap, mm
0.22
Air gap in bearing
0.08...0.15
Axial deflection
pinion gear
0.27...0.36
0.36...0.49
Pump drive crankshaft

pinion gear:
and a pump with an
ration =73/45
84.26
84.35
84.404 0.024
42.50
84.4890.024
Pump pinion gear
42.95 0.030
Lube oil pump R22:

Diameter of shaft
32
-0.07...-0.10
Diameter of bearing sleeve
32
+0.039..-0
Air gap in bearing
0.07...0.14
Axial deflection
0.18...0.25

pinion gear
0.36. ..0.49

and a pump with an
ration =73/45
Pump pinion gear
Additional
air gap, mm
84.26
84.35
84.404 0.024
28.20
84.4890.024
28.53 0.030
06-8
Item
19
Part, place of
measurement
Water pump:
pinion gear
Length of common normal of
a pump with a standard
and a pump with an
ration =73/27
22
23
Drawing size,
allowance, mm
Normal air
gap, mm
0.55...0.68
53.515 0.021
53.34
53.735 0.021
53.55
Regulator drive shaft
20
+0...-0.021
Regulator shaft bearing
20
+0.053...+0.020
Air gap in bearing
0.020...0.07
Axial deflection
0.10...0.15
Air gap in drive pinion gear
0.10...0.20
Balancing shaft pinion gear,

air gap between crankshaft
pinion and idler pinion
Idler pinion and balancing
shaft pinion
Air gap in balancing shaft
drive pinion gear
Additional
air gap, mm
0.1...0.6
0.1...0.5
0.1...0.35
0.15
0.0
07.
07.1

Stud, bolt and nut torques
Item numbers refer to the picture on page 07-51. Threads and surfaces of nuts and
bolt heads must be greased if otherwise specified. Please, take into consideration
that in several cases the locking liquid or special grease (Molykote) must be used.
Using grease "Molykote" other than in cases recommended by the engine
manufacturer may result in breaking bolts or studs.
1 Nm = 0.102 kgf.m
Item
Threaded connection
Torque, Nm
Scale setting,
kgf.m
Side bolts of main bearings.

Use combination tool as shown
at the picture A page 05-15
1200 20
30
Fastening bolt of flywheel shield

bearing
Cover the threads with Loctite
242
210 10
21
Connecting rod bolts (not

hydraulically tightened).
After tightening, the bolts must
be locked in pairs with steel wire
2 mm.
Cover the lower surface of the
head, guide surface and thread
of the bolts with Molykote G-n
Plus".
260 10
4A
Counterbalance bolts (single-bolt

connections)
Cover the butt end of the bolt
i.e. bottom end with Molykote
Paste G. Grease up the
threads.
500 10
4B
Counterbalance bolts (doublebolt connections)

Grease up the threads. Use the
combination tool shown at the
picture A on page 05-15.
1320 20
33
Threaded connection
Torque, Nm
Scale setting,
kgf.m
5A
Bolt connecting flywheel to crankshaft

(bolt-free connection), 20 each.
Cover the washers with Molykote Gn Plus" and grease up the threads.
Use the Torque multiplier X 4.
1160 20
29
5B

(bolts), 10 each.
Cover the contact surfaces of the bolts
and holes with Molykote G-n Plus". Use
the Torque multiplier X 4.
640 20
16
5C

(bolt-and-nut connections), 20 each.
Cover the contact surfaces of the bolts
and nuts with Molykote G-n Plus",
grease up the threads. Use the Torque
multiplier X 4.
630 20
16.3
Fastening bolts of the power shaft from

the crankshaft end, side opposite to
drive end.
600 20
15
Fastening bolts of the pump drive pinion

gear from the side opposite to drive end.
600 20
15
Crankshaft split pinion gear:

- Bolts connecting pinions to crankshaft
Cover the threads with Loctite 242
120 5
12
Crankshaft split pinion gear:

- Bolts connecting pinion halves
together
Cover the threads with Loctite 242.
See sub-section 07.2.
140 5
14
Item
10
Item
Bolts connecting camshaft sections to

spacer.
The bolts are treated with locking liquid
and may be used three times saving
their connecting capacity. After that, the
bolts must be replaced.
Use combination tool as shown at
picture B on page 05-15.
Do not wash the bolt threads but
store them in a clean and dry place.
Threaded connection
80 5
Torque, Nm
Scale setting,
kgf.m
11
Bolts connecting the limit switch to the

camshaft
45 5
4.5
12
Limit switch loading bolt
85 5
8.5
13
Retaining stud nuts of valve tappet guide

block
85 5
8.5
14
Retaining stud nuts of high-pressure fuel

oil pump
85 5
8.5
15
M10 bolts for retaining high pressure fuel

pump (by "Lorange" company)
85 5
8.5
16A
M12 bolts for retaining pump element of

the high pressure fuel pump (by
"Lorange" company)
65 3
Bolts for retaining cover of the high

pressure fuel pump (by "Bosch"
company)
45 5
17
Nozzle body reducer retainer
65 5
6.5
18
High pressure fuel oil tube cap screw
50 5
19
M12 nuts for nozzle retaining studs
50 3
20
Injector retaining cap screw
110 5
11
85 5
8.5
40 4
40
16B
21
22
Nuts for retaining studs of rocker

actuator pin.
Lubricate threads and holes for studs in
the cylinder head with "Loctite 270"
liquid.
Starting valve:
- retaining bolts
(0 30 50 65)
6.5
(0 50 80 100)
4.5
(0 20 35 45)
(0-20-40)
- connecting rod nut
14 2
1.4
Torque, Nm
Scale setting,
kgf.m
23
Bolts for retaining drive pinion gears of

the lube oil pump and fresh water and
sea water pumps (single-bolt
connections for the pumps).
Lubricate threads with "Loctite 270"
liquid.
85 5
8.5
2A
Retaining bolts of drive pinion gear of

water pump (connection with three
"Inbus plus" bolts)
23 3
2.3
23B
Retaining bolts of drive pinion gear of

lube oil pump for engine types 6R22,
8R22, V22 (connection with four "Inbus
plus" bolts)
75 5
7.5
23C
Retaining nut of drive pinion gear of lube

oil pump for engine types 4R22
210 10
21
24
Retaining nut of drive pinion gear of fuel

feed pump (for non-electric driven
pumps)
Cover the shaft thread and nuts contact
surface. The tapered part of the
connection must be degreased and
cleaned; its lubrication is not allowed.
135 5
13.5
25
Impeller retaining nut of fresh and sea

water pumps
150 5
15
26
Balancing device of four-cylinder

engines:
.1 - retaining bolts of bearing cap
250 10
25
.2 - retaining bolts of pinion gears
120 5
12
Item
Threaded connection
.3 - retaining bolt of idler pinion gear
250 10
25
.4
- retaining bolts of idler pinion gear

bearing pin
290 10
29
.5
- bolts retaining idler shaft to balancing

shaft
120 5
12
.6
- bolts (M16) retaining crankcase oil pan

to cylinder block
250 10
25
We recommend using torque wrenches for handling other bolts and nuts also. The
torque values specified in the below-mentioned table are applicable for bolts of
Property Class 8.8.
Bolt
size
Mouth size of wrenches

for tightening hex head
bolts
Mouth size of wrenches

for tightening hex socket
bolts
Nm
kgf.m
13
25
2.5
10
17
50
5,0
12
19
10
85
8,5
16
24
14
200
20
07.2
Torque values
Locking fluid application
When applying locking fluid ("Loctite"), all parts must be thoroughly degreased and
before the application of the locking fluid they must be absolutely dry.
07.3
Hydraulic torque of threaded connections
07.3.1
Threaded connections hydraulic torque pressure
The items numbers refer to the Picture on page 07-51.
Item
Threaded connection
Make-up
hydraulic
pressure,
Bar
Make-up
torque,
Nm
Maximum
break-out
pressure,
Bar
Hydraulic
cylinder
27
Studs 42 of the main

bearing
540
200
560
861020
28
Studs 42 of the cylinder

head
500
200
5 20
861020
29A
V22
Studs 30 2 of the
connecting rod
555
85
575
861027
29B
R22
Studs 30 2 of the
connecting rod
555
85
575
861034
30
Studs 24 of flywheel shield

bearing
285
50
295
861020
861030
07.3.2
Topping-up and checking hydraulic accessories set and bleeding-off air

(Picture on page 07-52)
a.
b.
Connect the hydraulic pump to the hydraulic cylinders according to the

diagram on page 07-52. Fill up the flexible vessel supplied together with the
pump with the lube oil having viscosity approximately 2 .
Open the unloading valve (3) and push pistons into cylinders (4)
in order to remove the lube oil residuals back in to the hydraulic pump.
c.
d.
e.
f.
g.
Raise the pump above the cylinder level and fix it with the plastic plug (2)
facing upward. Remove the plug and the bolt inside of it.
Place the vessels neck in the fill-up hole and squeeze the vessel to push the
lube oil out. Let the air enter the vessel and top up the vessels tank until it is
full with the lube oil.
Restore the bolt and the plastic plug.
Bleed off the air from the accessory closing the valve (3) undoing air outlet
screw (7) and pumping until the lube oil exits without air bubbles. Screw in the
screw (7).
If the significant volume of the lube oil was lost during bleeding-off the tank
must be re-filled.
07-7
The system is equipped with quick release connections complete with nonreturn
(check) valves thus requiring bleeding off air only while topping-up tank.
The nonreturn valves open with the help of dowel pins installed in the center of each
half of the quick release connection. If these dowel pins are worn the quick release
connection must be replaced in order to avoid malfunction of the accessory.
If in exceptional cases, it is necessary to use partially faulty connections it is
recommended to unscrew the air outlet screw to avoid lube oil passing through all
hydraulic cylinders prior to install the connection.
07.3.3 Undoing hydraulically torqued threaded connections (Picture on page 07-52)
a.
b.
c.
d.
e.
f.
07.3.4
a.
b.
c.
Install the distance sleeves and hydraulic cylinders according to picture at

page 07-52. Tighten hydraulic cylinders by-hand.
Connect the hoses to the hydraulic pump and hydraulic cylinders according to
the diagram B on page 07-52. Make sure that the unloading valve (3) is open
and screw in the hydraulic cylinders clockwise to push out the potential lube oil
residuals back into the hydraulic pump.
Turn pistons of the hydraulic cylinders counterclockwise half-turn (180O).
Close the unloading valve and charge the lube oil to the predetermined
pressure.
Unscrew the nuts counterclockwise approximately one turn.
Open the unloading valve and remove the hydraulic cylinders.
Hydraulic tightening of threaded connections

Screw in the nuts and install the distance sleeves. Screw in the hydraulic
cylinders by-hand.
Connect the hoses to the hydraulic pump and hydraulic cylinders. Make sure
the unloading valve is open. Turn the hydraulic cylinders clockwise for to push
out the potential lube oil residuals back into the hydraulic pump.
Close the unloading valve and charge the lube oil to the predetermined
pressure.
d.
e.
Tighten the nuts clockwise until the contact with the surface. The pressure
must be steady constantly.
Open the unloading valve and remove the hydraulic cylinders.
08.
Preventive measures are specified in sections 03 and 04.

Certain malfunctions require immediate actions. That is why the engine operating
crew must carefully study the contents of this section.
8.1
Failures, possible causes
Item
Failure and potential cause
See section, sub-section
CRANKSHAFT DOES NOT ROTATE DURING

START-UP
a.
V-engines: barring gear engaged

NOTE! The engine may not be started if the barring
gear is engaged. But it is necessary to make sure
11; 12
that the barring gear is disengaged prior to start up
the engine.
b.
Starting air is too low, the starting air inlet valve is

closed
21
c.
Starting valve in the cylinder head is jammed
21
d.
Slide valve of the air distributor is jammed
21
Starting air solenoid valve is faulty
21
Inlet or outlet valve is jammed in the open position.

No air gap between the valve stem and the
regulating screw of the rocker actuator or the air
gap is negative (load whistling noise)
12
Starting automatic gear failure outside the engine
03.1.2; 23
4-cylinder engine: Starter is faulty
21
CRANKSHAFT TURNS WITH THE AIR BUT NO

COMBUSTIONS IN THE ENGINE CYLINDERS
Low RPM value
08.1.16
The automatic protection device is not put at the

starting position
23
Load limit switch of the fuel oil supply regulating

shaft or regulator are set at a too low value
22
Limit switch tripped
22
Starting fuel supply limit switch is set incorrectly
22
Item
Some part of the fuel supply regulating system

is jammed affecting fuel supply
22
The air is not bled off from the fuel supply

system and fuel injection system, tubing
connections between high pressure fuel pump
and nozzles are not tight.
17
Fuel oil filter is clogged
17
Three-way valve of the fuel oil filter is installed

incorrectly, the fuel oil supply valve at the tube
is closed, the fuel oil day tank is empty, the fuel
feed pump is off or faulty
17
Very low air and engine temperature (preheat

the fresh water) when using low flash point fuel
oils
02.1.4j
Preheating or preliminary fuel circulation are not

sufficient
02.1.2b
Compression pressure is low
08.1.1f
INTERMITTENT FUEL COMBUSTIONS IN

ENGINE CYLINDERS, LACK OF
COMBUSTION IN SEVERAL CYLINDERS
Valves are jammed, insufficient fuel oil supply,

low temperature of the fuel oil
08.1.1f;
08.1.2f, g, h, j, k
High pressure fuel pump fuel rack is set

incorrectly
22
Ring gear of the high pressure fuel pump is

incorrectly engaged at the fuel rack (if the ring
gear shifted to the fuel supply increase side this
may result in engine racing)
16
High pressure fuel pump is faulty (jammed

piston or cam follower, broken fuel pressure
valve spring, jammed fuel pressure valve)
16
Faulty nozzle, clogged injection holes
16
Faulty piston rings, low fuel compression

pressure
11
Item
Eight and sixteen cylinder engines: the fuel

combustions in cylinders in the idle mode may
be impeded due to the low fuel oil supply
required. This is allowed for the normal
operation.
In special cases when engines due to any

reason are to run idle continuously (for several
hours) it is recommended to thoroughly adjust
the position of the fuel racks of the high
pressure fuel pump reducing the fuel supply of
those cylinders that have the highest
temperature of the exhaust gas and slightly
increasing the fuel supply of the cylinders
without fuel combustions. The adjustment must
be performed stepwise and the difference
between fuel rack positions of the cylinders
must not exceed 1 mm.
ENGINE RUNS INTERMITTENTLY
Regulator is incorrectly adjusted (usually

insufficient compensation)
Some part of the fuel oil supply regulating

system is jammed affecting the normal fuel
supply
Low fuel oil supply pressure
Water entrapped in the preheated fuel oil (vapor

lock in the high pressure fuel pump)
Starting automatic gear failure outside the

engine (for example, the gear of controllable
pitch propeller)
SLAPS OR DETONATIONS IN ENGINE

(if causes cannot be identified immediately shut
down the engine without delay!)
Excessive air gap in the crank pin bearings

(loose bolts!)
06.2.11;
07.1.3
Springs of valves, valve tappets or high

pressure fuel pump are damaged
12; 16
22
01.2.2
23
Item
Inlet or outlet valve is jammed in the open

position
Excessive air gaps in the valves
06.1; 12
One or several cylinders are significantly

overloaded
08.1.3b, c
Guide block of the valve tappets or the high

pressure fuel pump is loose
16; 14
Early signs of the pistons jamming
Insufficient engine preheating when using low

flash point fuel oils (detonation combustion)
DARK EXHAUST GAS
The engine is significantly overloaded (check

the positions of fuel racks of the high pressure
fuel pump and exhaust gas temperature)
Commissioning report
Delays in fuel injection (incorrect camshaft drive

pinion gear engaging)
06.1; 16; 13
Faulty high pressure fuel pump or nozzles
08.1.3b, c, d, e
Insufficient volume of charging and purging air

charging air filter is clogged
turbocharger compressor is clogged
air cooler is clogged from the air side
turbocharger turbine is very dirty
Commissioning report;
15; 04.7; 04.4
Load dependent cooling system does not work

as it must do, low temperatures at low load.
Applied only to diesel engines type 22HF
and 22 running on heavy fuel.
NOTE: After the start-up on heavy fuel, the
engine may produce dark smoke when running
idle
18
Item
WHITE-BLUE EXHAUST GAS
Abnormally high consumption of the lube oil due

to the gas leakage at the piston rings, worn or
broken oil rings or worn cylinder liners, burned
compression rings, upside-down compression
rings, scratches at the rings (signs of burning at
the sliding surface)
The engine may accidently produce white-blue

exhaust gas after continuous idle running at the
low ambient temperature or shortly after the
start-up
ABNORMAL HIGH EXHAUST GAS

TEMPERATURE OF ALL CYLINDERS
The engine is significantly overloaded (check

the positions of the fuel racks of the high
pressure fuel pump)
Commissioning report
Insufficient volume of the charging air
08.1.6d
High charging air temperature
Commissioning report;
01.2.1
- air cooler is clogged from the water end or

dirty from the air end
15.
- high temperature of the water entering air

cooler, insufficient water volume
01.3
- abnormally high temperature in the Engine

Room
01.3
Significant depositions in the inlet and outlet

valves of the cylinder heads
Dirty turbocharger compressor or turbine
ABNORMAL HIGH EXHAUST GAS

TEMPERATURE OF ANY CYLINDER
Faulty exhaust gas temperature gauge
Outlet valve
jams in the open position
no air gap or negative air gap in the
valve
burned sealing surfaces, gas leakage
11
04.4; 04.5; 15
23; 03.3.1
Item
c

Faulty nozzle
low needle opening pressure
injector needle is jammed in the open
position
-

06.1
16.
broken spring
Delays in the fuel injection
06.1; 16
Clogged fuel oil filter
Faulty high pressure fuel pump
10
ABNORMAL LOW EXHAUST GAS

TEMPERATURE OF ANY CYLINDER
Faulty exhaust gas temperature gauge
23; 03.3.1a
Insufficient fuel oil supply, faulty high pressure

fuel pump or nozzle
08.1.2f, h; 08.1.3b, c, d, e
Leakage at the high pressure fuel tube or tube

connections
16
When running idle, see item 08.1.3g
03.3.1a
11
VERY UNEVEN EXHAUST GAS

TEMPERATURE
Faulty exhaust gas temperature gauge, faulty

nozzle
08.1.9c
Too low fuel oil supply pressure, insufficient fuel

flow through the high pressure fuel pump. This
may result in the big difference of the load in
different cylinders although the positions of the
fuel racks of the high pressure fuel pump stay
the same. WARNING! This causes high thermal
overload of the cylinders.
01.2.2; 08.1.2h, i
Fuel oil supply mechanism is jammed
When running idle
Delays in the fuel oil injection
08.1.3d
08.1.3g
Item
12
LOW LUBE OIL PRESSURE OR NO LUBE OIL

PRESSURE
01.2.2
Faulty pressure gauge, the pressure gauge tube

is clogged
23
Very lube oil level in the crankcase
01.1; 18
Incorrect setting of the lube oil pressure

regulating valve or the valve is jammed
18
Incorrectly setting of the three-way valve of the

lube oil filter
18
Leaking lube oil supply tubing connections
18
The lube oil is significantly diluted with the fuel

oil, lube oil viscosity is too low
02.2.1; 02.2.3
Lube oil tubing inside the engine are loose or

damaged
18
13
HIGH LUBE OIL PRESSURE
Faulty pressure gauge or pressure regulating

valve
18
14
HIGH LUBE OIL TEMPERATURE
01.2.1
Faulty temperature gauge
Insufficient volume of the cooling water passing

through the lube oil cooler (faulty pump,
entrapped air in the system, closed valve), high
cooling water temperature
19
Lube oil cooler clogged, depositions in tubing
18; 19
Faulty thermostatic valve
15
ABNORMAL HIGH DISCHARGE COOLING

WATER TEMPERATURE, BIG DIFFERENCE
IN SUCTION AND DISCHARGE COOLING
WATER TEMPERATURES
One of the temperature gauges is faulty
Fresh water cooler is clogged, depositions in

tubing
19
Item
Insufficient volume of the cooling water

passing through the engine (faulty fresh water
pump, entrapped air in the system, closed
valves)
19; 03.3.1e
Faulty thermostatic valve
19
16
NOZZLE TEMPERATURE ADJUSTING LUBE

OIL TEMPERATURE IS HIGHER OR LOWER
THAN RATED, BIG OR SMALL
TEMPERATURE DIFFERENCE IN THE
SYSTEM
(applicable for the engine types 22HF and
22HE running on heavy fuel)
One of the temperature gauges is faulty
Insufficient lube oil flow
The gas enters the system through the faulty

injector
17
Faulty heater / cooler
17
17
WATER IN LUBE OIL
02.2.3b; 03.3.1d
Leakage at the lube oil cooler
18
Seal O-rings at the cylinder liners leak (the

pressure test must be carried out always after
draining system or after the removal of the
cylinder liners)
10.6
c
18
Faulty lube oil purifier

See the lube oil purifier operation manual
WATER IN AIR RECEIVER
(drains through the drain tube in the air cooler
body)
Leakage in air coolers
Condensation (low cooling water temperature

of the charging air system)
19
ENGINE RPM FALLS DOWN AT

CONTINUOUS OR INCREASED LOAD
02.2.3a
15
03.3.1a; 03 page 03-52
Item
Engine overloaded, the fuel oil supply increase

is prevented by the mechanic load limit switch
22
Insufficient fuel oil supply
08.1.2c, f, g, h, I;
08.1.4c, d
Mechanical failure
08.1.5g; 08.20d
20
ENGINE STOPS
Insufficient fuel oil supply
08.1.2h, i
Tripped limit switch
22
Tripped automatic protection device
23
Faulty RPM regulator
22
21
ENGINE DOES NOT STOP THOUGH THE

SHUTDOWN HANDLE IS IN STOP
POSITION OR A REMOTE SHUTDOWN
SIGNAL IS ACTIVATED
Teeth of the fuel racks of the high pressure

fuel pump have the incorrect profile
Trip manually the limit switch. If the engine
does not stop immediately the fuel oil supply
must be closed as close to the engine as
08.1.3b, c
possible (for example, with the three-way valve
of the fuel oil filter)
The malfunction must be identified and
eliminated prior to the next start-up.
Big risk of the engine racing
Faulty automatic shutdown gear. Stop the

engine with the shutdown handle.
The engine rotates with the generator,

propeller shaft of an adjacent engine
connected to the same reduction gear
22
ENGINE OVERRUNS AND DOES NOT SHUT

DOWN IN SPITE OF TRIPPED LIMIT
SWITCH
23
Item
22
ENGINE OVERRUNS AND DOES NOT SHUT

DOWN IN SPITE OF TRIPPED LIMIT
SWITCH
Teeth of the fuel racks of the high pressure

fuel pump have the incorrect profile
Load the engine if it is possible
Shut the fuel oil supply, for example, with the
three-way valve of the fuel oil filter or close the
air supply with closing air filter
08.1.3b, c
Problems with shutting-down overrunning

engine. That is why it is necessary to check
periodically the adjustments of the regulating
gear (positions of the fuel racks of the high
pressure fuel pump):
1. When the stop handle is at the "stop"
position or when the limit switch tripped
and the RPM regulators position at the
maximum fuel supply mode
2. When the stop handle and limit switch
position at the run mode and the RPM
regulator is at the stop mode
This check must be executed every time
after the regulating gear or high pressure
fuel pump has been dismantled
22
08.2
Emergency operation
08.2.1
Running with faulty air cooler (s)
If the tubing of the air cooler is faulty the cooling water may enter the cylinders. If the
water or the water mist exits the drain tube at the bottoms of the air cooler body,
check where this water came from: cooling system or the condensate. If the water is
generated due to the condensation reduce cooling (see section 0 page 03-52). If
this is the cooling water it is necessary to shut down the engine immediately and
replace the air cooler with a spare one.
In case if the spare air cooler is not available the following measures are allowed as
contingency:
a.
Remove the air cooler for repair and close tight the hole in the air cooler body.
Close the supply and discharge piping. Repair the air cooler, for example,
blank flange the leaking pipes.
b.
If there is no time to remove the faulty air cooler for the repair it is necessary to
close the water inlet and outlet pipes.
c.
Operation after partial closing tubes, after shutting-down or the complete

removal of the air cooler is allowed. The engines load must be limited in such
a way that the exhaust gas temperature of the cylinders does not exceed the
temperature of the exhaust gas of the engine running at the normal condition
with the full load.
Surging may occur in the gas turbocharger before the allowed temperature of
the exhaust gas is achieved. In such cases it is necessary to reduce the
engines load in order to avoid continuous surging.
08.2.2
Running with faulty turbocharger (s)
The faulty gas turbocharger must be handled as according to the Operational Manual
of the turbocharger (stopping rotor, etc.).
If in a V-shape engine, one of the turbochargers is faulty and it is necessary to
interlock this turbocharger, the second turbocharger must be interlocked as well, the
piping between turbochargers and air coolers must be removed in order to keep the
engine running with the natural air.
When running engine without a turbocharger, the load must be limited in such a way
that the temperature of the exhaust gas doe not exceed the temperature of the
exhaust gas of the engine running at the normal condition with the full load.
08.2.3
Running with broken cams
If a section of the camshaft with broken cams may not be removed or replaced with a
new one the engine may keep running in case if the following measures are taken:
a.
Cams of the high pressure fuel pump
Minor damages: Put the fuel rack of the high pressure fuel pump at the zero position
and lock it with the rolled wire wrapping around the pump.
Severe damages: Remove the high pressure fuel pump. See the section 16.
Attention!
Torsional vibrations and other oscillations, please see at section 08, item 5.
When the engine runs with the fuel oil pump working continuously it is necessary to
remove the rods of the inlet and outlet valve tappet and the indicator valve of the
corresponding cylinder must be opened once an hour to remove the accumulated
fuel oil.
When running with one cylinder off, it is necessary to reduce the engine load in order
to avoid exceeding pre-established exhaust gas temperature of the other cylinders.
b.
Valve cams
Close the fuel oil supply to this cylinder. See the section 16. Remove the followers
and followers rods of these cylinders. Restore the safety tubing of the followers rods.
Attention!
Torsional vibrations and other oscillations, please see at section 08, item 5.
When running with one cylinder off, it is necessary to reduce the engine load in order
to avoid exceeding pre-established exhaust gas temperature of the other cylinders.
08.2.4
Running with uninstalled piston and connecting rod
If a faulty piston, connecting rod and crank pin bearing cannot be eliminated it is
allowed to run the engine at the contingency mode in when following measures are
taken:
-
removed piston and connecting rod;

closed lube oil hole in the crank pin bearings neck with an appropriate clamp
and snap it;
install the cylinder head assembly without the valve tappet rods;
close the supply starting with air supply in the cylinder head having removed
control air tube;
disconnect the fuel oil supply pump (section 08, sub-section 08.3, item a).
When running with a cylinder off it is necessary to reduce the engines load in order
to avoid exceeding rated temperature of the exhaust gas from the other cylinders.
If the gas turbocharger (s) has surging it is necessary to reduce the load in order to
avoid constant surging.
Running without piston and connecting rod of one or more cylinders must be allowed
only in the emergency case when the navigation with other means is not possible.
08.2.5
Torsional oscillations and other vibrations
When running engine with one or several cylinders off the balance of the engine is
disturbed potentially resulting in serious and dangerous oscillations.
09.
09.1.1

Maximum limitations for the fuel oil specification
Density at 15O C
kg/ltr
0.9200
kinematic viscosity
cSt at 40O C
14.00
kinematic viscosity
cSt at 50O C
11.00
kinematic viscosity
At Redwood #1 at
100O F
70.00
Coke number by Ramsbottom
Weight percentage 2.5
Water content
Water content at the engine inlet
Ash content
Sulfur content
Congelation point
Vanadium content
mg/kg
100
Aluminium content
mg/kg
30
09.1.2
Minimum limitations for the fuel oil specification
Closed cup tester flash point by Pensky-Martens 60.0 .

The given specification meets the British standard MA 100 1982 of class with the
additional limitation for the water content at the engine inlet.
10.
ENGINE BLOCK WITH CYLINDERS, BEARINGS, CYLINDER LINERS

AND CRANKCASE
10.1
Description
The cast iron engine block is solid mold. The distribution manifold of cooling water
and the lube oil as well as the purge air receiver are molded together with the block.
The main bearing housings are suspended and bear the crankshaft which rests on
the replaceable shells of the precision type bearings. The upper shell is fixed in the
lubrication groove with the help of the lugs (one at each butt end). The lower shell
has a lug at one butt end with the help of which the shell is prevented from shifting at
the axial direction. Fixing shells is provided with their circumference being longer than
the one of the corresponding holes. The first from the drive end main bearing is
equipped with four snap rings that prevent crankshaft shifting in the axial direction. If
required, it is possible to install an additional so-called shield bearing.
The bearing bushing shells of the camshaft are installed in the holes machined in the
transversal walls of the engine block.
The engine block contains cylinder liners manufactured using the special cast iron.
The liners surface is treated to the perfect state using honing process. Sealing
cylinder liners and engine block at the upper part is provided with the very tight
contact of the landing surfaces and at the lower part it is provided with two seal Orings.
The crankcase hatch covers and the thick light-metal alloy covers of the camshaft
hatches are sealed with the help of gaskets of the special profile. Some crankcase
hatch covers are equipped with spring loaded safety valves reducing the
overpressure in the crankcase in order to prevent the detonation. The crankcase is
equipped with a vent tube for the crankcase ventilation having nonreturn valve. This
vent tube must be exit the engine. The cover having lube oil port is installed at the
drive end.
The crankcase is made of steel plates welded together. The crankcase oil pan is
sealed to the engine block with the help of special profiled rubber gasket.
10.2
Main bearing shell removal (Picture on page 10-54)
1.
Remove crankcase hatch covers closest to the required bearing.
2.
Loosen side bolts of the main bearing housing approximately one turn with the
help of the 4X combination tool. See Picture on page 10-54.
3.
Install the distance sleeves (8) (Picture , page 10-51) and insert pins (10) into
liner grooves to fix them.
4.
Connect the hydraulic cylinders (9) to the pins of the main bearing. Hook up
the hoses according to the diagram at the picture , page 10-54, and open
unloading valve (3). Tighten the hydraulic cylinders more by-hand in order to
push out the potential lube oil residuals from the hydraulic pump. Loosen
slightly pistons of the hydraulic cylinders to half-turn (180) (See section 07,
sub-section 07.3).
5.
Pull the studs with charging lube oil until the pressure specified in section 07,
sub-section 07.3, Picture on page 10-54. Undo nuts approximately one turn
with the help of pins.
6.
Bleed off pressure with opening unloading valve of the hydraulic pump.
Disconnect the hoses, unscrew the hydraulic cylinders and remove the
distance sleeves.
7.
Remove the nuts and install the lifting tool for main bearing cap 832003 to
raise the main bearing housing (Picture on page 10-52; Picture D on page 1054). Remove the side bolts and lower down the housing with the help of a tool
connecting the handle to the edge of the crankcase hatch cover. The lower
shell may now be removed from the housing.
If it is necessary to remove the main bearing housing the angle of the handle
must be changed installing retaining pins into other two holes. Thus it is
possible to lower down the main bearing housing further until it is completely
free from studs and may be removed. In order to make it easier, unscrew side
bolts of the adjacent bearings.
8.
To remove the upper shell, it is necessary to install the turning tool for main
bearing shell R22HF 851001 (single-row engine) or turning tool for main
bearing shell V22HF 851002 (V-shape engine) into the radial lubrication port
of the shaft journal, turn carefully the crankshaft until the upper bearing shell
turns 180 and remove it. See Picture , F on page 10-54.
Close both lubrication ports in the shaft journal with adhesive tape.
In order to support the crankshaft it is necessary that at least each third main
bearing stays in its place at a moment.
9.
Snap rings may be removed from the main bearing housing when it is lowered
down.
To remove the upper snap rings you must insert turning tool for thrust bearing
shell R22HF 851005 (single-row engine) or turning tool for thrust bearing shell
V22HF 851006 (V-shape engine) into the radial lubrication port of the shaft
journal. Turn carefully the crankshaft until the upper bearing shell turns 180
and remove snap rings.
10.3 Bearing shell and snap ring inspection

Flush the shells and make sure that there are no excessive wear and tear, cracks or
other defects. The size of the wear is identified measuring thickness of the lower
shells. To do this, a micrometer gauge with the spherical contact surface must be
used. In case if the wear of all lower shells is uniform the shells are allowed for
further use if the shell thickness does not exceed the minimum allowed value
specified in item 10 in sub-section 06.2 of section 06 or the galvanized upper layer
is not worn at the area more than 30% (three-layered bearings). If the wear is not
uniform we recommend replacing shells.
Put marking with corresponding identification numbers at the new bearings.
Snap rings must be replaced in pairs to assure that the thickness of the axial bearing
surfaces is uniform.
Scraping or other similar types of the treatment of the shells, housings or foundations
must not be carried out. Only local dirt notches are allowed to be removed.
The journals surface must be inspected for cleanliness. The damaged journals (
(surface roughness of the journals, scratches, impact traces on the journals) must be
polished. If after a continuous engine operations a significant uneven wear appears
(see section 06, sub-section 06.2, item 11) the crankshaft may be polished and
reinstalled together with thicker shells. See "Spare part catalogue".
10.4
Installation of shells and main bearing snap rings

(See picture on page 10-55)
1.
Clean very thoroughly holes, housings, shells of the main bearing and shaft
journal.
2.
Remove the protection tape from the journals lubrication ports and lubricate
the journal with the clean lube oil.
3.
Lubricate the surface of the upper shell bearing (not from the back side). Make
sure that the bearing shells are installed correctly.
4.
Insert the butt end of the shell into the air gap between the journal and bearing
bed and push it by hand as far as possible. See Picture on page 10-55.
5.
Insert turning tool for main bearing shell R22HF 851001 (single-row engine) or
turning tool for main bearing shell V22HF 851002 (V-shape engine) into the radial
lubrication port of the shaft journal and turn carefully the crankshaft until the shell
seats at its place. See Picture on page 10-55. Make sure that the lug enters the
lube oil groove without damaging. Remove the pin.
6.
7.
Lubricate the surface of the lower shell (not from the back side) and put it into
the housing; raise the housing with the lifting tool for main bearing cap 832003 (See
Picture on page 10-52 and picture on page 10-55) until the lubricated side bolts
can be inserted by-hand into the threaded hole of the main bearing housing. Remove
the tool.
Lubricate nuts and tighten them by-hand.
8.
Install the distance sleeves (8) (See Picture on page 10-51) back and fix
them at their places with pins (10) inserted into the nuts holes along the liner
grooves. Screw in the hydraulic cylinders (See Picture D on page 10-55) and hook up
the hoses. Open the unloading valve of the hydraulic pump. Tighten the hydraulic
cylinders by-hand in order to push out the potential lube oil residuals back into the
hydraulic pump.
9.
When assembling main bearing: shift the crankshaft in the axial direction to
the side opposite to the drive end.
10.
When installing main bearing with the snap rings: remove the protection tape
from the from the lubrication ports. Insert turning tool for thrust bearing shell R22HF
851005 (single-row engine) or turning tool for thrust bearing shell V22HF 851006 (Vshape engine) into the lube oil port. Lubricate the crankshaft, bearing (not from the
back side) and snap rings. Install them crankshaft and rotate the shaft to 180 until
the bearings are at their places then rotate the crankshaft backwards and remove the
pin. The installation of the lower shell: lubricate the bearing and snap rings. Place
them in the main bearing housing. Install the bearing housing as indicated in item 8.
Note: The snap rings have marking as according to picture on page 10-59
(engine control side).
11.
Tighten up preliminary the side bolts from the side opposite to the drive end
only to 300 Nm torque, then stretch the main bearing studs charging the lube oil to
the pressure value specified in sub-section 07.3, section 07. See Picture on page
10-55.
12.
Tighten the nuts with the help of rods (10) until the contact to the surface. The
pressure must be maintained steady constantly.
13.
Bleed of the pressure opening the unloading valve of the hydraulic pump.
Disconnect the hoses, unscrew the hydraulic cylinders and remove the distance
sleeves and rods.
14.
Tighten up the side bolts with the combination tool. See Picture F on page 1055 to the torque value specified in sub-section 07.1 section 07.
15.
After having inspected bearings, prior to start up the engine, check the axial
deflection of the crankshaft (See section 11, sub-section 11.3).
10.5
Removal and installation of additional flywheel shield bearing
Removal (Picture on page 10-56)

If the engine is equipped with an additional main bearing (i.e. flywheel shield bearing)
between thrust bearing and flywheel, the inspection must be carried out in the
following way:
1.
Remove two lower parts of the butt end cover. The upper part may stay at the
place.
2.
Undo four bolts connecting the bearing housing to the engine block with the
help of the combination tool as according to picture on page 10-56.
3.
Loosen the nuts of two vertical studs with the help of the hydraulic tool as
according to picture on page 10-56. See section 07, sub-section 07.3.
4.
Lower down the bearing housing in such a way that it rests at the edge of the
crankcase oil pan. See Picture on page 10-56. (If it is required to remove
the housings the studs must be undone).
5.
To remove the upper shell it is necessary to rotate the shaft clockwise with the
help of the turning tool for shield bearing shell 851004 inserted into the
lubrication port. See Picture D on page 10-56. Remove the pin. Cover the
lubrication port with adhesive tape.
6.
Inspect the bearing the same way as the other main bearings. See section 10,
sub-section 10.3.
Installation (Picture on page 10-57)

7.
Lubricate the surface of the upper bearing shell and crankshaft journal.
8.
Insert the shells butt end without lug into the air gap between the journal and
the bearing bed from the groove side. Push the shell by-hand as far as
possible.
9.
Insert the turning tool for shield bearing shell 851004 into the radial lubrication
port and rotate carefully the crankshaft counterclockwise until the shell is at its
place so that its edge fits the surface of the bearing body split. Make sure that
the lug at the shells butt end is not damaged. Remove the pin as shown at
Picture and on page 10-57.
10.
Lubricate the surface of the lower shell and insert the shell into the bearing
housing. See Picture on page 10-57.
11.
Raise the housing until the butt ends of the shells contact each other tighten
up the nuts by-hand.
12.
Impact two guide pins at the top for centralizing lower half of the bearing body.
111
13.
Install the distance sleeves back; insert the pins into the slots.
14.
Hook up the hydraulic cylinders.
15.
Connect the hoses, open the unloading valve of the hydraulic pump and then
tighten the hydraulic cylinders.
16.
Stretch the studs with charging the lube oil to the pressure value specified in
section 07, sub-section 07.3. See Picture on page 10-57.
17.
Maintain the pressure steady constantly and tighten up the nuts with the help
of pins for hydraulic tightening device 861025 (See Picture on page 10-51).
18.
Bleed off the pressure opening unloading valve of the hydraulic pump.
Disconnect the hoses, loosen the hydraulic cylinders and remove the distance
sleeves and stems.
19.
Tighten up four bolts to the torque value specified in sub-section 07.1 section
7. See Picture D on page 10-57.
10.6
Removal and installation of cylinder liner

(See Picture on page 10-53)
If it is required to replace the cylinder liners or to inspect the m from the water cavity
side the extracting and lifting tool for cylinder liner 836001must be used. Lubricate
the tools thread and the contact surface of the nuts with the grease "Molykote Paste
G".
When installing cylinder liners, it is necessary to take the following measures:
1.
Make sure that all guide and contact surfaces between the engine block and
the cylinder liner (at the upper part) are clean and defect-free.
2.
Make sure that the seal O-ring grooves at the cylinder liners are clean and
install new seal rings.
3.
Cover the seal O-rings and sealing surfaces with the grease "Molykote Paste
G" or with the soft soap and install the aforementioned tool to raise the liner at
this time.
4.
Bring down carefully the liner into the engine block slot. When the lower seal
O-ring contacts the engine block, turn the liner in such a way that it faces the
drive end. Then, lower down the liner and push in by-hand to its place. If
required, knock the liner several times with a rubber or plastic hammer.
112
5.
Check the inside diameter of the cylinder liner especially in the area of the seal
O-rings (390 mm from the upper edge of the liner). See section 06, subsection 06.2, item 11. The cylinder liners ellipticity must not exceed 0.02 mm.
After the installation of the cylinder liner and filling cooling water system, make
sure that the seal O-ring from the crankcase end is tight. If it is possible check
the integrity with the high pressure water circulating in the system (1.25 rated
pressure) shutting down cooling water pump.
10.7
Camshaft bearing sleeve inspection
After the removal of the camshaft spacer, the inside diameter of the bearing sleeve
may be measured at the side with the help of micrometer gauge with the spherical
contact surface. The maximum allowed wear value is specified in item 10, section 06,
sub-section 06.2. The order of the visual inspection is the following:
1.
Remove the covers of two camshaft crankcase hatches in the area adjacent to
the given bearing.
2.
Remove the cover of the air distributor. See section 14.
3.
Disconnect the spacer from the camshaft section flange towards the drive end
relative to the given bearing.
4.
Shift the camshaft section at the other side of the given bearing not more than
20 mm to the direction opposite the drive end with the help of a suitable lever.
5.
Inspect the open part of the bearing sleeve with the help of a mirror. All
bearings of the camshaft located relative to the given bearing to the direction
opposite the drive end may be inspected while the camshaft stays at such
position.
10.8
Camshaft bearing sleeve removal

1.
Remove the camshaft crankcase hatch cover, high pressure fuel oil pump,
guide blocks and the camshaft section adjacent to two cylinders closest to the
given bearing. In order to remove the outermost bearing it is necessary to
remove accordingly the end section of the camshaft.
2.
Remove the camshaft spacer.
3.
Install the mounting device for camshaft bearing bush 834001 as according to
picture on page 10-58 or according to picture on page 10-58 for to remove
the bearing the closest to the side opposite the drive end. In order to remove
113
the outermost bearing, it is necessary to install the guide sleeve 234001 and
the tool in such a way that the hydraulic cylinder is outside the engine.
4.
Fix the hydraulic cylinder with light tightening bolt.
5.
Hook up the hoses of the hydraulic pump to the hydraulic cylinder.
6.
With the help of the hydraulic pump increase the working pressure in the
hydraulic cylinder to push out the bearing sleeve. The pressure must not
exceed 600 Bars. If the bearing sleeve does not move after having reached
the aforementioned pressure, it is necessary to knock slightly the tools flange.
7.
Open the unloading valve, disconnect the hoses of the hydraulic pump and
remove the extractor.
10.9
Camshaft bearing sleeve installation

1.
Lubricate slightly the surface of a new bearing with pure lube oil and install it at
the guiding collar of the guide sleeve.
2.
Install the mounting device for camshaft bearing bush 834001 as according to
picture on page 10-58 or for the installation of the bearing closest to the side
opposite to the drive end take the measures as according to picture D on page
10-58. In order to install the end bearing it is necessary to install the tool in
such a way that the hydraulic cylinder is positioned outside the engine. Make
sure that the mark at the bearing sleeve corresponds to the mark at the engine
block.
3.
Fix the hydraulic cylinder with light tightening bolt.
4.
Hook up the hoses of the hydraulic pump to the hydraulic cylinder.
5.
With the help of the hydraulic pump increase the working pressure in the
hydraulic cylinder to push the bearing sleeve to its place. The pressure must
not exceed 600 Bars. If the bearing sleeve does not move after having
reached the aforementioned pressure, it is necessary to knock slightly the
tools flange.
6.
Open the unloading valve, disconnect the hoses of the hydraulic tool and
disconnect the tool.
7.
Lubricate the working surface of the bearing and insert the camshaft spacer.
8.
Put back the camshaft sections, guide blocks, high pressure fuel pump and
camshaft crankcase hatch cover.
114
115
10-52
116
10-53
REMOVAL OF CYLINDER LINER
117
10-54
REMOVAL OF MAIN BEARING
118
10-55
ASSEMBLING OF MAIN BEARING
119
10-56
REMOVAL OF SHIELD BEARING
120
10-57
Assembling of shield bearing
121
122
10-59
MARKING OF THE THRUST WASHERS OF THE CRANKSHAFT
123
11.
11.1
Description
(See Picture on page 01-51, 01-52, 01-52, 01-54, 11-51)
The crankshaft is a solid forged piece. The first main bearing from the drive end is
equipped with snap rings thus considered as a thrust journal bearing. The
crankshafts of the V-shape engines are equalized with counterweights in each crank
and the crankshafts of the single-row engines are equalized with the counterweights
as required. Each counterweight is fixed with the help of two bolts.
From the drive end the crankshaft is equipped with a preheated oil thrower in order to
prevent lube oil and gas leakage. Also, from the same end, the crankshaft is
equipped with a split pinion gear. See section 13. From the side opposite to the drive
end, the crankshaft if required is equipped with a regulation weight or dampener and
with as pinion gear as well for driving installed pumps.
The balancer of engine type 4R22. The four-cylinder single-row engine is equipped
with two balancing shafts rotating at a double speed of the crankshaft. The drive of
the shafts is provided by the crankshaft with the help of the idler pinion gear. Each
shaft is installed onto four journal bearings with the pressure-feed lubrication. One of
the bearings is a thrust journal bearing. The counterweights are forged together with
the shaft. The balancer does not usually require any maintenance. When overhauling
an engine, the journal bearings may be inspected. If the gearing was opened, it is
necessary to make sure that the pinion gears are installed at their respective
positions according to the stenciled marks.
The flywheel is connected to the crankshaft partially with four bolts and partially with
power delivery shaft bolts. That is why, usually, the flanges of the crankshaft and the
generator shaft are pressed to the flywheel through the free-sized holes. At that, the
power is transferred with the fraction force between flanges and flywheel. In engine
types Vasa 22HF, and MD, the power delivery, if required, may take place from
the side opposite to the drive end as well.
The flywheel position indicator is equipped with the vernier designed to read out the
crankshafts rotation angle with the accuracy of 1.
Barring gear is a pinion gear connected to a square pin of the ratchet. See Picture D
on page 11-52. The rotation direction may be changed with shifting the reverse lever
of the ratchet to another position. The signal lamp at the instrument panel comes up
at the moment when the barring gear is activated.
The crankshafts of single-row engines are rotated with the help of a lever inserted
into the flywheels hole.
124
Note! Do not forget to remove the barring gear from the flywheel prior to start
up the engine!
The connecting rod is hot press formed and completely treated. The coupled
surfaces of the lower head split have precisely shaped teeth. The steel three layered
crank pin bearings has the same design as main bearings. The lube oil is supplied
through the main bearings and the ports drilled in the crankshaft.
Head bearing has a big bearing area at the most loaded lower part of the bearing.
The lube oil is supplied to the bearing from the crank pin bearing through the ports
drilled in the connecting rod. The connecting rod is secured from shifting in the axial
direction with the help of the upper part of the head bearing.
The piston pin is hollow and has the radial holes for the lube oil supply from the
connecting rod to the piston. The butt ends of the pin are blanked to prevent lube oil
leaking. The piston pin is fixed in order to prevent shifting in the axial direction with
the help of the elliptical retaining rings.
The piston is made of cast iron with globe-shaped graphite and cooled with the lube
oil supplied the piston pin into the circle-shaped cavity. From there, the lube oil is
charged into the crankcase through the port. The piston skirt is lubricated with the
lube oil coming from the head bearing along the drilled channels.
Note! The piston must always be handled with care.
Piston ring set consists of three compression rings being two upper chromed rings
and one chromed self-adjusting oil ring.
11.2
Crankshaft package removal (warmed-up engine)
1.
Put the crank of the first cylinder in the position close to BDC and fix the
indicator (with the air gap between measuring pins approximately 150 mm for
V-shape engine and 96 mm for single-row engine) to the marks stamped at
two sides of the crank. It is recommended that the air gap between the
indicator and the connecting rod is as small as possible. Set the indicator at
zero.
2.
In order to take readings of deflections, it is necessary to turn the crank to four

different positions: right side, TDC, left side, BDC. Record the indicators
readings taken at these positions in the Crankshaft deflection protocol (blank
forms are included in the delivery package). Take similar measurements of the
deflections at the other cylinders.
125
For each crank, the difference of two diametrically opposite measurements

must not exceed 0.04 mm after the installation or re-installation of the engine.
If the difference exceeds 0.07 mm, it is recommended to re-install the engine if
the difference is 0.10 mm the re-installation is absolutely necessary. Before
the re-installation of the engine and other devices driven by it, it is necessary
to check the thickness of main bearing shells.
3.
When the last crank is at TDC, the indicators readings must be negative
(maximum 0.04 mm or zero). The recommended value is 0.02 mm.
4.
If it is impossible to attain the values specified in items 2 and 3 it is necessary

to repeat the installation.
5.
After the reinstallation of engine block and generator, it is always necessary to

inspect the axial deflection of the crankshaft as well.
In engines which flywheels are connected with flexible couplings, the closest to the
flywheel crank has the biggest deflection difference due the crankshafts bowing.
After the installation or re-installation of such engines, the difference must not exceed
0.06 mm. When the main journal is at the upper position, the readings of this crank
must be must be negative. The maximum allowed difference when the re-installation
is absolutely necessary is 0.11 mm in this case.
11.3
Axial deflection check
Prior to carry out the axial deflection check with the indicator, it is necessary to switch
on the lube oil precharging pump for several minutes for to lubricate the bearings.
Shut down the pump and place the indicator, for example, on the butt end surface of
the flywheel. Then, put the indicator at zero, shift the crankshaft to the opposite side
and read out the value of the axial deflection with the indicator.
The axial deflection must stay within the limits specified in item 10, section 06, subsection 06.2.
When installing or re-installing, make sure as well that the radial air gap around
circumference between the crankshafts flange and the butt end cover from the drive
end divided in three parts. The normal air gap is 0.62 0.93 mm.
11.4
Connecting rod and piston removal

1.
Remove the cylinder head (section 12, sub-section 12.2). Remove the carbon
deposition from the upper part of the cylinder liner face. (To collect the
particles of the removed carbon deposition and other dirt, it is recommended
to cover the piston head with textile tissue or paper sealing tight the air gap
between the piston and the liner.)
126
2.
Clean the threaded hole in the piston head with a tap borer 12 and fix the
lifting tool 832002 using the hex head bolt M12 80. See Picture and on
page 11-52.
3.
Single-row engine: Rotate the crankshaft to the position at 95 from TDC of

this cylinder to control end.
V-shape engine, row A: Rotate the crankshaft to the position at 95 from TDC
of this cylinder to row A.
V-shape engine, row B: Rotate the crankshaft to the position at 95 from TDC
of this cylinder to row B.
See Picture D on page 11-52. (The picture is applicable to V-shape engines
only. To rotate the crankshafts of single-row engines the lever 844022 must be
used. The lever is to be inserted into the flywheel hole.)
4.
Install the distance sleeves for tightening device 861033 on the studs of the
connecting rod of single-row engines. For V-engines, use the distance sleeves
861026.
5.
Screw in the hydraulic cylinders: for single-row engines use the hydraulic
cylinder 861034 with the distance sleeve 861032 screwed in the piston (See
Picture on page 11-52); for V-shape engines, use the hydraulic tightening
device 861027.
6.
Hook up the hoses according to the diagram on page 11-55 and open the
unloading valve.
7.
Screw in the hydraulic cylinders further on until the hydraulic cylinder piston
reaches the bottom.
8.
Loosen the hydraulic cylinder pistons half-turn (180).
9.
Close the unloading valve and charge with the pump to the specified pressure.
10.
Loosen the nuts approximately one turn with the help of pins for hydraulic
tightening device 861025.
11.
Open slowly the unloading valve of the hydraulic pump, disconnect the hoses
and undo the hydraulic cylinders.
12.
Undo the nuts and remove the connecting rod studs with the help of mounting
device M33 for studs 803011. See Picture F and G on page 11-52.
13.
Remove the cover of the crank pin bearing together with the shell from the
engine. See Picture on page 11-52.
127
14.
Raise the piston a little bit to remove the upper shell of the crank pin bearing
(applicable to single-row engines only). For V-shape engines, it is necessary to install
casings 835003 and 835004 back to their positions engaging teeth of the connecting
rod for cylinder liner protection. See Picture on page 11-54. When raising piston,
make sure that the crank pin bearing journal or the walls of the cylinder liner are not
damaged. See Picture I on page 11-52.
15.
Lubrication ports in the crank pin bearing journal must be covered with
adhesive tape.
16.
If it is necessary to remove the connecting rod from the piston, you must
remove the circlip from the groove underneath the piston pin. See Picture on page
11-53 from the side as shown at the pins drawing using circlip pliers 843004.
Note! Never press the circlip tighter than it is required for its removal from the
groove.
Push out the piston pin at the opposite side. When the temperature of the
piston is below +18 +19, the piston pin may become jammed but it may
be easily removed when heating piston to the temperature approximately
30.
17.
Remove the piston rings with the help of piston ring pliers Unistress 843003.
See picture C on page 11-53. The pliers are specially designed to assure that there
is no overstress of the rings. Nevertheless, it is recommended not to remove the
rings if they and their grooves do not require cleaning, measuring, etc. When using
old rings again pay attention to the position at which they must rest. See sub-section
11.6.3.
Every time the piston is removed, you must thoroughly record all applicable
information. Use Maintenance report blank form supplied with every power
plant.
11.5
1.
Piston and connecting rod maintenance

When removing the burnt layers of the carbon deposition, it is necessary to
make sure that the piston surface is not damaged. Never use the sand paper.
It is easier to clean if the coked fixed bed is soaked with the kerosene or diesel
fuel. It is recommended to use an effective thinner, for example, "ARDROX
No. 668" or similar liquids to facilitate cleaning and to protect the pistons from
mechanical damages. When using chemical cleaning agents, avoid applying
such agents at the piston skirt as it may damage the surface
phosphate/graphite layer. Measure the piston ring grooves height. See item
11, sub-section 06.2 of section 06.
128
2.
In case of the excessive dirt or burns, it is necessary to remove the rings from
the pistons for inspection.
Check the ring wear inserting the rings into a new cylinder liner and measuring
air gaps at splits. Also, take measurements of the elevation air gaps when the
rings are installed into their grooves. See item 11, sub-section 06.2 of section
6.
You must be extra careful with inspecting two upper chromed rings. If the
chrome layer is completely worn the ring must be replaced with a new one.
When installing new or re-honed cylinder liners, all rings must be replaced new
ones.
Check the piston pin end cap.
3.
4.
Check the air gaps in the main and crank pin bearings (See section 06, subsection 06.2, item 11) within the time frames specified in section 04 taking
measurements of shaft journal and pin diameters as well the diameters of the reinstalled bearings (connecting rod bolts must be tighten to the specified torque).
When measuring with feeler, use as thin as possible shims. When using thicker
shims, the upper surface of the bearing may be damaged.
Make sure that the teeth of the connecting rod split are not damaged.
5.
6.
The strength margin of the connecting rod bolts assures their normal operation
without periodical replacement provided that:
- the bolts are not damaged;
- the bolts are not corroded;
- the bolts were not overloaded, for example, due to overrunning or
damages to the engine or due to overtorquing bolts.
If it is required to replace the bolts due to the aforementioned reasons it is
necessary to use the genuine spare parts.
11.6
Installation of connecting rod and piston

1.
Make sure that the piston skirt lubrication ports are not clogged.
2.
The piston pins must always be installed from the same side from which they
were removed installing them with their butt end with the number (as per the
drawing) to the original position. See sub-section 11.4.5. When the
temperature of the piston is below +18 +19, the piston pin may become
129
11-7
jammed but it may be easily removed when heating piston to the temperature
approximately 30. Prior to start the installation, lubricate the pins.
Note! Never press the circlip tighter than it is required for its installation into
the groove. If after the installation the ring does not have sufficient spring
power it must be replaced with a new one.
When fixing connecting rod to the piston, it is necessary to make sure that
the cylinder numbers at the piston head and the connecting rod are at the
same side. When replacing pistons, a new piston must be marked with the
same cylinder number as at the old piston. The arrow at the piston head must
point to the control side.
3.
Old piston rings must always be installed into the same grooves and turned at
the same position as previously.
Prior to install new rings, it is always necessary to check the air gap in splits
using new cylinder liner. Also, take measurements of the elevation air gaps.
See section 06, sub-section 06.2, item 11).
When installing the rings use the pliers. The rings splits must be distributed at
the angle of 120 to each other.
4.
Clean thoroughly the piston, cylinder liner, crank pin bearing housing and
crank pin bearing journal, flush the crank pin bearing. When replacing
bearings, both shells must be marked with cylinder number similar to the old
one. Lubricate the piston and crank pin bearing journal. Install the clamp for
pressing piston rings at the piston head and make sure that the rings slide into
their respective grooves without damage. See Picture on page 11-53.
Single-row engine: Rotate the crankshaft to the position at 95O from TDC of
this cylinder to the control side.
V-shape engine, row : Rotate the crankshaft to the position at 95O from TDC
of this cylinder to the row A.
V-shape engine, row B: Rotate the crankshaft to the position at 95O from TDC
of this cylinder to the row B.
For V-shape engines, it is necessary to install the upper shell and casings
835003 and 835004 at their positions. See page 11-54. Bring down the piston
carefully. Turn the piston with its connecting rod in such a way that the side
where the cylinder number is stenciled faces the camshaft side.
130
11-8
Single-row engine: When the connecting rod is lowered down to the crank pin
bearing journal, it is necessary to install the upper shell into the housing
directing the lug to the corresponding slot.
5.
Lubricate the connecting rod stud thread. Reinstate the bearing cover together
with the lower shell. See Picture on page 11-53. Put back the connecting
rod studs and tighten them up with the help of mounting device M33 for studs
803011 to the specified torque. See Picture F and G on page 11-53. Unscrew
the nuts and tighten them by-hand until the lower surface of the crank pin
bearing cover split touches the surface of the connecting rod split starting with
the lower nut.
6.
The distance sleeves for tightening device 861033 must be installed at the
connecting rod studs for single-row engines and the distance sleeves 861026
must be used for V-shape engines.
7.
Make up the hydraulic cylinders: for single-row engines hydraulic cylinder

861034 with distance sleeve 861032 screwed in the hydraulic cylinder piston
(See Picture on page 11-53) must be used; for V-shape engines: the
hydraulic tightening device 861027 must be used.
8.
Hook up the hoses according as shown at Picture on page 11-55 and open
the unloading valve.
9.
Tighten up the hydraulic cylinders until the piston reaches the bottom.
10.
Close the unloading valve and charge the lube oil to the specified pressure.
See Picture on page 11-53.
11.
Tighten up the stud nuts with the help of pins for hydraulic tightening device
861025.
12.
Open slowly the unloading valve, disconnect the hoses and undo the hydraulic
cylinders.
131
132
11-52
REMOVAL OF PISTON
133
134
11-53
INSPECTION AND REFITTING OF PISTON
135
136
137
Measurement
In order to prevent bearing damages due to the ellipticity, it is necessary to take
control measurements of the connecting rods during each normal raise of the pistons
(every 8000 running hours). The measurement is taken when the bearing shells are
removed and the connecting rod bolts are tightened to the normal torque. The
diameter is measured in four directions both at the right and the left side as specified
in the appendix. The rated hole diameter is 190 H6 (+0.029/0).
Criteria for choosing measures

o If the ovality does not exceed 0.08 mm or if the minimum diameter is 189.92
mm or bigger:
- no measures are required
o If the ovality exceeds 0.08 mm but equal to 0.12 or smaller or if the minimum
diameter is less than 189.92 mm:
- new connecting rods must be ordered immediately from Wartsila factory at
Vasa, Finland;
- the engine may be re-assembled; it is allowed to run the engine with old
crank pin bearings until the new connecting rods arrive;
- after replacing connecting rods, the old ones must be sent to Wartsila
factory at Vasa, Finland for overhauling (applicable for connecting rod with
the tooth profile with 90O).
o When the maximum ovality exceeds 0.12 mm or the minimum diameter is
below 189.88 mm:
- new connecting rods must be installed immediately;
- running engine before the replacement of the connecting rods with new
ones is risky;
- after replacing connecting rods, the old ones must be sent to Wartsila
factory at Vasa, Finland for overhauling (applicable for connecting rod with
the tooth profile with 90O).
The traces of the abrasive wear of the split plane teeth do not result in the need to
replace the connecting rods.
138
MEASUREMENT PROTOCOL OF HOLE FOR CRANK PIN BEARINGS
Picture 1
Picture 2
Rated diameter (D) 190H6
+0.029
0
Left
Right
D1
D2
D3
D4
The measurements are taken at 5 mm distance from the edge. The Picture shows
the left side of the connecting rod.
139
12.
12.1
Description

The engine cylinders are equipped with individual heads made of cast iron. Each
head has two inlet and two outlet valves, nozzle installed in the center of the head,
starting valve and indicator valve.
Inlet and outlet valves are similar and have landing surfaces of the enhanced
hardness and chromed connection rods. They have a tight contact to the landing
rings of the seats installed in the cylinder head with precooling. The outlet valve seats
are water cooled.
Use Maintenance report form.
12.2
Removal of cylinder head assembly

1.
Drain the cooling water. Remove the cooling water drain pipe. See Picture
on page 12-53.
2.
Remove cylinder head cap, fuel oil crankcase hatch cover. See Picture on
page 12-53.
3.
Undo the retaining bolts of exhaust pipe using the tool shown at Picture on
page 12-53. Disconnect the lube oil supply piping, lube oil suction and
discharge piping of the nozzle temperature regulating system and control air
tube. Remove the high pressure fuel oil pipe. See Picture D on page 12-53.
4.
Remove rocker actuator pin and cam followers as well as caps of the cylinder
head retaining studs. See Picture on page 12-53.
5.
Reinstate the hydraulic cylinders 861020 and screw them up on the heads
studs. See Picture F on page 12-53. Hook up the hoses according to diagram
on page 07-52. Open the unloading valve and tighten up hydraulic cylinders
further on for pushing out the potential lube oil residuals back into the pump.
Then, undo the hydraulic cylinders half-turn (180). See Picture on page 1253. See also sub-section 07.3, section 07.
6.
Do the preliminary stretch of the studs charging the lube oil to the pressure
value specified in sub-section 07.3 of section 07. Loosen the nuts
approximately one turn. See Picture I on page 12-53.
7.
To bleed of the pressure, open the unloading valve. Disconnect the hoses,
undo the hydraulic cylinders and remove them.
140
8.
Remove nuts of the cylinder head retaining bolts. See Picture on page 1253.
9.
Fix the lifting tool for cylinder head 832005. See Picture L on page 12-53.
10.
Remove the cylinder head. See Picture L on page 12-53. Close the cylinder
holes atop with plywood or something similar. See Picture on page 12-53.
11.
Put protection caps at the stud threads.
12.3
Installation of cylinder head

1.
Check the condition of sealing rings in the connections of the water, charging
air, starting air supply lines and protection pipes of push rods. Check the
cylinder head gasket. Clean and lubricate all sealing surfaces. Reinstate the
sealing ring of the exhaust pipe. Push it slightly if required so that it seats at
the groove (See Picture on page 12-54).
2.
Fix the lifting tool for cylinder head 832005 to the cylinder head.
3.
Pick up the cylinder head and lower it down carefully. When lowering cylinder
head to its place, make sure that the starting air connection pipe, air supply
pipe and push rod protection pipes enter the sealing rings without forcing. See
Picture on page 12-54.
4.
Tighten up the nuts of the cylinder head retaining bolts. See Picture on page
12-54.
5.
Install the hydraulic cylinders 861020 to their places. Make up the hydraulic
cylinders, hook up the hoses and open the unloading valve. Tighten up the
cylinders by-hand to push out the potential lube oil residuals back into the
pump. See Pictures D, , F, G on page 12-54.
6.
Stretch the studs charging lube oil to the pressure value specified in subsection 07.3, section 07. See Picture on page 12-54.
7.
Tighten up the nuts with the bars to the tight contact. While tightening-up,
maintain constantly the steady pressure. See Picture I on page 12-54.
8.
To bleed off the pressure open the unloading valve. See Picture on page 1254.
9.
Remove the hoses and undo the hydraulic cylinders. See Picture I on page
12-54.
141
10.
Put protection caps at the cylinder head retaining studs. See Picture L on
page 12-54.
11.
Install the spreader beams. The spreader beams must be installed at the
same guide as previously. Consider the marks at the spreader beams: =
outlet valves, In = inlet valves. See Picture on page 12-54. Prior to install
the rocker actuator, make sure that all retaining bolts of the rocker actuator pin
are tightened up until they go. If the bolts are not completely made up, undo
them and cover the threads with the grease "Loctite 270". Then, tighten up the
bolts into the cylinder head.
12.
Install the push rods and rocker actuator pin. Tighten the nuts to the torque
specified in subsection 07.1 of section 07. See Picture N, on page 12-54.
13.
Connect the exhaust pipe, lube oil supply piping and nozzle temperature
regulating system lube oil discharge pipe, high pressure fuel oil pipe and
control air pipe. Hook up the water discharge pipe. See Pictures , R, S on
page 12-54.
14.
Adjust the air gaps in the valves. See Picture on page 12-54 and page 1255.
15.
Install the cylinder head cap and the crankcase hatch cover of the fuel oil
gear. See Picture U on page 12-54.
16.
Prior to start up, fill up the fresh water system and rotate the crankshaft two
turns with open indicator valves. See Pictures V, W on page 12-54.
12.4
Valve air gap adjustment

1.
Install the engine crankshaft at TDC of the combustion in the given cylinder.
See section 00, sub-section 00.3.
2.
Undo the lock nuts of the adjusting screws of the rocker actuator and spreader
beams, turn the adjusting screws to create a sufficient air gap. See Pictures , , D
page 12-55.
3.
Press the non-regulated spreader beams end against the valve stem and
tighten up the adjusting screw until the contact with the valve. See Picture F on page
12-55. Continue tightening until the non-regulated spreader beams end starts
moving away from the valve stem. See Picture G on page 12-55. Turn the adjusting
screw back to the position between F and G (See page 12-55) and lock the lock nut
holding the adjusting screw. See Picture on page 12-55.
142
4.
Insert the feeler gauge shim with the thickness equal to the air gap in the valve
into the air gap between the spreader beam and hinged connection of the regulating
rocker actuator. Tighten the adjusting screw to the position allowing the back-andforth motion of the feeler gauge shim with a slight force. Holding the adjusting screw
tighten the lock nut. See Pictures I, on page 12-55. Make sure that the air gap did
not change during tightening-up lock nut. The feeler gauge shim must be of the
sufficient thickness so that the hinged connection is not skewed.
12.5
Inlet and outlet valve maintenance

12.5.1
Valve disassembly
a.
Install the dismantling device for valves 846010 according to picture D on

page 12-52.
b.
Press the springs screwing device clockwise.
c.
Knock at the valve disks center of each valve one by one thus the conical split
keys are loosened and may be removed.
d.
Unload the device and the spring cups and springs themselves may be
removed.
e.
Check the free motion of the valves in their guides. Make note in which guide
the valve was at first.
12.5.2
Inspection and repair of valves and seats
1.
Clean the valves, seats, channels and guides and the lower side of the cover.
2.
Check the sealing surfaces of the valves and seat grooves. In order to do this,
it is recommended to put a thin layer of fine lapping compound on the seat
grooves and while pressing slightly valve to the seat, turn it by-hand several
times. If the sealing surfaces are shiny or if there is a continuous sealing
surface, it is not recommended to carry out polishing. If there is some pitting, it
is recommended to carry out lapping. If the pitting covers the whole sealing
surface or if there is insufficient density at the contact area it is recommended
to polish the valve and the seat.
3.
Prior to polish, check the air gap between valve stem and its guide. If the air
gap exceeds the allowed value, measure the stem and the guide, and replace
the worn part; the valve guide may be pushed out. Check guide hole in the
cylinder head. In order to push the guide in, it is recommended to cool it with
143
the liquefied nitrogen, when pushing in it is allowed to apply the lube oil as
well. After pressing-in, check the diameter of the guide and if required, adjust it
to its normal value.
Lapping. If there are some pitting at the sealing surfaces, it may be removed
with manual lapping:
4.
Connect the device to the valve as shown at Picture on page 12-52.
Put a thin layer of the lapping compound at the sealing surface of the
valve. For coarse lapping, use paste #1 and for fine lapping use the paste
#3.
Make the back-and-forth motion of the valve in the seat with the help of the
crank brace. When lapping, the valve must be elevated above the seat
several times.
Remove steel as low as possible from the valve and seat surfaces as the
sealing surfaces hardened during operation and are valuable. Polishing all
pitting is not compulsory.
After lapping, clean thoroughly the valve and the seat.
Mechanical polishing. If there are deep cavities or other defects, it is

recommended to polish the valve and the seat with mechanical method.
5.
a.
Valve landing surface

In order to assure the continuous contact of the valve with the seat at the
whole circumference, the valve disks angle is 30 with 0.5allowance.
The minimum allowed value from the upper edge of the conical landing
collar to the valve disk surface is 5.2 mm when the value of this valve is
lower, such valve must be replaced.
After polishing, it is recommended to carry out a smooth lapping to create
the contact between the valve and the seat along the whole circumference.
b.
Landing ring of the inlet valve seat

The landing surface angle of the inlet valve is 30 with +0.25 allowance.
Polishing seat is allowed to achieve the outer diameter not exceeding 74
mm, then, the landing ring must be replaced with a new one.
the contact between the valve and the seat.
c.
Landing ring of the outlet valve seat

The landing surface angle of the outlet valve is 30 with +0.2 allowance.
144
Polishing seat is allowed to achieve the outer diameter not exceeding 73

mm.
the contact between the valve and the seat.
6.
Replacement of the seat landing ring

Removal of the seat landing ring (See Picture on page 12-52)
a.
Prepare a steel flat bars having dimensions approximately 10 30 mm
according to the seat inner diameter and weld it to the seat with electric
welding.
The old valve may be used as well. In such case, it must be welded to the
seat all around.
b.
Push out or knock out the landing ring with the help of swage inserted
through the valve guide.
Installation of a new landing ring of the inlet valve seat. (See Picture on
page 12-52)
c. Check the hole diameter in

sub-section 06.2, item 12.
d.
the
cylinder
head.
See
section
06,
The landing ring is pressed in with the preliminary cooling using the
liquefied nitrogen -190 at the cylinder heads temperature not less than
+20 or pressed in along the guiding swage.
Always make sure that the landing ring rests at the bottom of the hole.
e. Check the eccentricity of the sealing surface related to the valve guide. If it
exceeds 0.1 mm the seat surface must be polished with the help of a
special tool. See Picture on page 12-52.
Installation of a new landing ring of the output valve seat.
f. To push in the landing ring of the output valve seat back to its place, it is
necessary to use the accessory 834002.
g. Check the hole diameters in the cylinder head. The landing ring must be
cooled in a freezer with the temperature regulated by the thermostatic
regulator
within
the
range
-15
to
-30
.
NOTE!
The sealing rings may be damaged at the lower temperature.
h. Install a new sealing ring at the landing ring of the seat and cover the hole in
the cylinder head with the locking compound "Loctite 272" and the
corresponding surface of the seat landing ring.
145
i. Insert the seat landing ring into the bushing retaining the sealing rings and
push it into the hole with the help of the guiding swage.
j. Check the eccentricity of the sealing surface related to the valve guide. If it
exceeds 0.1 mm the seat surface must be polished with the help of special
tool. See Picture on page 12-52.
k. For hardening locking compound, it is recommended to maintain the
temperature of the cylinder head not less than +20 for six hours.
12.5.3
1.
Installation of the engine valves

Make sure that there are no cracks and traces of wear at the springs. If there
are any such defects, it is necessary to replace the springs with new ones.
2.
Install new sealing rings into the valve guides.
3.
Lubricate valve stems with the engine oil.
4.
Insert the valves and check their mobility.

5. Install the springs and spring cups at the valves and compress the springs
with the tool. Install the conical valve split keys and unload the springs. Make
sure that the conical valve split keys are at their places.
12.6
1.
Cylinder head maintenance general information

Starting valves are described in section 21.
When installing starting valves, the outer cylindrical surfaces must be
lubricated with the lube oil or special lubricating compound.
2.
Nozzles are described in section 16.

When installing nozzles, they must be lubricated only with engine oil.
146
12-51
147
12-52
VALVE SEAT MAINTENANCE
148
12-53
REMOVAL OF CYLINDER HEAD
149
12-54
REFITTING OF CYLINDER HEAD
150
12-55
ADJUSTMENT OF VALVE CLEARANCE
151
13-1
13.
CAM SHAFT DRIVE (See Picture on page 13-51)
13.1
Description
The camshaft is driven by the crankshaft (1) with tooth gear. The drive pinion gear of
the crankshaft has a split design and retained with the crankshaft flange with the help
of bolts (4). These bolts and the pinion gear retaining bolts are locked with the
locking compound "Loctite 242". The idler pinion gears (5) and (6) installed onto the
axis.
The drive pinion gear of the camshaft (18) is connected to the camshaft spacer with
the help of pins (22) and fixed with a flanged connection between spacer (20) and the
camshafts end section (25). The worm gear (23) of the RPM regulator drive and the
limit switch are connected to the camshafts end section (for V-shape engine in the
row A). The lube oil nozzles supply the lube oil for lubricating and cooling drive.
13.2
Removal of camshaft drive
Prior to remove the camshaft, check air gaps in the bearings and in the pinion gears.
Also check them as according to the schedule specified in section 04 as well.
1.
Remove the camshaft crankcase and camshaft drive hatch covers.
2.
Undo the bolts of the flange connection (19).
3.
Undo the retaining bolts (28) of the limit switch and bolts of the bearing
housing in the row .
4.
The limit switch or the bearing housing as well as the end section (25) of the
camshaft may be removed in the axial direction now.
5.
Undo the bolts (21) of the camshaft drive pinion gear. Remove the pinion gear
(18).
6.
Undo the bolts (13), (10) and (15) (2 pcs) in the aforementioned order.
Remove the flange (14).
7.
Rotate the shaft until the hole (diameter 60 mm) at the inner side of the
flywheel matches the axis of the idler pinion gear.
8.
Undo the bolt (13) to approximately 10 mm and push out the axis. Remove the
bolt and pull out the axis.
9.
The idler pinion gear may now be removed, for example, with the help of a
chain block.
10.
Rotate the flywheel at such position that the removal of the axis (11) of the
idler pinion gear from the flywheel hole becomes impossible.
152
11.
Idler pinion gears must not be dismantled if it is not extremely required as their
corresponding positions are adjusted to having correct positions of the cams in
each row.
13.3
1.
Camshaft drive assembly

Rotate the crankshaft in the following order:
a. Single-row engine: Put the crankshaft at TDC of the cylinder #1.

b. V-shape engine: With camshaft drive pinion gears removed of the both
cylinder rows, put the crankshaft at of the cylinder #A1.
c. V-shape engine: With the camshaft drive of the row A installed and with
camshaft drive of the row B removed, put the crankshaft at TDC of the
combustion in the cylinder (See section 00, sub-section 00.3). Then, rotate
the shaft 55 to the direction of TDC of the cylinder #B1.
d. V-shape engine: With the camshaft drive of the row B installed and the
camshaft drive of the row A removed, put the crankshaft at TDC of the
combustion in the cylinder #B1 (See section 00, sub-section 00.3). Then
rotate the shaft to the direction of TDC of the cylinder #A1.
Simultaneously with rotating, insert the axis into the flywheel hole the closest to
the mark "Cyl.1 TDC".
2.
Install the distance sleeve (12) into its slot and release the idler pinion gear
assembly, for example, with the help of a chain block. Make sure with a mirror that a
marked tooth of a marked idler pinion gear engages as required with a marked cavity
of the split pinion gear (2) teeth. See Picture on page 13-51.
3.
When the idler pinion gear is engaged with the camshaft pinion gear, rotate
the crankshaft carefully until the axis (11) matches the hole and it is impossible to
insert the crankshaft into the idler pinion gear and the bushing (12). Rotate the
crankshaft to the original position i.e. to TDC of the combustion in the cylinder #1 as
described in item 1.
4.
Cover the bolt (13) with the locking compound "Loctite 242" and tighten it up
by-hand.
5.
Install the flange (14) together with a new sealing ring and tighten up the bolts
(15). Tighten the bolt (10) at first and then the bolt (13).
153
6.
7.
8.
9.
Measure the axial deflection in the bearing of the idler pinion gear and the
lateral air gap between teeth of the pinion gear (2) and pinion gear (5). See section
06, sub-section 06.2, item 13.
Use the wire to wire lock the bolts (10) and (15).
The camshaft drive pinion gear is engaged and installed in such a way that the
mark corresponds to the engine block edge. See Picture D on page 13-51. The
pinion gear has marks for the row A and row B. With the help of the guide pin (22),
the collocation of the camshaft and the pinion gear is retained. Tighten up the bolts
(21) to the torque value as specified in the sub-section 07.1 of section 07. These
bolts are treated with the locking compound and may be used twice before loosing
their locking efficiency if they are slightly wiped with rags.
Install the limit switch and the end section (25).
10.
Measure the air gap between the teeth of the pinion gear (6) and the pinion
gear (18). See section 06, sub-section 06.2, item 13.
11.
Install the adjacent parts. For cylinder heads without sealing, use non-drying
sealing compound.
12.
In V-shape engine, check the sequence of combustions in both rows of the

cylinders (See section 01, sub-section 01.1).
13.
Check the valve timing at least in one cylinder (See section 06.). If any
component of the gear system was replaced, it is necessary to check the sequence
of combustions in both rows of cylinders as described in sub-section 16.4 of section
16.
154
155
14.
VALVE MECHANISM AND CAMSHAFT (Picture on page 14-51)
14.1
Description of valve mechanism
The valve gear consists of valve followers of the piston type moving in the common
cast iron block, tubular follower rods with ball-and-socket hinges, press formed rocker
actuators installed onto a bracket and a spreader beam with a guide.
The valve gear, usually, does not require any maintenance but it must be inspected
and checked for wear according to the schedule specified in section 04. The scope is
given in section 06. See the adjustment of the air gaps in the valves in section 12,
sub-section 12.4.
You must remember that the parts that were running in for a long time and
consequently having a certain wear must be installed to their original positions
relative to each other in order to avoid extra running-in parts after re-assembly.
14.2
Actuator arm disassembly and assembly
1.
Remove the post from the cylinder head undoing nuts (4).
2.
Rocker actuators may be removed after the removal of the circlip (1) with the
help of circlip pliers 843001.
3.
When cleaning rocker actuator bracket and journals, pay attention to the
lubrication ports.
4.
Inspect the parts and check them for wear (See section 06, sub-section 06.2,
item 14).
5.
Lubricate the parts with the lube oil prior to assemble.
6.
Measure the axial deflection of the rocker actuators after the assembly; the
minimum play must be 0.15 mm.
14.3
Cam follower disassembly and assembly
1.
Remove the guide block (10) from the engine. To do this, it is necessary to
remove the rocker actuator bracket and follower rods with protection pipes.
2. Remove the lock bars (15).
3. Now, the followers may be removed. Mark the parts in such a way that they
could be installed back to their original positions relative to each other.
156
4. Follower rollers, bushings and pins are disconnected when the pin (14) is
pushed out.
5. Remove the bushings (17) for cleaning and measurements of the hole in
the guide block. Replace the rubber seal O-rings of the bushing if they are
damaged of hardened.
6. When cleaning parts, be especially careful with the lateral ports in the
followers and roller pins.
7. Inspect and measure the parts for wear and damage. See Section 06, subsection 06.2, item 14.
8. When re-assembling, it is recommended to lubricate the parts and the
components with the compound "lycote Paste G".
9. When installing the retaining plate (15), use the undamaged corners of the
plate for retaining bolts (16). It is necessary to make sure that the steel junk
does not stay in the mechanism or get apart when running engine.
10. Prior to install the guide block, inspect the gasket and replace it with a new
one if required.
14.4
Description of camshaft
The camshaft consists of sections (one section per cylinder) and separate spacers.
The sections are hot formed together with the cams which sliding surfaces are
reinforced with tempering. The working surfaces of the spacers are glued . The
camshaft is driven by the crankshaft with the help of the tooth gear being at the drive
end. From this end to that camshaft, the limit switch and helical pinion gear of the
RPM regulator drive are installed. From the side opposite to the drive end, the
camshaft has an end section with the air distribution cam.
The camshaft of the row B in V-shape engine has thrust journal bearing only installed
at the drive end.
14.5
Camshaft section removal

1.
Remove the camshaft crankcase hatch cover, high pressure fuel oil pump,
follower guide blocks of a given cylinder.
157
2.
Undo the flange connection bolts (See Picture on page 14-53) from both
ends of the section to be removed with a combination tool according to Picture
on page 05-15.
3.
Remove air distributor cover and shift the camshaft section located at the side
opposite to the drive end with the help of a bars about 15 - 20 mm to the side
opposite the drive end.
4.
Set free the camshaft section from the centralizing shoulders and guide pins
(See Pictures , on page 14-53) and remove the section in the transversal
direction.
14.6
Camshaft section installation

1.
Remove the dirt and degrease the contact surfaces between the spacer and
sections flange and threaded holes.
2.
Insert the guide pins together with retaining rings with long end into the
corresponding holes of the spacer.
3.
Install both ends of the camshaft section at the guide pins and centralizing
shoulders, and then press them against each other.
4.
Insert dry bolts of the flange connection and tighten them with the
combination tool according to picture on page 05-15. The flange connection
bolts were previously treated with the locking compound and may be used
three times when clean thoroughlyed.
5.
Inspect carefully the followers and the rollers. The follower rollers having even
minor defects must be replaced.
6.
Install the air distributor cover, high pressure fuel oil pump, follower guide
blocks, etc.
7.
From the side opposite to the drive end of a given cylinder, check the air gaps
in the valves and at the fuel injection moments of the high pressure fuel pump
of all cylinders.
158
14-51
159
14-52
160
14-52
REMOVAL OF CAMSHAFT SECTION
161
15.
Exhaust gas turbocharger

VTR 201 2 W3P
With self-lubricated roller bearings
With centrifugal oil pumps
Maintenance and operation manual
JV Brown Boveri and Co, CH-5401, Baden, Switzerland

TLV 1102
HTLV 93900
162
VTR 201 2 W3P

This maintenance and operation manual consists of the following sheets:
HTLV 93900
HTLV 91036
HTLV 91005
HTLV 91007
HTLV 93901
HTLV 91002
HTLV 93904
HTLV 91008
HTLV 93902
HTLV 91003
HTLV 93905
HTLV 93907
HTLV 93903
HTLV 91009
HTLV 91014
HTLV 93908
HTLV 91000
HTLV 91043
HTLV 91011
HTLV 93909
HTLV 91001
HTLV 91010
HTLV 93906
HTLV 93910
Appendix
Drawing
Description
HTLT 308057
Section view
HTLT 408701
2.1 / 2.2
Bearing assemblies
TL 404134
2a
Bearing housing cover
TL 404141
2b
HTLV 99545
Available bearing hosing covers
HTLT 412670
Silencer K27
HTLT 411640
3.1
Filter cleaning K27
HTLT 411396
3.2
Filter element replacement K27
Gas inlet
HTLT 407312
A15 (1 central inlet, radial)

Or
HTLT 407313
A20 (2 radial inlets) or
HTLT 407314
A21 (2 axial inlets) or
HTLT 407315
A22 / A41 (2 or 4 V-shape inlets) or
HTLT 407316
A30 / A40 (3 or 4 radial inlets) or
HTLT 407317
A42 (4 rectangular radial inlets)
HTLT 407318
Gas outlet casing
HTLT 408522
Filter cleaning K11
HTLT 408523
Filer packing replacement K11
163
HTLV 93902i
HTLT 308056
8.1 / 8.2 / 8.3
Removal and replacement of bearings and

rotor assemblies
HTLT 407561
14
Air gaps
TL 401634
15
Turbocharger preservation
HTLT 407559
16
Rotor interlocking from turbocharger side
HTLT 407558
16.1
Rotor interlocking from turbine end
TL 402950
20
Closing units
TL 403986
21
Turbocharger cleaning
TLV 6001
List of representative offices and service

centers
164
HTLV 93902i
TABLE OF CONTENTS
0.1
Technical data
0.2
Requisitions for spare parts and technical information
0.3
Control programme
0.4
General notes
0.5
Turbocharger design description
0.7 New turbocharger store-keeping

1.
OPERATION
1.0
Lube oil
1.1
First start
1.1.0
Prior to first start
1.1.1
During first start
1.1.2
After first 100 running hours
1.3
Control and maintenance programme
1.5
Post shelf life operation
2.
MAINTENANCE
2.0
Cleaning job
2.0.0
Air filter
2.0.2
Cooling water chambers
2.0.3
Lube oil chambers
2.0.4
Turbine end
2.0.5
Compressor end
2.0.6
Compressor cleaning during operation
2.1
Compressor assembly and disassembly
2.1.0
Bearing assembly removal and installation
2.1.1
Rotor removal and installation
2.1.2
Rotor mounting and dismounting
2.1.3
Jet ring removal and insertion
2.2
Spare parts replacement
2.2.0
Jet ring
2.2.1
Seal bushings
165
HTLV 93903c
2.2.3
Turbine blades
2.2.4
Guide plates
2.2.5
Roller bearings
2.6
Air gaps
2.7
Bearings
2.8
2.9
Main spare parts
2.9.0
List of main spare parts
3.
TROUBLESHOOTING
3.0
Malfunctions and their causes
3.1
Turbocharger shutting-down
3.1.0
Troubleshooting with site available spare parts
3.1.1
Rotor removal and closing unit installation
3.1.2
Interlocking unit installation
3.1.2.0
Compressor end interlocking
3.1.2.1
Additional rotor interlocking at turbine end
4.
PART NUMBERS
4.0
Hand tools
4.2
Turbocharger
4.4
Closing unit
5.
APPENDIXES
Drawings
1.
Turbocharger with filter silencer or air inlet tube
2.1
Bearing assembly at compressor end
2.2
Bearing assembly at turbine end
2a
Bearing chamber cover
2b
Bearing chamber cover
3.
Silencer K27
3.1
Filter cleaning K27
3.2
Filter element replacement K27
4.
Positions of exhaust gas housing guide plates and cooling water inlets
HTLV 93903c
166
5.
Positions of exhaust gas housing guide plates and cooling water inlets
6.
Filter cleaning
7.
Filter element replacement
8.1
Bearing assembly removal and insertion at turbine end
8.2
Bearing assembly removal and insertion at compressor end
8.3
Rotor removal and installation
14.
Air gaps
15.
16.
Rotor interlocking at compressor end
16.1
Rotor interlocking at turbine end
20.
Closing unit
21.
Compressor cleaning
TLV 6001 List of representative offices and service centers
HTLV 93903c
167
0.1
Technical data
Diesel engine
Manufacturer
Model and design type
Rated power, kW (hp)
Rated RPM
Installation elevation above MSL, m .

Suction air temperature K, (degr. C) .
Unless otherwise specified the environment conditions are assumed to be:
Air pressure
1 0.02 bars = 100 2 kN/sq.m
Suction air temperature
300 6 K = 27 6 degr. C
Name plate with rated specification:
BBC
Exhaust gas turbocharger
BROWN BOVERI
Type VTR
Speed max.
________ RPM
No. HT
T max.
________ O C
Specification
Estimated bearings service life hours
HTLV 91000c
168
0.2
Requisitions for spare parts and technical information
Any requisition for spare parts and as well as for technical information must include
the following:
Type
Serial number
Specification
As per the manufacturers name plate at the turbocharger
Identification number and part description
As per the drawing and part list Item 4
Also, please, specify picture and drawing numbers given at the lower part of each
sheet.
Our representative offices and service centers (see the last appendix) accept
requisitions for the provision of spare parts. Also, they provide the information to
clarify special technical queries not covered in this manual and having a general
character.
Example of requisition for spare parts or technical information
Turbocharger VTR
Manufacturers serial number

Specification
10 each filter elements, part number 80319, drawing , picture 7 (for filter
silencer K10, K11) or picture 3.2 (for filter element K22 K29).
1 each cover of gas inlet body cast rod for cooling water access, as per picture 4,
part E, drawing (nipples position in the gas inlet body is to be indicated)
or
1 set of gas outlet body, part 60, as per picture 5, drawing (position of the gas
outlet body is to be indicated)
(Positions of bodies and bases are specified from turbine end).
HTLV 91000c
FACTORY
_____________________
COUNTRY
_____________________
or
VESSEL
_____________________
169
FLAG
_____________________
Manufacturer
Model and design type
Rated power, kW (hp)
Rated speed, RPM
Installation elevation above MSL, m .

Suction air temperature K, (degr. C) .
Unless otherwise specified the environment conditions are assumed to be:
Air pressure
1 0.02 bars = 100 2 kN/sq.m
300 6 K = 27 6 degr. C
Please, fill in here and send it to BBC Company in Baden, Switzerland

HTLV 91041a
170
Please, fill in your requisition properly and send it to us in order to avoid a situation
as shown above.
See the form at the previous page.
HTLV 91041a
171
0.3
Control programme
Prior to first start see Item 1.1.0

During first start see Item 1.1.1
Daily routine see Item 1.3
Every 25 75 running hours see Item 2.0.6
After first 100 running hours see Item 1.1.2
Every 1000 running hours see Item 1.0
Roller bearings service lives see Item 0.1
Periodical inspection depending on type of installation see Item 2.0 and Item 2.8
0.4
General notes
The text contained and the part number lists in the given manual are intended for
different turbocharger fabricating options. That is why the part number lists contain
the parts not related to the provided equipment. Misunderstandings are excluded as
the attached drawings have the reference numbers directly corresponding to the
option provided as according to the requested turbocharger.
The yellow sheet and the envelop with the address (BBC Baden, Sweiz, Abt. TLVA)
are the integrated part of each instruction.
Any information provided by the user is useful for the turbocharger manufacturer
(BBC Baden) for the further development of the turbocharger service system.
0.5
Turbocharger design description (drawings 1, 2.1 and

2.2)
The turbocharger consists of the following major components: turbine and

compressor integrated in a single unit.
HTLV 91001c
172
The exhaust gases of a diesel engine are directed into the water cooling gas inlet
body 50, discharged in the jet ring 30 and after having passed through the turbine
blades 21 exit through the discharge tube of the water cooling chamber 60.
The air coming through the suction tube 82 or filter silencer 80 is directed to the
working wheel 25 and diffuser 28 and then goes into the air manifold of the diesel
engine set through the intermediate pipe of the compressor body 72 or through the
air outlet body 74.
The spacer 70 with the heat chamber separates the air end from the gas end.
The buffer air is supplied through the X channel from the compressor to the labyrinth
sealing of the turbine rotor thus preventing access of exhaust gases into the channel
Z and the bearing housing.
The rotor rotates on flexibly two-end installed easy accessible roller bearings.
Each bearing is equipped with lubrication and lube oil cooling assemblies.
Bearing housing covers are usually equipped with loading and drain holes and sight
glass.
Channels Y and Z serve to balance the pressure of bearing housings and to prevent
lube oil losses.
Cooling water chambers (drawings 4 and 5) installed at gas inlet and gas outlet
bodies are equipped with guide plates protecting body walls against water erosion.
Air cooler is used in case if the turbochargers pressure is too high and if the suction
air temperature is high.
HTLV 91001c
173
0.7
New turbocharger store-keeping
New turbochargers supplied by BBC company directly from the factory may be stored
for 12months in a dry warehouse with the normal air humidity without any anticorrosion measures provided that the warehouse is not subject to vibrations.
See item 1.1 New turbocharger first start procedure.
In case if the warehouse is affected by significant vibrations (the acceleration
exceeds 10m/sec2) it is necessary either to replace the roller bearings prior to
operate the turbocharger or store the turbochargers according to provisions of Item
2.8 with regards to preservation rules.
See Item 1.5 Post shelf life operation.
HTLV 91036a
174
1.
Operation
1.0
Lube oil
Self-lubricating ball bearings

(There are two letters stamped at the name plate of the turbocharger compressor at
the third position: W.E., W.P. or W.Z.)*
In order to increase the service life of the equipment, the turbine lube oils are used.
Viscosity at 323 K (50O C) (122O F)
Centistokes
Engler
Redwood #1
Seybold Universal
30 55 cSt (mm2/sec)
4.0 7.3 E
125 255 sec. R1
140 253 S.S.U.
That corresponds to the following viscosity classes at 313 K (40O C) (104O F)

ISO VG 68 and VG 55, 77, 78, 82
*) See name plate at the turbocharger or technical characteristics sheet in the
beginning of this manual (Item 0.1).
Quality of lube oil
To fill up both bearing housings it is required to provide approximately the following
volume of the lube oil:
VTR
160
200
250
320
400
500
630
750
201
251
321
401
501
631
751-1
0.9
1.7
3.3
4.4
7.8
12.7
33
dm3
0.75
VTR
161-3
251-3
321-3
dm3
3.0
4.5
4.7
Lube oil replacement schedule

The lube oil is to be replaced not less than once in every 1000 running hours.
Increased neutralization coefficient may be achieved maximum 2 mg KOH/gr. and
correspondingly the viscosity may go up to 20%. If due to some reasons diesel
HTLV 91002d
175
engines lube oil is being used it results in shortening lube oil replacing intervals
corresponding to the quality of the lube oil.
The lube oil replacing intervals must be scheduled with consideration not to exceed
the afore-mentioned limiting values.
1.1
First start
When starting new or overhauled turbocharger the following conditions have to be

taken into account:
1.1.0 Prior first start

Both lube oil housings are to be topped up through the special ports with clean lube
oil to the upper marking line of the sight glass (drawing 1 or 2a/2b/2c, etc. for
corresponding bearing housing cover). The quality and the volume as specified in
Item 1.0.
Switch on the circulation of the lube oil.
Check with opening drains 0 (drawing 5) the potential rain water or other condensate
liquids accumulation in the gas discharge body. In case of the presence or risk of
such accumulation, it is necessary to equip the machine with liquid discharge
arrangement complete with an isolation valve or a siphon.
Switch on the starter of the diesel engine for a short-time and inspect with the help of
a steel rod a smooth and trouble-free operation of the compressor.
If the turbocharger has lube oil consumption control feature, see Item 1.4.
1.1.1 During first start

After having started the diesel engine, check topping-up bearings with the lube oil
through the sight glass of the bearing housings.
Carry out the leak-off test of all gas and air pipelines and cooling water line.
HTLV 91002d
176
Record the speed of the turbocharger, charging pressure, temperature before and
after turbine, before and after compressor at the different diesel engine loads.
Compare the recorded values with the data achieved at the test stump taking into
consideration different operational conditions.
The cooling water temperature increase at the gas suction and gas discharge bodies
provides the rough idea about the flow volume. Inserting perforated plates into the
water discharge tube may help to maintain the temperature difference within the
range of 8 12O C at the full engine load.
The cooling water temperature at the body outlets must not exceed 80
C; it is
recommended to maintain this temperature at about 75 O C.

The purging air pressure gage must not be subject to any mechanical vibrations. The
influence of the vibrations to the purging air pressure may be compensated with a
dampener connected to the pressure gauge. With the help of dampeners with felt
washers provided by our company upon a special requisition the dampening effect is
increased.
1.1.2 After first 100 running hours

It is necessary to replace the lube oil.
1.3
Control and maintenance programme
Apart from the routine control of the lube oil level or bearing greasing measures, the
turbochargers do not require much of control.
But, it is recommended to have an overall control of the whole power plant in order to
receive the results of the turbocharger operation (Item 3.0). It is recommended to
carry out the periodic measurements and recording in the log-book thus giving the
possibility to disclose causes of potential malfunctions.
The following information has to be recorded in the log-book:
Diesel engine power
HTLV 91003c
177
RPM of diesel engine

Pressure loss at filter
If the data is available:
Discharge air temperature at compressor and air cooler outlets
Cooling water temperature at the air cooler suction
Cooling water temperature at the turbine body suction
Cooling water temperature at the turbine body discharge
Exhaust gas temperature before the turbine
Volume, brand-name and quality of the added lube oil
After periodical inspection:
Condition of the drained lube oil
Condition of the air filter
Type of contamination
Condition of cooling water chambers
Were bearings changed?
For VTR 400-751-1: Were gear oil pumps replaced?
Inventory records:
Spare parts used
Additional requisitions for the provision of spare parts and tools (Item 0.2)
If available: air filter, compressor and air cooler are to be periodically cleaned
according to the power plant requirements and operational conditions. It is
recommended to replace filter segments with clean spare ones from time to time one
by one (Items 2.0.0, 2.0.5 and 2.0.6).
Bearing assemblies
Bearing assemblies must be replaced after a certain service life period as specified
at the specification sheet in the beginning of this manual (Items 0.1 and 2.1.0)
HTLV 91003c
178
Cooling water chambers

Cooling water chambers of the turbine body must be periodically inspected and
cleaned as required (Item 2.0.2).
Open drain holes at the gas discharge body (drawing 5) and dump the water
accumulated in the body.
For VTR 400-751-1 to check gear oil pumps after 16,000 running hours for wear
and sealing (Item 2.2.6). Such inspection may be carried out at the manufacturers
service center as well.
HTLV 91003c
179
1.5
Post shelf life operation of turbocharger (Drawing 15)
Clean the outer surface of the turbocharger.

Remove wooden crate.
Remove support flanges of bearing housings.
Clean neatly lube oil chambers (Item 2.0.3)
Assemble as according to Item 2.1.0
Actions as during the first start (Item 1.1)
Bearing assembly at the turbine end
To assemble the dampening radial packing 384, the following conditions are to be
followed:
-
The dampening radial packing is to be clean and in good condition;
All keys are to be positioned from one side diametrically opposite to the main
port of the lube oil manifold or the flange and tighten at the key slots. (For VTR
750 and VTR 751 these slots are at a certain angle).
Install different parts of the dampening packing starting with the ones being at
the outer side, followed with the parts being at the inner side up to 0.5mm thick.
The longest part is to be outside and the shortest one is to be inside;
Edges of each side are to protrude by at least 3mm. They have never overlap
each other.
The orientation sequence of the part edges of the similar thickness is as follows:
VTR 160 VTR 501:
opposed as 2 to 2
VTR 630 VTR 631:
opposed as 3 to 3
VTR 750 VTR 751-1: opposed as 3 to 3

For others:
opposed as 2 to 2
They have to be turned with 180O angle to each other. (For VTR 750 VTR 7511, the part 0.5mm thick is to be turned outside and inside).
-
If all parts of the packing are correctly positioned the edge protrusion of each
group must be approximately equal.
If any part of the dampening packing is damaged it is necessary to replace the

whole packing with a new one.
Bearing assembly at the turbine end

See Item 2.7
HTLV 91009a
180
2.
Maintenance
2.0
Cleaning
2.0.0 Air filter (drawings 3.1, 3.2 and 6.7)

The choice of an agent for cleaning the copper mesh is made based on the type of
the contamination. For example,
-
soda solution with maximum concentration of 1%;
kerosene;
mixture of 6.5% of trichlor-ethylene, 9.5% Tipol by Shell, 4% cyclohexanol and

80% of fresh water (poisonous mixture).
The filter packing may be removed during cleaning (drawings 3.2 and 7).
Cleaning with burning is prohibited.
The filter packing soaked with oil enhances the filtering function.
When replacing filter packing of all air filter segments the numbers of segments and
weight requirements for the copper mesh 80319 are to be followed as specified in the
table below.
2.0.2 Cooling water chambers

When de-scaling, please, use 5% hydrochloric acid. The industrial acid available at
the market 20/21O Be with 1.16 s.g. with 36 volumetric percentage concentration
must be diluted with six (6) volumetric parts of water. In order to reduce the cast iron
corrosion it is necessary to add immunizers (for example, 0.2% industrial alcohol or
0.1 0.2 volumetric percentage of Polyrad 110A (by Hercules Powder company
based in Wilmington, USA) or 0.5 volumetric percentage of bone glue. (The
immunizers are given in the order of efficiency decrease).
De-scaling must be carried out at the open space if possible due to the risk of
explosion. Due to the same reason, the use of open fire is not allowed in the closed
spaces.
The upper water discharge outlet must be kept open in order to facilitate the gas
evaporation. Depending on the thickness and type of the scale the duration of the
HTLV 91043b
181
acid solution exposure may vary from 2 to 6 hours. Light impacts to the housing
enhance the detachment of scale layers. Straight after having removed the acid
solution, it is necessary to flush thoroughly the chambers with the fresh water. Finally,
flush with water saturated with 5% of soda.
If possible, use soft cooling water.
Copper mesh weight for filling all segments of the air filter
VTR
K10, K11
Filter & segment q-ty
Copper mesh kg/filter
K20, K21
K22, K23
K27
K24, K25
K29
160
200
250
320
400 500 630 750 900
161-3 201-2 201-3 251-2 251-3 321-2 321-3 401-2 501-2 631-1 750-1
751-1
2
1.2
2
1.8
2
2.8
4
3.6
4
2.5
2
1
4
8.2
4
13.4
4
20
4
5
4
8
6
12
4
5
4
8
6
12
6
33
6
14.6
2
0.8
2
0.8
4
2.5
2
1.0
HTLV 91043b
182
8
30
2.0.3 Lube oil chambers

The cleaning is performed with the kerosene with 20% of pure mineral oil. Using of
gasoline due to the corrosion prevention reason is not allowed. In case of the bearing
replacement as well as when a bearing is hardly contaminated, it is necessary after
having removed nipple 3312 to clean the spacer housing of lubrication plate 3311
centrifuge. After cleaning, make sure that the ports of the lubrication plate 3311
providing bearings with the lube oil are not blocked.
2.0.4 Turbine end (drawing 1)

Air suction channel X, equalizing channel Z and entrainment separator 572 are to be
kept clean. Aluminum sealing bushing 505 or 506 are to sit tight in the housing and
bushing slots must be absolutely clean and in good condition.
2.0.5 Compressor end (drawing 1)

Equalizing channel Y with splashproof device 730 must be kept clean. Sealing
bushing 725 must sit tight in the housing. Slots and holes must be in good condition
and contamination-free.
HTLV 91010f
183
2.0.6 Compressor cleaning during operation (drawing 21)

General
Periodical cleaning of the operated compressor must be usually carried out after
each 25 75 running hours.
Using water injection method, the compressor cleaning may be performed without
intermissions of the compressor operation. This method is applicable in case when
the contamination is at the highest degree. At the highest degree of the
contamination when the sediments have already accumulated, the cleaning may be
carried out only under condition of the complete disassembly of the compressor.
In such case, the water does not act as a thinner and sediments are removed with a
mechanical impact of water drops. This is why it is recommended to use pure water
without any thinning additives. This water must not contain any saturation agents
either as such agents may accumulate at the walls of the compressor.
The periodical cleaning of the compressor prevents or slows down the process of
contamination accumulation but anyhow it does not replace the overall inspection
during which the compressor is subject to the complete disassembly.
Operation mode
The channel that is used to inject the water into the compressor is situated at the
compressor
housing
72
or
in
air
suction
housing
76.
the injection takes place at the maximum operational temperature when the engine is
under the full load that is at the highest RPM of the turbocharger.
All water is to be dispersed within 4 10 seconds.
The required volume of water:
VTR
160
161
200
201
250
251
320
321
400
401
500
501
630
631
750
751-1
900
cub.dm
0.3
0.3
0.5
0.5
1.0
1.0
2.5
2.5
2.5
The injection may take place with the help of either a hand pump or a metering
vessel pressurized (for example, with purging air). The injection tube must never be
HTLV 91005a
184
connected directly with a valve to a pipeline or a high volume vessel as this may
cause the uncontrolled water volume accessing the turbocharger or the engine.
The drawing 21 shows a vessel maintained as follows:
1. Release the screw by hand and remove cover B.
2. Fill up vessel A with water to the level 1 cm below the top.
3. Restore the cover B and tighten the screw by hand.
4. Push lever C to be pressed down.
The action of the push lever opens the valve making the compressed air access the
vessel A through the pipeline D. The compressed air forces the water through the
cover channel B and the pipeline W to the compressors impeller.
The injection results are identified by purging or blowing pressure and by the
temperature of exhaust gases. The resultless cleaning is to be repeated but not
earlier than in 10 minutes.
After having cleaned the compressor, the engine must work over under a certain load
for at least 5 minutes.
This manual is applicable only when cleaning the turbocharger with water provided
that the engine manufacturer allows the aforementioned method of cleaning. When
cleaning with gasoil, it is necessary to stick strictly to the engine manufacturers
instructions and to use a measuring device supplied by this manufacturer.
HTLV 91005a
185
2.1
Compressor assembly and disassembly
2.1.0 Bearing assembly removal and installation (drawings

8.1. and 8.2)
The required special tools are specified and highlighted with green colour at the
drawings 8.1, 8.2 and 8.3.
The sequence of assembly and disassembly is highlighted with red colour.
Compressor end (drawings 2.1 and 8.2)
Remove plug 5861 and drain the lube oil.
Remove bearing housing cover 78.
Undo hexagonal head screws 33060 and spring washers 33061.
Do not remove the guide screw 50240 as it provides the correct position of the lube
oil manifold 3283.
Remove oil suction tube 3700.
Undo screws with hexagonal slotted heads 33130 and remove spring washers 3314.
Remove nipple 3312.
Put retainer 1042P1 onto the guide screw 50240 and fix its lubrication plate 3311.
Indo nut 20180 with the help of socket wrench 1130P.
Remove clamping plate 20809.
Undo nut with inner ring 20810 with the help of socket key 1130P.
Remove lubrication plate 3311 with the help of bearing extractor 1020 and plate
extractor 1022P.
Remove bearing assembly 32 with the help of bearing extractor 1020.
Do not remove insert 7228 as it provides the axial air gap.
Wrap the removed parts with paraffinic paper to preserve them.
Prior to install a new bearing it is necessary to clean bearing housing (Item 2.0.3).
The bearing assembly is provided by the manufacturer with dampening springs 324,
324a and radial springs 323 air gap and with the axial position double ball bearing
320 (Item 2.7).
The assembly is to be carried out in the reverse order according to drawing 8.2.
HTLV 93904c
186
Tighten nut with inner ring 20810 to assure a close contact of the bearing assembly
to shaft shoulder. Then, release and slightly re-tighten. Restore clamping plate 20809
and tighten nut with inner ring 20810.
Measure the distance K at the compressor end and make sure that it corresponds
to the value at the label inside the bearing housing cover (drawings 1, 2.1, 8.2 and
14).
Attach nipple 3312 with screws with hexagonal slotted heads 33130.
Make sure that nipple 3312 rotates properly (drawing 8.2).
Connect oil suction tube 3700. All screws are to be properly tightened.
Tighten bearing housing cover and add the clean lube oil as described in Item 1.0.
Make sure that all screw-in plugs are properly tightened.
Turbine end (drawings 2.2 and 8.1)
Undo plug 5861 and drain the lube oil.
Remove bearing housing cover 58.
Undo hexagonal head screws 33060 and spring washers 33061.
Do not remove the guide screw 50240 as it provides the correct position of the lube
oil manifold 4002.
Remove oil suction tube 3700.
Undo screws with hexagonal slotted heads 33130 and remove spring washers 3314.
Remove nipple 3312.
Put retainer 1042P1 onto the guide screw 50240 and fix its lubrication plate 3311.
Indo nut 20180 with the help of socket wrench 1130P.
Remove clamping plate 20809.
Undo nut with inner ring 20810 with the help of socket key 1130P.
Remove lubrication plate 3311 with the help of bearing extractor 1020 and plate
extractor 1022P.
Remove bearing assembly 38 with the help of bearing extractor 1020.
Do not remove insert bushing 5092 as it provides the axial air gap.
Make sure that the bearing does not get apart. The bearing must stay in the oil
manifold 4002.
If the dampening spring set is disassembled the parts are to be restored according to
Item 1.5.
Wrap the removed parts with paraffinic paper to preserve them.
187
HTLV 93904c
Prior to install a new bearing it is necessary to clean bearing housing (Item 2.0.3).
Tighten nut with inner ring 20810 to assure a close contact of the bearing assembly
to shaft shoulder. Then, release and slightly re-tighten. Restore clamping plate 20809
and tighten nut with inner ring 20810.
Attach nipple 3312.
Make sure that nipple 3312 rotates properly (drawing 8.1).
Make sure that all screw-in plugs are properly tightened. All damaged washers are to
be replaced.
2.1.1 Rotor removal and installation (drawing 8.3)

Remove silencer 80 or air suction tube 82. Remove the bearings as described in Item
2.1.0.
Turn the turbocharger with the body 72 in horizontal position.
Remove retainer nuts 7233 and hexagonal head screws 7232 from stud 7230.
Release compressor body 72 undoing screws 6007 and remove it.
Screw in lifting nut 1056 to the shafts end, connect to a hook and pull out the rotor
completely.
Make sure that all screw-in plugs are properly tightened.
HTLV 93905b
188
2.1.2 Rotor mounting and dismounting

The rotor itself is dismounted in special cases only. This job must be carried out only
by the specialists of Brown Boveri.
HTLV 91014a
189
2.1.3 Jet ring removal and insertion

The jet ring is removed only in case if it is damaged of has to be replaced. In such
case, it is necessary to remove the rotor and to detach gas suction body 50 from gas
discharge body 60 thus providing the access to the jet ring. For VTR 161-3, VTR 250,
251-2 and 251-3, it is necessary to undo set screws and remove them. The ring is
removed with the help of pushing screws.
Everything related to cracks of the jet ring can be found in Item 2.2.0. When installing
the jet ring back, please, make sure that the ring gets to the correct position which is
to correspond to the position of elastic cylindrical pin 5027. Screws 5038 must not be
tightened hard. The screws are to be properly locked.
2.2
Spare parts replacement
2.2.0 Jet ring

During manufacturing, the jet ring is notched in several locations. Consequently, the
presence of notches is normal. If the jet ring has additional cracks it must be replaced
without the risk that some of its metal particles will get loose.
2.2.1 Seal bushings

The worn seal bushings 506 and 725 are to be hammered out with a wooden head
hammer and replaced with new ones. The edges of new bushings are to be
hammered to have a tight contact.
2.2.3 Turbine blades

Ruptured or bent blades with wooden shanks and dampening wires must be replaced
according to special instructions. Such replacement may be carried out by the
HTLV 91011d
190
specialists of Brown Boveri. Only the spare parts provided by the manufacturer or its
representative offices are allowed to be used to replace the blades and dampening
wires.
The blades repaired with welding are not recommended. If a turbine blade is
damaged but the turbocharger is to operate before the arrival of a replacement part
the damaged blade and the opposite blade are to be cut at the bending area in order
to eliminate a huge misbalance. The ends of dampening wires in blade gaps are to
be shortened to 10 mm and bent outward.
2.2.4 Guide plates

The guide plates are situated at the chamber water inlet as shown at the drawings 4
and 5.
2.2.5 Roller bearings

The service life specified in the technical specification section is a roughly estimated
value (see Item 0.1). The quality of the lube oil, maintenance and operational
conditions influence significantly the bearing service life.
It is recommended to check carefully the lube oil for suitability and cleanness (Item
1.0).
It is allowed to use only the bearing assemblies supplied by the manufacturer having
specially assigned bearings. See the special recommendations in Item 2.7.
2.6
Air gaps (drawing 14)
The air gap control is necessary only after having changed several spare parts.
HTLV 91011d
191
2.7
Bearings
The bearing assembly at the compressor end is a complete unit. That is why it has to
be replaced as a whole component (Item 2.1.0)
In order to eliminate failures of the bearing assembly a qualified engineer and
workshop having all necessary tools are required. The faulty bearing assemblies may
be sent well greased and protected against corrosion to our representative offices or
service centers (see appendixes) where a complete repair of the worn parts including
bushings thus the bearing will become fit for use again.
If a dampening springs set at the bearing side became faulty it is necessary to
inspect this bearing carefully according to the order specified in Item 1.5.
HTLV 91011d
192
2.8
If it is necessary to stop the operation of the turbocharger for a long period or to send
it to a warehouse he following measures are to be taken (drawing 15):
Remove centrifugal oil pumps and bearing assemblies (Item 2.1.0).
Lubrication plate 3311 and jet 3710 or 3713 must not be submerged in any case into
petrolate solution as it may result in lubrication drops clogging small ports.
The bearing assemblies must be submerged into the petrolate solution heated up to
80O C for 30 minutes. Then the drops must drain. The petrolate acidity must not
exceed 0.1 and the dew point must be 61 62O C.
Then, the centrifugal pumps and bearing assemblies must be wrapped with paraffin
paper and stored separately in a steel box in a dry place.
Cover shaft ends with hot petrolate (approximately 80O C) especially the areas
having contact with the bearings.
Retaining tool 12095 (supplied upon special requisition) must be installed instead of
the bearing assemblies at the compressor end. Thus, the rotor is fixed to the body.
Cover the bearing housings at the turbine end and other holes at the turbocharger
body with wooden covers using tarred paper as gasket.
All preserved turbochargers and spare rotors must be periodically inspected and regreased if required.
See Item 1.5 Post-shelf life operation.
2.9
Main spare parts
The spare parts set supplied with the turbocharger must be kept in the full scope and
ready for use at any moment. The used spare parts must be replenished without
delay (Item 0.2). The corroded parts must be properly cleaned and greased.
Corroded bearings must never be used. That is why the bearing assemblies are
packed in steel watertight boxes that have to be opened straight before their use
only.
HTLV 93906d
193
2.9.0List of main spare parts

1 *)
Bearing assembly for compressor end 32 consisting of part numbers 320, 321,
322, 323, 324, 324a, 3261, 3267, 3283, 329.
1 *)
Bearing assembly for turbine end 38 consisting of part numbers 380, 382, 383,
384.
Sealing slotted bushing 725
Sealing bushing 506
Tensioning ring
Set of screws, nuts, washers and lock nuts 930
Bearing housing cover gasket 585
Sight glass with measuring scale 583
Sight glass gasket 584
Oil separator 3270
Oil separator 50910
Piston ring 3712
Snap ring 3711
Part list
*) Packed in a watertight steel box.
3.
Troubleshooting
HTLV 93906d
194
3.0
Malfunctions and their causes
Exhaust gas temperature exceeds the normal value

At the constant engine power load and speed:
High air suction temperature when operating without cooling purging air.
Engine
Failure in fuel injection system.
Turbocharger
Lack of air, for example contaminated filter.
Contaminated compressor
Excess exhaust gas back pressure
Turbine blade damage.
Purge air cooler
Contamination, lack of cooling water, excess cooling water temperature
Insufficient ventilation.
Purge air below normal
At the same engine speed and normal condition at the air suction:
Engine
Leaking air manifold.
Leaking gasline between engine and turbine
Turbocharger
Incorrect reading of the pressure gauge or leakage at the inlet tube.
Contaminated air filter resulting in pressure decrease.
Contaminated turbocharger
Faulty labyrinth sealing
Damaged turbine blade
Excess exhaust gas back pressure
HTLV 91007a
Purge air above normal
195
At the same engine speed and normal condition at the air suction:
Engine
Failure in fuel injection system.
Engine power exceeds the estimated value.
Turbocharger
Incorrect reading of the pressure gauge.
Contaminated or partially clogged jet ring.
Turbocharger vibration
Significant rotor imbalance due to the compressor contamination or damaged turbine
blades.
Bent shaft.
Faulty bearing.
Wrong installation of bearings especially dampening packages.
Abnormal noise during speeding-up or delay in pickup
Faulty bearings
Rotor traction
Contaminated turbocharger
Foreign object in turbocharger
Leakage in body
Cracks
The cracks are the result of heat stresses caused for the irregular cooling, lack of
water or due to the huge scale accumulation.
Gas side corrosion
Water accumulation in body.
Sulphuric corrosion induced erosion due to pulverized ash.
HTLV 91007a
Water side corrosion
196
Using sea water for cooling.

Absence of corrosion prevention means at the water chamber inlets.
Slotted plates are installed in the water supply pipeline instead of water discharge
lines (See Item 1.1).
Quick darkening of lube oil
Exhaust gas access the bearing housing.
Sealing air channel X is clogged (drawing 1).
Mesh or slots of the equalizing channel Z are clogged.
Air gap at the sealing bushing 505, 506 or 507 is too big.
Lube oil loss
Air gap at the sealing bushing 505 or 506, 507 725 or 726 is too big.
Holes of equalizing channels Y or Z or holes on the sealing bushing 725 are clogged.
Lock screws of the bearing housing cover are loose.
Some lock screws of the bearing housing cover are loose.
Moisture in turbocharger or bearing housings
Water drops or injection water penetrate channels Y and Z.
Water condensation in bearing housings at the high ambient humidity and low
cooling water temperature and when the turbocharger is stopped.
HTLV 91007a
Continuous turbocharger exhaust
197
Excessively high resistance at the air flow, for example, due to the contamination of
air cooler, air filter or engine if abnormal sounds are detected in engine valve
operation. If the reason of the continuous exhaust cannot be identified it is necessary
to inform a manufacturers representative office.
Air cooler leakage
See the special instructions related to the air cooler.
3.1
Turbocharger shutting-down
In certain circumstances, for example, in the deep sea, it is necessary to keep the
engine running even if the turbocharger is down. The following measures may be
taken if there is a possibility to shut down the engine for some time.
3.1.0 Troubleshooting with site available spare parts

Take measures as according to the corresponding sections of this operational
manual.
3.1.1 Rotor removal and closing unit installation (drawing

20 and Item 4.4)
Remove bearing assemblies form turbine and compressor ends as specified in Item
2.1.0.
Remove the rotor as specified in Item 2.1.1.
Close the holes with closing unit as shown at drawing 20.
Connect pull rods 9100 and 9101 to closing unit cover and fix to cover 9106 at the
turbine end.
Screw nut 9107 until washers 9117 are tight.
198
HTLV 91008b
Install cover 9105 at the compressor end and screw nut 9107 until washers 9103 are
tight.
Cooling water must be closed only in case if a serious leakage is detected at the gas
side which is dangerous for the engine operation.
3.1.2 Interlocking unit installation

Supplied upon a special requisition (See Item 4.0).
For the engine running at the continuous load it is sufficient to interlock the engine at
the compressor end according to Item 3.1.2.0.
For the engine running at the override mode in many cases the toque created by the
exhaust gas at the turbine end is too high to secure the independent interlocking at
the compressor end.
The following may be used as a guide: When the average effective pressure is not
less than 5 Bars (about 500 kN/m2 = 5 kg/cm2) or when at the aforementioned
pressure the one in cylinders acting to the corresponding turbine of the turbocharger
is approximately 5.7 Bars (about 570 kN/m2 = 5.7 kg/cm2) it is necessary to interlock
at the turbine end as well See Item 3.1.2.1.
It is important to take bear in mind the recommendations of the engine manufacturer
especially if they are related to such issues as air flow separation and power
reduction of one or the other cylinder.
The cooling water is to be shut down only if a serious leakage is detected at the
turbine body gas side which is dangerous for the engine operation.
If the gas continue to circulate through the turbine of the interlocked turbocharger it is
important that the sufficient air pass by the compressor impeller thus assuring that
the overheating is prevented. If the air is sucked through an inactive compressor that
means that the cooling is secured.
If several turbochargers are connected to a single shared air manifold it is necessary
to close the air discharge outlet of the interlocked turbocharger in order to prevent air
leaking.
In this case, there should be an access providing the cooling air flow. This access
HTLV 91008b
must have at least the following dimension:
199
VTR
160
200
250
320
400
500
630
750
161
201
251
321
401
501
631
751
10mm
13mm
16mm
20mm
25mm
32mm
40mm
48mm
900
57mm
HTLV 91008b
3.1.2.0 Compressor end interlocking (drawing 16, Item 4.0)
200
Take the following measures:

Remove bearing from the compressor end as described in Item 2.1.0.
Put spacer sleeve 10709 and interlocking device 1070 onto the shaft and guide
screw 50240. Control the position of shaft wedge slots relative to guide screw 50240.
Tighten slightly screws 10703.
Tighten up screw 10701 and then screws 10703.
Install bearing housing cover 78.
NOTE
Do not disassemble the bearing at the turbine end.
At the end of the interlocking period, the turbine end bearing assembly must be
replaced. But, if the interlocking exceeds 60 minutes, for example, at the test bench
or during the deep sea trials there is no need to replace the bearing.
3.1.2.1 Additional rotor interlocking at turbine end (drawings

16 and 16.1 and Item 4.0)
The rotor must be interlocked at the compressor end at first and then at the turbine
end.
When interlocking rotor at the compressor end, please, follow the instructions
described in Item 3.1.2.0.
When interlocking rotor at the turbine end, please, carry out the following:
Remove turbine end bearing as described in Item 2.1.0.
Install interlocking device 1070T on the shaft and guide screw 50240 and control the
position of guide screw 50240.
Tighten up hexagonal head screw 10701.
Fix membrane 10716 with screws 10718 which must be tightened up. Make up
hexagonal nut 5034 and lock nuts 5029.
4.
HTLV 93907a
Part numbers
201
All requisitions must be accompanied with the following numbers and descriptions
(See examples of the ordered spare parts as specified in Item 0.2).
4.0
Hand tools
The kit of the required hand tools is in the wooden box and is supplied together with
your turbocharger. This kit contains the following items (special tools have their
individual numbers):
P/N
Name
1020
Bearing extractor
1022P
Plate extractor
1042
Retainer
10424
Retainer screw
1056
Rotor lifting nut
1070 *
Interlocking device
1070T *
Interlocking device
10701 *
Hexagonal head screw
CE
10703 *
CE
10704 *
Spring washer
CE
10707 *
Spring washer
CE
10709 *
Spacer sleeve
CE
10716 *
Membrane
TE
10718 *
TE
10719 *
Spring washer
TE
CE
TE
+
TE
TE
* - The asterisk indicates the parts of the interlocking device that are supplied upon
special requisition. These parts are usually used for turbochargers onboard selfpropelled vessels.
CE Compressor end
TE Turbine end.
P/N
Name
1101
Nut wrench 22
HTLV 93908c
202
1102
Nut wrench 17
11020
Nut wrench 8
1105
Nut wrench 14
1118
Double-ended wrench 10 / 13
1129
Screwdriver 1.0 x 6.5 / 140
1130P
Socket wrench
1135
Wrench for sight glass ring
1137
Inner hex socket wrench 4
11393
11394
Socket wrench 10
11395
Socket wrench 13
1142
Socket wrench 17
11421
Nut wrench 6 / 160
11431
Nut wrench 8 / 180
11451
Nut wrench 10 / 200
1146
12090 *
Wooden cover
12095 *
Retaining tool
Assembly / disassembly information board (drawing 8)
* - The asterisk indicates the parts of the interlocking device that are supplied upon
special requisition.
4.2
Turbocharger (drawings 1, 2.1, 2.2, 4 and 5)
203
HTLV 93908c
P/N
Name
20
Shaft
20809
Clamping plate
20810
Nut with inner ring
2085
Compressor impeller wedge
2086
Topping impeller wedge
2087
Sealing bands
21
Turbine blade
218
Dampening wire
22
Pull ring
25
Compressor impeller
2534
Lock wire
26
Topping impeller
28
Diffuser
2838
Lock washer
2839
Hex head screw
30
Jet ring
30425
Cover ring
30426
Hex socket head screw
30427
Spring washer
32
Bearing assembly, compressor end
320
Double ball bearing
321
Bearing inner race
322
Bearing outer race
323
Dampening springs, radial
324
Dampening springs, axial
324a
Dampening springs, axial
3261
Hex head screw
3267
Spring washer
3270
Oil separator
3283
Oil manifold
P/N
Name
329
Plate
HTLV 93909c
204
33060
Hex head screw
3311
Lubrication plate
3312
Nipple
33130
3314
Spring washer
3316
Spring washer
3700
Oil suction tube
3711
Snap ring
3712
Piston ring
3713
Jet
3721
3722
Spring washer
38
Bearing assembly, turbine end
380
Ball bearing
382
Inner bearing bushing
383
Outer bearing bushing
384
Dampening springs, radial
4002
Oil manifold
50
Gas inlet body
50240
Guide screw
5027
Elastic cylindrical pin
5029
Lock nut
5034
Hexagonal nut
5035
Pin
5039
Gasket
5044
Plug
506
Sealing bushing
50910
Oil separator
5092
Insert bushing
5095
Spacer sleeve
5096
5097
Spring washer
P/N
Name
5102
Cover studded flange
HTLV 93909c
205
5103
Hex head screw
5104
Gasket
52
Studded cover set
52E
Studded covers
52R
Studded covers
52Z
Studded covers
52M
Studded covers
520
Studded cover
521
Studded cover
522
Gasket
572
Entrainment separator
5720
Flange
5721
Casing
5722
Hex head screw
5723
Lock washer
58
583
Sight glass
584
Glass
585
Gasket
5861
Plug
5862
Gasket
5874
Sight glass screen
588
Compression ring
5891
Plug
5892
Gasket
5893
Plug
5894
Gasket
60
Gas discharge body
6001
Stud
6003
Hexagonal nut
6004
Lock nut
6005
Elastic cylindrical pin
P/N
Name
60061
Guide screw
HTLV 93909c
206
60065
Cover
60066
Gasket
60067
Hex head screw
6007
Extraction screw
6111
Flange
6112
Gasket
6113
Hex head screw
P/N
Name
62
Studded cover set
HTLV 93909c
207
62E
Studded covers
62R
Studded covers
62Z
Studded covers
620
Studded cover
621
Studded cover
622
Gasket
6545
Guide plate
6546
Hex head screw
6547
Retainer plate
68
Base
70
Spacer assembly
7011
Hex head screw
7012
Hex head screw
702
Spacer flange
7021
Sealing bands
7022
Lock wire
7023
Retainer plate
7024
Spacer disc
7026
Retainer plate
704
Shaft saver bushing
7065
Hex head screw
7066
Cap screw
7067
Retainer plate
72
Compressor body
7211
Stud
7214
Hexagonal nut
7215
Lock nut
7228
Bushing
72281
Hex head screw
72282
Spring washer
7230
Stud
7232
Hexagonal nut
P/N
Name
7233
Lock nut
HTLV 93910b
208
7234
Hex head screw
72340
Spring washer
7238
Setting stud
725
Sealing bushing
730
Entrainment separator
7300
Flange
7301
Casing
7302
Hex head screw
7303
Pull ring
7613
Plug
76130
Gasket
77
Spacer
77006
77008
Nib washer
78
80
Silencer
80K27
Silencer K27
80229
Rivet
803
Air filter
8030K27
Air filter segment K27
80319
Copper mesh
8065
Stud
8066
Hexagonal nut
8067
Lock nut
80761
Front disc
80763
Silencer disc set
80764
Silencer disc set
80765
Felt segment
80766
Steel mesh segment
80767
Tube rivet
80768
Lifting stud
80769
Pull screw
P/N
Name
80770
Spring washer
HTLV 93910b
209
80771
Hexagonal nut
80772
Washer
80781
Filter frame
80782
Protection screen
8081
Silencer ring
80816
Hexagonal nut
80817
Lock nut
8084
Pull screw
809
Front tube
8094
Spacer tube
8095
Outer tube
8097
U-type pressure gauge assembly
80970
U-type pressure gauge
80972
Washer
80973
Washer
80974
Retainer plate
80975
Spacer sleeve
80978
Hex head screw with ball bearing
80979
Hex head screw
82
Air inlet tube
4.4
Closing unit (drawing 20)
Fabrication drawing may be supplied for free if required.

P/N
Name
9100
Connection rod
9101
Connection rod
9102
Inner sealing cover
9103
Spring washer, compressor end
P/N
Name
9105
Sealing cover, compressor end
HTLV 93910b
210
9106
Sealing cover, turbine end
9107
Nut
9117
Spring washer, turbine end
HTLV 93910b
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
16.
FUEL INJECTION SYSTEM WITH HIGH PRESSURE FUEL OIL PUMP

"LORANGE"
16.1 Description
This section refers to the high pressure fuel oil system including the high pressure
fuel oil pump, high pressure fuel oil piping and nozzles.
Fuel oil pumps (one each per cylinder) complete with the integrated followers. The
piston pair is lubricated under the pressure, the fuel oil leaks drain into the piping
system with the atmospheric pressure outside the pump.
Each high pressure fuel pump is equipped with an emergency shutdown cylinder
connected to the electro-pneumatic overrunning protection system.
The high pressure pipeline consists of a high pressure piping and a reducer
connected from a side of the nozzle body.
The nozzle consists of nozzle body and a spray gun with several ports.
The spray guns are heated/cooled with the lube oil. Running engine is allowed only
when there is lube oil circulation available in the spray guns. (Applied only to diesel
engines type 22HF and 22, running on heavy fuel).
16.2
High pressure fuel oil pump, description

The high pressure fuel oil pump includes the casted body with flanges for retaining
the pump to the engine block. The follower complete with a roller is located in the
lower part of the body. The roller slides along the cam of the high pressure fuel pump
under the stress of the compressed springs (17). Between the follower and the
piston, there is a thrust disk (28) to which the piston end is set.
The pump element (5) is located in the upper part of the body and consists of a
piston and a liner fitting each other and it is necessary to handle them as one single
assembly. The piston liner is manufactured as an integrated part of the pump cover.
The upper part of the pump element that is the fuel end is sealed with sealing O-rings
(24) from the bottom. The piston liner is pressure lubricated thus preventing fuel oil
entering below and mixing fuel oil with the lube oil.
The regulation of the fuel oil supply the piston rotation takes place with the help of
fuel oil racks through the ring gear (14).
The charging valves are installed in the upper part of the pump element and in the
fitting assembly. The seal between the liner and the fitting is made of steel.
243
16.3
Removal
1.
Shut down the fuel oil supply to the engine prior to remove the high pressure
fuel pump.
2.
Dismantle the fuel oil supply piping elbows, high pressure fuel oil supply piping
and the drain pipe. Close all ports with adhesive tapes or with plugs to prevent
the dirt contaminations.
3.
Undo the bolt fastening the fuel oil supply crankcase crank case equipment.
4.
Remove the pneumatic cylinder of the fuel oil supply shutdown. See Item 4,
page 22-53. Including the pipe that is removed from the distribution pipe.
5.
Disconnect the connecting part from the fuel oil racks undoing nut and
removing bolt. In order to avoid any parts missing, please, pt the nut back to
its place without delay.
6.
Rotate the crankshaft the way that the pump follower roller seats at the
working surface of the cam.
7.
Undo the flange nuts with the special socket wrench 806005 and remove the
pump from its place. Close the lubrication ports and the pump of the engine
block itself.
8.
Clean the pumps from the outside.
Re-assembly
9.
The pump must be assembled and cleaned. The surface and port in the
cylinder head must be cleaned as well.
10.
Check the rubber O-rings of the pump body, lubricate it and install it onto the
slots. Make sure that the roller of the high pressure fuel pump is at the notrunning part of the cam.
11.
Install the pump back again and tighten the nuts of the flange to the torque
value pacified above.
12.
Hook up the connection part between the regulating lever and fuel rack with
the help of a bolt and a nut. Note: Centralizing connection with the torque
between the fuel rack and the connection part. See section 22, Picture, page
22-51. Check the free motion of the connection.
244
13.
Remove the protection tape or the plugs and connect the fuel oil supply fuel oil
pipelines and the drain pipe. Install the fuel oil supply line of the high pressure.
Tighten up the cup nuts of the fuel oil supply line of the high pressure. To the
value specified in section 07, sub-section 07.1, item 18 with the help of a
special open wrench for injection pipe 806007.
14.
Open the fuel oil supply to the engine and bleed the air off from the fuel oil
filter and high pressure fuel oil pumps according to recommendations specified
in section 17. The high pressure fuel oil pump is equipped with the air outlet
plug (42).
15.
Check positions of the fuel oil racks according to section 22., sub-section
22.3.1, item b.
16.4
The start of the high pressure fuel pump piston stroke is detected by the indirect
method that is by the moment of closing drain port of the piston upper piston edge.
See Picture on page 16-52. This is the so-called cut-off.
The check of the fuel oil supply start-p moment is necessary only in cases when the
major components, as high pressure fuel pump, pump element or camshaft sections
are to be replaced.
In this case, take the following measures:
1.
Shut down the fuel oil supply to the engine.
2.
The fuel oil supply take place when connecting checking device for fuel
injection timing 862007 to the pump (See Picture on page 16-52).
3.
Remove the fitting (35) of the high pressure fuel pump and the charging valve
(5) complete with the spring. Put the spring back again. See the sub-sections
16.5.6 and 16.6.6.
4.
Connect the tubing elbow to the fitting as shown at Picture on page 16-52.
5.
Install the fuel oil rack at the position between marks 32 and 36 mm.
6.
Install the crankshaft at the position of 22 to TDC of the combustion.
7.
Fill up the funnel with the fuel oil. At that, the fuel oil will start leaking fuel oil
supply pipe.
8.
Keep the fuel oil level in the funnel with continuous topping-up and rotating
slowly crankshaft in the direction of the engine rotation. Take a record of the
moment of the fuel oil stopped leaking. Calculate the position of the crankshaft
as according to the flywheel marking. See sub-section 06.1 of section 06.
245
9.
Repeat steps 2...8 for the other cylinders.
10.
Compare the position of the crankshaft against the recommended. The

difference between the positions of the various cylinders of the same engine
must not exceed one degree of the crankshaft rotation. If there are any
deviations exceeding the aforementioned value, it is necessary to replace the
high pressure fuel pump and/or overhaul and inspect it.
11.
Install back the charging valve.
16.5

When operation fuel oil gear, you must be comply with the following:
It is assumed that the high pressure fuel pump is removed from the engine prior to
disassembly and cleaned thoroughly from the outside.
1.
2.
3.
It is recommended put the pump into the vise in the position comfortable for
handling operations.
Holding follower by hand, undo the retaining bolt (21).
Then, the follower and the piston may be removed. Handle carefully the
piston as it may get apart from the follower.
4.
Remove the spring and the ring gear.
5.
Rotate the pump to the vertical position.
6.
Undo stagewise the nut (52) of the fitting by 30.
7.
Undo stagewise the pump element liner bolts (9) by 30 in order to avoid
overloading last bolt.
8.
Remove the charging valves.
9.
Remove the pump element liner.
10.
Flush the piston and the liner with the clean fuel oil or special lube oil and
always keep them assembled inserting piston into the liner.
11.
Usually, the further disassembly of the pump is not required. It is

recommended store the components and parts of the different pumps
separately from each other or mark the parts in such a way that they may be
246
installed in the same pump. The parts must be preserved especially avoid
touching them piston working surfaces with your fingers.
16.6
High pressure fuel pump

1.
Flush the parts in the absolutely clean diesel fuel and lubricate the inner parts
of the high pressure fuel pump the engine oil. When handling fuel oil gear it is
necessary to keep hands absolutely clean and to cover them with grease or lube oil.
2.
Replace the piston liner sealing rings and lubricate the rings with lube oil.
3.
Install the pump element liner at the position when the retaining dowel pin
enters the guide slot.
4.
Install the charging valves (if it is required to identify the fuel oil injection
moment, see sub-section 16.4).
5.
Put back the pump fitting and tighten the bolts (52) by-hand. Install back the
bolts (9) and tighten them by-hand.
6.
In order to assure an even torque of each bolt, they must be tightened in three
stages. The bolt (9) must be tightened as specified in item 16 and the bolt (52) must
be tightened according to item 15 of sub-section 07.1.
7.
Turn the pump and install the ring gear. Put the fuel rack to the position at
which two marks are seen at the rack. One of the teeth of the ring gear is made with
a bevel and this tooth must be engaged with the pitch point between the marked
teeth of the rack.
8.
Insert the spring disk (16), ring (19) and spring (17).
9.
Put together the piston and follower with the spring disk and the thrust ring
(28).
10.
Pay attention to the mark at one of the plunger lever. The marked surface of
the plunger lever must be situated from the fuel rack end of the ring gear that is it
must correspond to the marks at the fuel rack and the beveled tooth of the ring gear.
The guide slot of the follower must be situated opposite the guide bolt.
11.
Insert the follower complete with the plunger into the pump body.
12.
Screw in and tighten the retaining bolt (21).
13.
Check the free motion of the fuel rack.
247
14.
In case if pump is to be installed straight at the engine it is necessary to

lubricate it thoroughly and protect it with a plastic cover or anything similar. The hole
at the fuel inlet and outlet and the pace of the high pressure fuel oil tube connection
must always closed with plugs or adhesive tape.
16.7
The high pressure line consists of two parts, namely a reducer inserted in to a nozzle
body and a high pressure fuel oil tube.
The reducer is sealed with fine polished steel surfaces which condition must be
inspected before the installation. Always make up the reducer to the specified torque
value before the installation of the high pressure fuel tube even if the fuel tube only
has been removed as there is a chance that the reducer gets loose during the
disassembly of the fuel tube.
The high pressure fuel oil tubes are supplied complete with the connection nuts. All
connections must be always made p to the predetermined torque value.
If it is required, the engine may be equipped with the high pressure fuel oil tube
failure alarm. In this case the high pressure fuel tubes are integrated in the outer
piping through which the drain pipe runs to the fuel oil drain collector. The collector
enters a tank with a lever gauge sending signals at a certain level. In order to prevent
warning during normal leakage, the fuel tank is equipped with a valve which must be
installed in such a way that the normal leakage continuously passes through it. Only
the flow increase up to an abnormally high level (high pressure fuel oil tube failure)
results in warning alarm signal.
After the removal of parts and components of the high pressure line, they must be
protected from the dirt and corrosion.
16.8
Nozzle, description
The nozzle is situated in the center of the cylinder head and includes a spray sparger
and a body. The fuel oil enters the nozzle body from a side through a reducer
screwed in the nozzle body. The spray sparger is heated/cooled with the lube oil and
the lube oil enters the body through the air gap between two upper rubber seal Orings (Applied only to the engine types 22HF and 22, running on heavy fuel).
16.9
1.
Nozzle removal
Remove the cylinder head cap and the fuel oil crankcase hatch cover as well.
Switch off the nozzle temperature regulation mechanism. (Applied only to the
engine types 22HF and 22, running on heavy fuel).
248
2.
Dismantle the fuel high pressure line.
3.
Undo the nozzle retaining nuts.

4. Take off the nozzle. The application of the excessive force may result in
potential shifting nozzle guide tube. Make sure that the tube did not move.
5. Close the nozzle fuel oil supply hole and the nozzle hole in the cylinder
head.
16.10
1.
Nozzle installation
Make sure that the guide tube in the cylinder head is clean from below. If it is
required, clean or polish the surface with the help of grinding device for valves
841008. If it is necessary to carry out the lapping, the cylinder head must be
removed. For lapping, use a steel washer and a fine lapping paste. The nozzle
body is sealed directly with the landing butt end inner surface of the guide
tube!
2. Install the rubber seal O-rings. Lubricate the nozzle.
3. Install the nozzle into its slot in the cylinder head.
4. Install new rubber seal O-rings at the reducers flange. Connect the flange
with the reducer and torque it up. Make up the flange to the predetermined
torque value.
5. Tighten up the nozzle retaining nuts to the torque level with 10 Nm steps.
6. Tighten up the reducers sealing flange.
7. Put back the high pressure line and tighten up the nuts to the
predetermined torque value.
8. Restore the cap and the cylinder head.
16.11 Nozzle overhaul

1.
Check the condition of the spray sparger straight after having removed
nozzles from the engine. The carbon deposition (of tubular shape) may be a
sign indicating that the spray sparger is in a bad condition, spring is broken or
(for engine types 22HF and 22 running on heavy fuel) there are
malfunctions of the nozzle temperature regulating system. Clean the spray
sparger externally with a wire brush and a brass wire.
249
2.
Unload the spring undoing lock nuts (10) and adjusting bolt (9).
3.
Remove the spray sparger from the nozzle body undoing nuts (5). Do not
allow the spray sparger to fall down. If the air gap between the spray sparger
and the nut is coked this may complicate the removal of the spray sparger. In
such case, put the spray sparger with the nut on a soft bed and knock out the
spray sparger with the help of piece of pipe (See Picture on page 16-52).
Never knock directly the tip of the spray sparger!
4.
Check the needle elevation of the spray sparger which may be changed as
follows:
sufficiently free elevation of the needle;
the elevation of the needle is free in normal limits;
the needle gets stuck.
The removal of the needle applying a lot of force is not allowed as it results
often in complete jamming. If the needle cannot be easily removed it is
recommended to submerge the spray sparger in lube oil and heat the lube oil
up to 150 ... 200. Usually, the needle may be removed from a preheated
spray sparger.
5.
Clean the parts. If is possible, try to use chemical coke thinning liquid. In case,
if such liquid is not available, submerge the parts in pure fuel oil, petroleum
spirit or similar liquid for thinning carbon deposition. Then, clean thoroughly
the parts with the nozzle cleaning kit 845006. The use of the steel wire brush
or other hard accessories is not allowed. Clean the ports of the spray sparger
with appropriate needles. After having cleaned the ports, flush the parts in
order to remove the residuals of coke and dirt particles.
Cooling cavities of the spray sparger must be clean thoroughlyed using coke
thinning liquid. Prior to install the needle into the nozzle, submerge the parts in
pure fuel oil or special lube oil designed for high pressure fuel oil gear. The
landing surfaces, the guide surfaces (needle stem) and the landing surfaces of
the spray sparger must be thoroughly checked.
6. Clean thoroughly the nozzle body and the retaining nut of the spray
sparger. If it is necessary, dismantle the nozzle body to flush the parts. Check
the needle spring of the spray sparger.
7. Check the high pressure sealing surfaces of the nozzle body that is the
surface sealing nozzle body against to the spray sparger and the reducer.
8. Check the maximum elevation of the spray sparger needle, for example,
totalize the measurements "" and "" according to picture on page 16-53. If
the wear level of the part "" exceeds 0.05 mm the part may be sent to the
manufacturer for the overhaul. If the total elevation is beyond the limits
specified in item 16 of sub-section 06.2 the spray sparger must be replaced
with a new one.
250
9. Put together the nozzle.

10. Connect the nozzle to the testing device for injection valves 864011.
Charge the fuel oil to bleed of the air. Close the pressure gauge valve and
pump the fuel oil to force out the dirt from the ports of the spray sparger. Put
dry paper under the spray sparger and with a quick stroke of the pump handle,
spray the fuel on the paper. Make sure that the trace of the fuel oil spray is
even.
11. Check the opening pressure value:
open the pressure gauge valve,
pump slowly and control the opening pressure with the pressure gauge. If
the opening pressure is more than by 50 bars below the predetermined
value, this means that the spring is broken or there is a serious wear of
the parts.
12. If the trace of the fuel oil spray is uneven, adjust the opening pressure to
the predetermined value and once again make sure that the trace of the fuel
oil spray is even.
13.
Make sure that the needles landing surface is tight:

build up the pressure to the value 20 bars below the predetermined value
of opening pressure;
keep the pressure continuously and make sure that there is no fuel
leakage from the tip of the spray sparger. A minor moisture is allowed.
14.
Make sure that the needles guide surface is tight

build up the pressure to the value 20 bars below the predetermined value
of opening pressure;
record the time for the pressure decrease by 50 bars. This time must not
be less than 3 seconds. If this time is more than 20 seconds that means
that the stem is excessively dirty.
14. If the inspections as per items 10 ... 14 have positive results a nozzle may
be allowed for the next installation at the engine. Otherwise, replace the spray
sparger must be replaced with a new one.
15. If the high pressure sealing surface is leaking it necessary to replace or to
overhaul the damaged part.
16. If it is required to store spray spargers or nozzles, they must be preserved
with the anti-corrosion lube oil.
16.12

(Picture on page 13-51} (fuel injection point)
251
1.
Check the fuel injection point in one cylinder.
2.
Single-row engine: Open the camshaft drive hatch cover and the small round
cover from the engine drive end.
V-shape engine:
Open the camshaft drive hatch cover of one row and the
small round cover of the row "" or the plug (17) of the
row "".
3.
Mark up the nut (7) of the camshaft idler pinion gear the closest to the drive
end hatch.
4.
Undo all nuts (7) of the idler pinion gear. The marked nut must be the very last
one.
5.
When the last nut (7) is removed, rotate the crankshaft in the direction
opposite to the normal rotation as much as required for the crankshaft to reach
the earliest fuel injection point.
Note! When rotating camshaft do not turn it completely.
6.
Lock the marked nut (7) and check the new fuel injection point.
7.
If the required fuel injection point was achieved the rest of the nuts (7) must be
tightened up.
8.
V-shape engine: Repeat the same measures for adjusting fuel injection point
of the second row pumps.
252
16-51
253
16-52
254
16-53
255
256
17.
FUEL OIL SYSTEM
17.1
General
The engine is equipped with the fuel oil system for running on fuels specified in class
M3 of the British standard BS 100:1982 (Marine Diesel Oils) and of a higher
quality.
As the fuel oil system before an engine may be significantly different for various
power plants this system is not described in this Operation Manual. See individual
manuals.
17.2
Description
The engine is equipped with externally installed fuel transfer pump (3) which is
usually electric driven (engine driven pumps may supplied upon special order). The
fuel oil passes through the plate-type filter (1) from the day tank (7) to the fuel feed
pump charging it through the duplex filter (4) into the distribution pipe and the high
pressure fuel pump.
The pressure regulating valve (8) provides the engines fuel oil system with the
pressure regulation within the limits recommended in section 01. With the help of the
pressure regulating valves (10), both blocks of the duplex filter may work
simultaneously to attain the filters maximum capacity. Nevertheless, there is a
possibility to replace the filter elements during operation. In this case, part of the fuel
oil enters the engine bypassing valve (10).
The pressure gauge (6) at the control panel indicates the pressure of the fuel oil
entering engine. The fuel oil low pressure transducer (5) is integrated in the
automatic alarm system. The fuel oil leakage from the high pressure fuel pump and
nozzles are collected in a separate closed-loop system due to which the fuel may be
used again.
See the high pressure fuel pumps and nozzles in section 16.
17.3
Maintenance
When working with the fuel oil system, it is always necessary to maintain the absolute
cleanliness. Pipes, tanks, pump regardless if they are a part of the engine delivery or
not must be allowed for operations only after their thorough cleaning. The filter
elements must be periodically replaced.
257
The fuel oil filter is equipped with a combination visual indicator/electrical

transducer connected to the automatic alarm system sending signals during an
excessive pressure differential in the filter informing that it is necessary to replace
shortly the paper filter inserts.
The recommend schedule of the filter insert elements are given in section 04.
It is necessary to clean periodically the plate-type filter rotating handle several turns
(See section 04.). When cleaning main filter, the plate-type filter must be opened as
well for the complete cleaning.
Always after having opened fuel oil system components, it is necessary to bleed off
the air from the system.
17.4
Bleeding-off air
Undo the air outlet screws situated in the high pressure fuel pump (See section 16,
Picture 16-51, item 42). If the position of the day tank does not allow sufficient static
pressure in the system, it is necessary to start up the fuel feed pump.
Always after having replaced the filter element insert, the air must be bled off from
the filter.
If the engine is shut down and the fuel feed pump does not work, it is possible to
switch the three-way valve to the position of both filter block operation and bleedingoff air through the filter air outlet screw. If the engine runs, the three-way valve must
be switched very carefully. The best practice is to have a throttle valve at the threeway valve to provide slow filter filling. At this, put the throttle valve at the "slow filling"
position (See Picture on page 17-54) and the filter will start filling slowly. Bleed off
the air from the filter. Put the three-way valve and the throttle valve to a normal
operating position (both filter blocks working).
Sudden switching three- way valve to the operating position with the empty filter
block results in a temporary pressure differential in the system. In this case the
automatic alarm system transducer sends a pressure differential signal. This
may cause as well the air to come from the filter to the high pressure fuel pump.
This may result in the engine shutdown.
17.5
Adjusting pressure regulating valves
Check the adjustment according to the schedule recommended in section 04.
258
The valves must be adjusted when running idle (at the normal RPM of the pump
driven by engine). In order to increase the pressure, turn the adjusting screw
clockwise and to reduce the pressure turn the adjusting screw counterclockwise.
All pressure values specified in the manual are valid for the pressure gauge (6)
readings at the engine control panel.
17.5.1
Adjusting pump valve
Gradually build up the pressure in the system closing valve (9).

Adjust the valve (2) to 8 bars. Open the valve (9) completely.
Such adjustment must be carried out as soon as possible as the pump may
become overheated if the system is shut down for a long time.
17.5.2
Adjusting pressure regulating valve (8)
Adjust the valve (8) to 4 bars.
17.5.3 Adjusting pressure regulating valves (10)

Close the valve (11).
Make sure that the recommended working pressure of +2.5 bars that is 6.5 bars is
achieved. Check that the valves are adjusted similarly closing blocks one by one. In
this situation, it is possible to achieve the pressure a little bit higher that the rated
pressure due to the double volume of the fuel oil passing through the filter. Adjust the
valves (10) if required.
After having adjusted, open valve (11) completely.
17.6
Fuel feed pump with electric drive
The fuel feed pump is similar to the lube oil precharge pump. See the description in
section 18, sub-section 18.9. The ball bearing of the fuel feed pump from the engine
side must be lubricated periodically.
259
17.6.1
Fuel feed pump (driven by engine. See Picture on page 17-52)
17.6.1.1 Description
The fuel feed pump is of the pinion gear type and driven by the tooth gear from the
side opposite of the drive end. The shafts rest on the bearing sleeves (2, 11) that do
not require any lubrication from outside and the ball bearing (18).
The drive shaft is sealed with two radial seal (14) separated by the drain channel
(13). The inner seal is lubricated with fuel oil and the outer seal as well as the ball
bearing are lubricated with the lube oil spraying out from the port (15).
The system pressure regulating valve is installed at the pump cover. When the
predetermined pressure is reached, the piston (5) opens the overflow channel to the
pump suction end. The pressure is regulated to the predetermined value with the
help of the regulating screw (3). The pressure increase is achieved with screwing-in
regulating screw resulting in spring loading (7).
Right-hand and left-hand rotation engine pumps are identical except that the pump
body (1) of the left-hand engine unlike the right-hand engine is turned 180 related to
the drive shaft axis.
17.6.1.2 Maintenance
Apart from a normal maintenance described in section 04, the pump must be opened
and the seals must be replaced if the fuel oil or the lube oil leak from the drain pipe
(13). Nevertheless, a minor leakage from time to time may be allowed.
a.
Undo the self-locking nut (19) and remove the pinion gear (16) from the drive
shaft with the help of extractor for gear wheels 837012.
b.
Now, the pump may be opened and the shafts and the bearings removed.
Avoid scratching sealing surfaces of the shaft.
c.
Check the bearings, shafts, teeth and seals. Replace worn or damaged parts.
d.
In case of replacing seals (14), remove the retaining ring (17) and take out the
bearing (18). Then, these seals may be removed.
e.
Check the free motion of the piston (5).
f.
When installing new radial seals (14), it is necessary to avoid installing them
skewed. Insert the seals and the spacer ring (12) into the pump cover 2 - 3
mm from the split plane. Push the bearing (11) into its place. This will make
the seals take automatically their correct positions. Make sure that
a sufficient contact is provided between the bearing (11) and the pump body.
260
g.
Check the drive shaft for scratches that may damage the seals after the shaft
installation.
h.
Remove the dirt and the lube oil from the tapered part of the connection. Using
any lubricant is not allowed.
i.
Lubricate the shaft thread and the contact surface of the nuts with the lube oil.
j.
Tighten up the nut (19) to the torque value specified in sub-section 07.1 of
section 07.
17.7
Fuel oil prefilter
17.7.1
Description
Fuel oil prefilter is a plate-type filter with the air gaps of 0.05 mm. The fuel oil passes
from outside into the filter element insert and dirt particles exceeding air gaps stay at
the outer surface of the prefilter. When turning prefilter handle, a special device
cleans the dirt that falls at the bottom of the prefilter body.
17.7.2
Cleaning
The prefilter is cleaned turning handle several times.

In order to remove the dirt from the prefilter body, the prefilter must be disassembled.
17.8
Fuel oil filter

17.8.1.
Description
This filter is a double type filter. With the help of the three-way valve (8), the fuel oil
flow may be directed to either of two filters or to both filters simultaneously. The flow
direction is indicated with a mark at the square valve stem (7). During normal
operation, both filters must work simultaneously in order to provide the maximum
filtration. The Picture A on page 17-53 shows the valve at this position. To replace
the filter element inserts when engine is running one block may be closed. The
Picture B on page 17-53A shows the valve at the position when the right block of the
filter is closed. In this situation, a part of the fuel oil goes through the pressure
regulation valve (10) (See Picture on page 17-51A) from the inner part of the opened
filter to the pipe at the engine discharge.
261
The flow direction through the filter is indicated with arrows at the picture. At first, the
fuel oil goes through the filter element insert (3) made a special paper which rated
filtration capacity is 15mcm, then through the filter element insert (4) consisting of the
perforated cylinder wrapped with meshed textile. The meshed textile insert with the
mesh size 40 mcm serves as a safety filter in case of failures of the paper filter
element insert. The three-way valve is equipped with a throttle valve to facilitate filling
empty filter block.
17.8.2
Filter element insert replacement and cleaning filter
The filter element inserts must be periodically replaced (See section 04.) as soon as
possible after the warning signal having been sent by the pressure differential
transducer. As the service life of the filter element inserts depends significantly upon
the quality of the fuel oil, the experience of running a given engine allows identifying
the optimum periods between the replacements of the inserts.
The replacement of the filter element inserts and filter cleaning are recommended to
be carried out when the engine is shut down. Nevertheless, switching off one of the
filters, it is possible to replace the filter element inserts while running engine as well.
Never open the working filter. See instructions on closing one of the filter blocks
at the filter itself or see Picture on page 17-54A
a.
Close the clean filter.
b.
Open carefully and remove the air outlet screw (1). Open the drain plug (6).
c.
Open the filter cover (2).
d.
Remove the meshed textile filter element insert (4). Flush it in the petroleum
gas oil. Check its integrity.
e.
Remove the paper filter element insert (s) and discard them. The paper inserts
are expendable. It is necessary to have always a sufficient number of spare
inserts.
f.
Clean thoroughly and rinse the filter body in the petroleum gas oil.
g.
Install new paper filter element inserts and cleaned meshed textile insert.
Check the correct position and integrity of all gaskets.
h.
In V-shape engines equipped with two paper inserts on each filter, it is

necessary to make sure that the guide ring (5) is at its proper place.
i.
Put back the drain screw and the cover.

17-7A
262
j.
If it is possible, top up the filter with pure fuel oil prior to switch the valve to
operating position (both filters work). If it is impossible to top up the filters,
switch it very slowly. See sub-section 17.4.
k.
Bleed off the air from the filter if it is not topped up as according to item j. See
sub-section 17.4.
263
264
265
266
267
18.
LUBE OIL SYSTEM
18.1
General
The engine is equipped with the lube oil pump (2) with the pinion gear drive from the
crankshaft situated from the side opposite to the drive end. Some power plants have
a back-up pump with the independent drive connected in parallel. The lube oil pump
sucks the lube oil from the engine crankcase oil pan and charge it through the lube oil
cooler (16) equipped with thermostatic valve (17) regulating the lube oil temperature
through the main filter (s) (13) to the main distributing manifold (12) molded in the
engine block. From the main distributing manifold, the lube oil goes through the holes
drilled in the engine block to the main bearings and then through the holes drilled in
the connecting rods to piston pins (11) and further to the piston cooling cavities.
Through the separate pipeline, the lube oil is supplied to other lubrication points such
as camshaft bearings (10), high pressure fuel pump followers, valves, bearings (9) of
rocker actuator brackets, pinion gear bearings of the valve gear drive, nozzles for
lubrication and cooling purposes. A part of the lube oil goes through the centrifugal
filter (s) (5) and back to the crankcase. The crankcase may be equipped with float
level detectors connected to the engine alarm system.
The electric lube oil precharging pump (4) connected in parallel with the engine
driven pump charges the lube oil through the engine when the engine is shut down
and especially before its start-up. The nonreturn valve (3) prevents lube oil entering
the unnecessary side during run. The charging line from the lube oil pump may be
equipped with a three-way valve which allows draining crankcase with this pump.
The pressure in the distribution manifold (12) is regulated with the pump regulating
valve (1). The pressure may regulated with the help of the regulating screw (17) (See
Picture on page 18-52) of the regulating valve. It is very important to maintain the
required pressure to provide the bearing lubrication and piston cooling. The pressure
is usually kept continuous after the adjustment to the predetermined value. The
pressure may exceed the rated value when starting with cold lube oil but after
preheating the pressure comes to the required value. The pressure gauge (7) at the
instrumentation panel indicates the lube oil pressure at the engine suction end (in the
engine distribution manifold). The system includes three transducers (8) for low lube
oil pressure two of which are connected to the engine alarm system and one is
connected to the automatic shutdown system (See section 23).
The temperature control may be carried out with the temperature gauges installed at
the lube oil coolers inlet and its outlet (the temperature at the engine inlet and outlet).
Lube oil high temperature transducer is connected to the automatic alarm system
(See section 23).
The RPM regulator and the turbocharger have individual lube oil systems. See their
individual operational manuals.
A connection to hook up the lube oil purifier is situated at the side opposite the drive
end.
268
The hole (14) for topping up engine crankcase with the lube oil is situated at the drive
end and the lube oil measurement rack (15) is installed in the middle of the engine.
18.2
General maintenance
Only high quality lube oils recommended by the engine manufacturer must be used.
See section 02.2.2.
The system must always be filled with the sufficient volume of the lube oil. The
measurement rack has marks for the maximum and minimum limits between which
the actual lube oil level must stay. The lube oil level must be maintained at the level
close to the maximum and never must be let to go below the minimum mark. The
lube oil level limits apply the running engine. The lube oil must be added not more
than 10% at a time (See section 02, sub-section 0 2.2). One side of the measurement
rack is calibrated in centimeters. This scale may used to determine the lube oil
consumption.
The lube oil replacement must take place periodically and the schedule is established
based on the experience of running given power plant. See sections 04 and 02, subsection 02.2.3. Drain the lube oil from the system including the lube oil cooler and the
filter while the lube oil is still hot. Clean the crankcase and the crankcase drip pan
with rags. Clean the main and centrifugal filters. Replace the inserts of the main filter
(s) if they were not replaced for a long time.
It is recommended to purify the lube oil. See section 02, sub-section 02.2.3.
When maintaining lube oil system, an absolute cleanliness must be provided.
Dirt, steel particles, etc. may result in serious failures of the bearings. When
dismantling pipes and parts, it is necessary to close all outlets with blank flanges,
adhesive tape or clean rags. When storing and transporting lube oil, it is
necessary to protect it from its contamination with dirt and foreign objects. When
adding lube oil, use filtering mesh.
18.3
Lube oil pump

18.3.1
Description
The lube oil pump is a pinion gear type pump. It is equipped with integrated
combination valve designed for pressure regulating and serving simultaneously as a
safety valve. The pump has five similar bronze journal bearings. Additional lubrication
from the outside is not required. The cover is sealed with seal O-ring.
269
18.3.2
Dismantling
a.
Remove and check the regulating valve as according to sub-section 18.4.
b.
Undo the bolt (4) and remove the pinion gear (2) with the tool
337012 as shown on Picture D on page 18-52.
c.
Remove the pump cover using two retaining bolts (1) as release bolts
screwing them in two threaded holes in the cover.
18.3.3
Inspection
a.
Check all parts for wear and tear (section 06, sub-section 06.2) and replace
worn parts.
b.
Remove the worn bearings from the body pushing them out with the help of a
suitable tool and from the cover machining them down.
c.
Install new bearings (cool them down if it is required) in such a way that they
are submerged 3 mm below the surface of the cover and body contact area
(size = 3). Make sure that the oil grooves (5) of the bearings are installed at
the required position according to Picture on page 18-52.
d.
After the installation, take measurements of the bearing inner diameter. Check
the axial deflection of the pinion gears. (See section 06, sub-section 06.2, item
18).
18.3.4
Assembly
Clean thoroughly all parts prior to assemble. Make sure that the sealing O-rings in
the cover are intact and installed at their proper places.
Put the pinion gear (2) complete with the washer (3) onto the shaft with the help of
extractor for gear wheels 837012 according to picture on page 18-52.
Lubricate the retaining bolt (4) with the locking compound "Loctite 274" and tighten it
up to the predetermined torque level (See section 07.).
If the pinion gear (2) was replaced, it is necessary to check the air gap in the pinion
gear after having installed the pump back to its place.
270
18.4
Lube oil pressure regulating valve and safety valve

18.4.1
Description
The pressure regulating valve is installed at the lube oil pump and adjusts the
pressure of the lube oil coming to the engine diverting excess lube oil volume from
the charging side of the pump to the suction end.
The pipe (10) is connected to the lube oil distributing manifold where a continuous
pressure is maintained at a constant engine speed. This pressure actuates the
servopiston (9) and the force is exerted by the stem (6) to the regulating piston (14).
The spring (16) is loaded to equalize this force at a certain pressure. Thus, the
constant pressure is maintained in the charging end of the pump and pressure
differentials in the system are avoided. The increase of the spring (16) load results in
a higher lube oil pressure.
In variable speed engines, the valve is designed in such a way that depending upon
engine speed the valve creates the lube oil pressure within the operating limits
recommended for various RPM values (section 01).
If due to certain circumstances, the pressure at the charging end increases suddenly,
for example, due to system clogging, the ball valve (12) opens and assures the lube
oil overflow to the servopiston (9) which with its stem (6) shifts the piston (14). In this
situation the valve acts as a safety valve.
18.4.2
Maintenance
a.
Dismantle all movable parts.

worn or damaged parts as required.
Check
their
wear
and
replace
b.
Clean thoroughly the valve. Make sure that the drain hole (13) is not clogged.
c.
Make sure that the parts are not stuck.
d.
During reinstating copper sealing rings (8) and (11), do not forget to put
them back to their original places. When replacing with new ones, make
sure that their thickness stays within the recommended limits (rings (8) = 2
mm, rings (11) = 1.5 mm) as their thickness affects the valve operation.
e.
After having assembled, make sure that the piston (14) covers the overflow
hole (especially when any parts were replaced).
271
18.5
Lube oil cooler

18.5.1
Description
The pipe bundle (2) is inserted into the casing (3). The bundle is fixed with one end
and the other end is mobile in longitudinal direction allowing expansion. The mobile
end is equipped with two seal O-rings (5) with drain holes (6) between them
indicating leaks and also warning about lube oil being mixed with water.
The lube oil flows from the outside and is directed by diaphragms (4) to create an
appropriate direction and the flow speed.
18.5.2
General maintenance
a.
Clean and test the lube oil cooler hydraulically as per the schedule specified in
section 04 or when a significant temperature increase of the lube oil is
detected.
b.
The water side may be cleaned with removing body cover without the removal
of the cooler itself from the engine. For more thorough cleaning, it is necessary
to remove the cooler (See sub-sections 3 and 4).
c.
When cleaning, always make sure that the cooler if free of corrosion and carry
out the hydraulic test.
d.
It is better to replace the pipe bundle slightly earlier than later. The lube oil
contamination with water results in serious consequences.
e.
Make sure that the drain holes (6) are not clogged.
f.
Make sure that the bolt (8) is installed at the appropriate place. This bolt retains
the pipe bundle in the correct position.
g.
Put the sealing compound onto the sealing surface between the distribution
wall of the body and the butt end cover of the pipe bundle.
18.5.3
Cleaning lube oil end
Dirtying of the lube oil end is usually insignificant. But the dirt from the other end may
very seriously affect the cooling capacity of the lube oil cooler.
272
Due to its design, the outer surface of the pipe bundle cannot be mechanically
cleaned.
Minor dirtying may be removed with steam cleaning of the pipe bundle.
In order to remove significant dirtying, it is necessary to chemical detergents
available at the market:
alkaline degreasers
suitable for normal degreasing but not effective when significant depositions of
grease, mud or coke are present. They require high temperature. It is
necessary to add slowly the degreasing agent in the hot water and never vice
versa. Always after degreasing, rinse thoroughly the lube oil end with the
water.
-
hydrocarbon solvents
There is a wide range from light petroleum products to chlorinated
hydrocarbons, for example, trichloroethylene. They must be handled carefully
as they are normally very volatile, harmful and/or poisonous.
dissolving emulsions
significant dirtying, for example, grease carbon deposition may often be
dissolved with these emulsions only. There are a lot of emulsion brands
available at the market now.
In order to achieve the best results, it is necessary to follow the instructions of

manufacturers of these emulsions.
18.5.4
Cleaning water end
The cleaning must be carried out either without damaging protective layer inside the
tubes or with the complete removal of this layer. Incomplete removal of this layer or
its damage increases the possibility of corrosion.
Remove friable deposits and mud with the brush 845004. Rinse with the water. The
cleaning may be done faster if the brush is connected to a hand drill.
If the protection layer is damaged it is recommended to remove it completely.
If the depositions within the pipes are hard (for example, calcium carbonate) they
may be removed with chemicals with some any suitable product available at the
market. (See section 19.). After cleaning with these agents, the pipes must be rinsed
and flushed if required with a solution that neutralizes the residuals of the cleaning
agent. For the rest, it is necessary to follow thoroughly the manufacturer instructions.
273
18.6
Thermostatic valve
18.6.1
Description
Picture on page 18-53 shows the valve in the closed position. When the temperature
exceeds the rated value, the sensing element (9) expends and shifts the valve (10)
towards the seat (11) passing part of the lube oil through the cooler. Such motion
continues until a predetermined temperature is reached. Due to the cooler
contamination, the temperature increases several degrees which is absolutely normal
as for a certain valve opening allowing lube oil flow increasing at the cooler it is
required to have some temperature increase.
18.6.2
Maintenance
Usually, no maintenance is required for the lube oil cooler. The reason of an
excessive lube oil temperature decrease is a defect of the thermostatic valve failure
and an excessive lube oil temperature increase may be caused by the thermostatic
valve failure but in most cases the lube oil temperature increase is a result of the lube
oil cooler contamination.
Disconnect the pipe situated behind the valve and open the valve cover and the
sensor elements then.
Check the sensor element preheating slowly in water. Pay attention to the
temperature at which the valve starts opening and at which it is completely open. The
appropriate figures are given in section 01. The smallest temperature value is the
opening temperature and the biggest temperature is the temperature when the valve
is completely open.
Replace the faulty sensor elements. Check the condition of the seal O-rings and if
required replace them.
18.7
Main lube oil filter

18.7.1
Description
This sub-section describes the main lube oil filter of a single-row engine. V-shape
engines are equipped with two filters connected in parallel.
The main lube oil filter is a duplex full-flow filter that is the lube oil flow passes
through the filter. The flow may be regulated with the three-way valve (9) through one
or the other block or through both blocks in parallel. The flow direction is marked at
the end of the three-way valve plug. Usually, both filter blocks (for V-shape engines,
both blocks of both filters) must be switched on for a better lube oil filtration. The
Picture C on page 18-54 shows the valve (9) at this position.
274
If a filter element insert is to be replaced while running, one block may be temporary
switched off, for example, closing right block as shown on the Picture D on page 1854.
The flow direction through the filter is indicated with the arrows at this picture. At first,
the lube oil, goes through the filter (2) made of a special paper with a rated filtration
capacity of 10 - 15 mcm, then through the filter (3) consisting of a perforated cylinder
wrapped with a corrugated meshed textile fabrics. The meshed textile with the mesh
size 60 mcm serves as a safety filter in case of defects of the paper filter element
insert or in case if unfiltered lube oil bypasses it.
The filters are equipped with the bypass valve (7) for by-passing paper inserts. This
valve opens when the pressure differential exceeds 2-3 bars.
The filter is equipped with a combination visual indicating/electric transducer
connected to the automatic engine alarm system that send an excessive pressure
differential in the filter warning that it is necessary to replace the paper filter element
packing shortly.
18.7.2
Replacing filter elements and cleaning filter
A proper maintenance of the filter reduces the engine wear. The inserts must be
periodically replaced (See section 04.) as soon as possible since the excessive
pressure differential warning signal coming up.
As the service life of the filter element inserts depends significantly upon the quality
of the fuel oil, operation loads, quality of the lube oil, purification and maintenance of
the centrifugal pump, the experience of running a given engine allows identifying the
optimum periods between the replacements of the inserts.
The replacement of the filter element inserts and filter cleaning are recommended to
be carried out when the engine is shut down. Nevertheless, switching off one of the
filters, it is possible to replace the filter element inserts while running engine as well.
This increases the load on other filter element inserts. That is why the insert
replacement must be carried out as quick as possible.
a.
Close the filter in which the insert must be replaced.
b.
Remove the protection cover from V-shape engines.
c.
Undo the air outlet screw (1) approximately two turns.
d.
Open the plug (8) and drain the lube oil.
e.
Open the plug (13) and drain the lube oil. For the single-row engines, open the
cover (12).
275
f.
Open the filter cover.
g.
Remove the meshed textile insert. Flush it with the petroleum gas oil. Check it
integrity.
h.
Replace the paper inserts. The paper inserts are expendable. It is necessary
to have always a sufficient number of spare inserts.
i.
Clean thoroughly and rinse the filter body in the petroleum gas oil.
j.
Install new paper insert and cleaned meshed textile inserts. Check the proper
position and that all seals are intact.
k.
Make sure that the guide (4) seats at the correct position.
l.
Install the plugs and the cover. Tighten up the air outlet screw.
m.
Put the three-way valve to the operational position (See Picture on page 1854).
18.8
Centrifugal filter
18.8.1
Description
In addition to the main filter, there is a bypass centrifugal-type filter. The V-shape
engines are equipped with two similar filters.
The filter consists of the body (13) including the steel stem (3) on which the
dynamically stabilized rotor (5) rotates. The lube oil passes through the body and
going along the stem enter the rotor.
The rotor consists of two cavities: cleaning and driving. The lube oil exits the central
pipe (6) to the upper part of the rotor where it is subjected to a high centrifugal force
and the dirt stays of the wall of the rotor as a thick sedimentation.
Then, this lube oil goes from the cleaning cavity into the separation cone (9) after
which it passes to the driving cavity having two drive nozzles (12). The flow of the
pure lube oil passing through nozzle creates the rotational moment and the lube oil
goes back into the engine crankcase through the filter body. The filter is equipped
with the shutoff valve (15) opening at 2.5 bars.
276
18.8.2
Cleaning
Periodical filter cleaning is very important (See section 04) as the filter accumulates a
huge volume of dirt thus facilitating the operation of the main filter and extending the
service life if the paper filer element inserts. When a dirt accumulation is detected in
its maximum allowed volume (approximately 3.7 kg) within the recommended time
frames between cleaning, the filter must be cleaned even more frequently.
The filter may be cleaned with the running engine after having closed valve at the
distribution manifold before the filter as follows:
a.
Undo
the
pressure
disc
nut
(11)
undo the nut (1) and remove the filter cap (4).
b.
Remove the rotor from the stem (3) and drain the lube oil through the nozzle
prior to taking rotor out from the filter body. Keeping rotor body at its place,
undo the nut (2) retaining rotor cap and then detach the rotor cap from the
body.
c.
Remove the retaining ring (8) and the separation cone (9).
d.
Remove the dirt from the inner surface of the rotor cap and body with a
wooden putty knife or a piece of wood having suitable shape and then clean.
e.
Clean the separation cone (9).
f.
Flush all parts, for example, with the petroleum gas oil.
g.
Clean the nozzles with a brass wire and compressed air. Check the upper and
lower bearings of the rotating pipe elements for any defects or excessive wear.
Make sure that the seal O-ring (7) is intact and replace it with a new one if
required.
h.
Put the rotor together. Make sure that the latch pins enter their slots and
tighten up the rotor cap retaining nut. Do not forget to install the seal O-ring (7)
as without this ring the rotor leaks causing misbalance and damage of the
filter.
i.
Check the working surfaces of the stem for damage or excessive wear. Make
sure that the seal O-ring (10) is intact. If required, replace it with a new one.
j.
Remove the shutoff valve plug (14) and the shutoff valve assembly. Make sure
that the spring and the stem are intact and mobile. If required, replace the
copper ring.
277
retaining
filter
cap,
k.
Put the filter together, making sure that the rotor moves freely, then put back
the filter cap. Tighten up the filter cap retaining nut and lock the pressure disc.
18.9
Lube oil precharge pump

18.9.1.
Description
The lube oil precharge pump is a screw-type pump and driven by an electric motor.
The pump is equipped with the pressure regulation valve (15). The pressure must be
set at the minimum value (approximately 2 bars) with unscrewing the regulating
screw (14) to the extreme position in order to prevent overloading electric motor at
the very cold lube oil.
The shaft is sealed with the contact rings which flat surfaces pressed very tight
against each other. One contact ring (8) rotates along with the shaft and another one
(6) is immobile.
18.9.2
General maintenance
Usually, the lube oil precharge pump does not require the periodical preventive
maintenance.
After 3 - 6 years of operation, the shaft sealing may require a replacement due to its
age. The lube oil coming out the hole (5) indicates that the seal is damaged and has
to be replaced.
Be especially careful with avoiding damaging sealing surfaces as any minor scratch
may affect the sealing capacity. The rotating corner ring (8) is very sensitive and it is
necessary to avoid touching sealing surfaces with your fingers.
18.9.3
Dismantling
a.
Undo the pipes and nuts (9) retaining the pump and remove the pump.
b.
Discard the collar half (1) of the shaft.
c.
Remove the upper part (10) of the pump body with the drive screw (2) and the
shaft seal. Put the bodys upper part onto two blocks in such a way that the
shaft journal could be accessible from the top.
278
18-11
d.
Remove the retaining ring (3) of the drive shaft. Knock the shaft journal several
times with a plastic hammer until the screw gets apart from the ball bearing.
Make sure that the screw does not fall onto the workbench and does not get
damaged.
e.
Remove sealing ring (8).
f.
Push the seals (13) out from the drive screw (2). The force required to push
the seals may be significant due to the rubber compensator.
g.
Knock out the immobile sealing ring (6) with a rubber seal O-ring from the
bodys upper part with the help of a chisel.
h.
In order to remove the ball bearing (4) from the bodys upper part, remove the
retaining ring at first.
Note! The ball bearing must be always cleaned in the pure petroleum gas oil. Clean
the bearing while cleaning part of the pump as the detergent may contain dirt
particles that could damage the bearing.
18.9.4.
Assembly
The assembly is carried out in the reverse order:

a.
Install the ball bearing in the upper part of the body with a protection washer
placed outward. Lock with the retaining ring.
b.
Lubricate the new seal O-ring (7). Install the immobile sealing ring (6) in the
upper part of the body. Make sure that the sealing surfaces are not damaged
and the pin (11) enters the rings hole.
c.
Clean thoroughly the driving screw and install the seals (13) except for the
corner ring on the shaft. Make sure that the rubber compensator is pressed
against the washer to hold the sealing spring. Keep the seal at this position for
some time in order to provide the retention of the compensator. Drop some
lube oil to facilitate the assembly of the driving screw.
d.
Put the corner ring back to its place in such a way that a smaller sealing
surface is faced upward and grooves match the marks.
e.
Install the upper part (10) of the pump body on the shaft journal of the driving
screw.
f.
Push the inner race of the ball bearing onto the shoulder of the driving pin. Use
a bushing of suitable for the bearing inner race.
279
g.
Lock with the retaining ring (3).
h.
Install the bodys upper part with the screw in the pump body. Do not forget to
install the seal O-ring (12) between the upper part and the body of the pump.
Fill the ball bearing with the grease.
i.
Install the collar half (1) onto the pump shaft and fix the arms. Make sure that
the air gap between collar halves (size as on Picture on page 18-56) is 2 mm.
j.
If the electric motor was switched off or replaced, make sure that it rotates in
the correct direction starting it several times.
280
18-51
281
18-52
282
18-53
283
18-54
284
285
286
JSC IMO - INDUSTRY
IMO LUBE OIL PUMPS OF SERIES
Picture 1. IMO pump ACE series
INSTALLATION AND MAINTENANCE

DESIGN FEATURES AND MODE OF ACTION
The working elements of the pump made by IMO-Industry are three IMO screws and
the body inside which the screws rotate. The threaded surfaces are designed in such
a way that they create tight seals against each other and against the pump body.
When the screws rotate, these seals shift along the axis charging liquid trapped
between them thus creating pumping action. Principle of operation is based on the
fact that the mobile parts are lubricated with the pumped liquid. That is why IMO
pumps are used both for lube oil and for other liquids with the similar lubrication
capacity. The liquids with poor lubrication capacity or contaminated liquids causing
corrosion and chemically aggressive liquids may result in wear and be not suitable for
these pumps. The design of the pump is shown on Picture 4 on page 7. The pump is
designed for a single rotation direction and a single pumping direction. This
information is given at the dimensional drawings and on the pumps themselves.
Pressure relief valve

In order to establish a certain lift height during the operation of the pump, it is
equipped with an integrated adjustable pressure relief valve. This valve is spring
loaded and when a predetermined pressure differential is attained the valve opens
the inner accessway from the charging end to the suction end of the pump. Due to
this, a part of the flow may return (flow back) to the entrance. Thus, the valve
operates in one direction only. Please, contact our sales offices with regards to
issues related to pressure settings in hydraulic systems.
287
Shaft sealing
Shaft sealing consists of mechanical seal created with two flat surfaces contacting
one to another. One of them rotates together with the shaft and another one is
immobile. The sealing surfaces are lubricated with the pumped liquid and the contact
pressure is maintained with the help of a spring. The tightness of the seals depends
upon the cleanliness and the quality of the surfaces.
Liquids
IMO pumps work effectively with light and heavy lube oils as well as the liquids
having similar lubricating properties. These pumps are self-suction and may operate
with very high suction heights. The coagulated lube oils or petroleum fuels with hard
paraffin sediments or other paraffin components may not be able to be pumped if the
pumps are not preheated. In exceptional cases when there is a doubt about the
assembly and a suitable way to install the pump, it is recommended to contact our
sales offices.
Standard materials and operational conditions for the series pumps
The pump body is made of cast iron and the screws are made of steel and cast iron.
The pump is coated with oilresistant paint. The shaft sealing contains parts made of
oilresistant rubber.
Max. working pressure:
Max. lube oil temperature:
16 kg/cm2 at 40 cst (5) in continuous mode

Type NC
= 90
Type NC/60
= 130
Operation specification, dimensions and other technical information may be found in

a booklet with the description of this series of the pumps.
Picture 2. The operational diagram of IMO pumps allows lube oil staying in the body by the end
of the pumping mode. This lube oil facilitates the next start-ups.
INSTALLATION
Protection covers
The pumps are supplied greased-up internally and with the protection covers at the
connection outlets. These covers must be removed as late as possible prior to the
installation and assembly.
288
Assembly
IMO pump screws operate independently from the position. The pump bodies are
manufactured with chambers or traps for liquids keeping lube oil in the pump by the
end of the pumping stage. This lube oil facilitates the next start-ups. If a pump is to
be installed in such a way that the lube oil may not be trapped in it, it is necessary to
install the pipeline in such a way that the pipeline together with the pump will create a
trap for the fluid.
Retaining
Pumps must always be installed at a solid foundation and allocated in such a way
that they are easy accessible for inspection and maintenance.
Piping connections
The pipelines must be connected in such a way that there are no stresses in the
pump body. The inlet and outlet ports are marked at the pump body. The shut-off
valves are installed at the pipelines usually before and after pumps. Back pressure
valves, if required to prevent back flowing are installed after the pumps (in the
charging line). The installation locations of pumps must be selected in such a way
that the lube oil leakage in case of a required disassembly of the pumps does not
cause a problem. It is recommended as well to install a drain line from the shaft seals
for draining leaking lube oil during operation.
Alignment
When connecting directly always use the flexible couplings of the shaft. A proper
alignment between the shaft and the pump and the drive shaft prevents noise and
wearing coupling as well as the undesired pressures in the bearings.
Picture 3. The alignment is checked with the help of a ruler installed at the coupling.
With the help of a feeler gauge the distance between coupling halves is to be similar
along the whole circumference.
Lube oil filters
The pump suction must be set with the lube oil filter for protecting pump from
damaging with solid particles of the contamination. When pumping ordinary
289
petroleum fuel oils, it is recommended that the mesh size of the filter is to be
approximately 0,50,8 mm. Cleaning is facilitated with the installation of the shut-off
valves at the appropriate locations at the both sides of the filter.
Max. radial deflection :
= 0.1 mm
Axial air gap between coupling halves: = 23 mm
Pressure gauge
Setting pressure of the pressure relief valve is controlled with the help of pressure
gauge connected to the charging manifold. When charging hot petroleum fuel oils
(with the temperature exceeding 60) to the suction chamber of the pump, a
vacuum gauge facilitating the pressure control at the inlet is connected to the pipeline
as well. There is a threaded connection as well. See section Suction height".
Pressure test
The pipeline pressure test is to be performed prior the pumps are connected the
pump. The pumps were pressure tested before the delivery. If the pressure test of
the pipes must be performed after having hooked-up pumps, the lube oil must always
be used as an agent for the test as the water may cause the corrosion and thus
affecting pumps.
STARTING-UP
Prior to start up
After the installation or the re-assembly of the IMO pump, it must be thoroughly
topped up with the lube oil in such a way that even the sealing chamber is topped p
for sure. Only after that, it is allowed to start up the pump without a risk to run it dry
that may cause the damage to the rotating parts and seals of the shaft.
Rotation direction
When the pump is ready to be started-up, make sure that the drive engine rotates in
the proper direction as indicated at the pump with switching it on for a short time. If
due to any reason, it necessary to check the rotation direction before the pump is
topped up with the lube oil, the shaft coupling must be disconnected (remove the
contact elements). This prevents pump rotating when the engine is started up.
Start up
The start-up must always take place when the valves are completely opened at the
suction and charging pipelines.
The engine start-up is to be carried out carefully and at that the pressure relief valve
must be set approximately at the half of RPM value of its stem (when the stem
rotates clockwise the tension increases).
290
As the IMO pump is a self-suction pump it removes the air in the suction pipeline and
the noise indicates that the pump started to work. It is necessary to assure that the
air is removed without creating significant backpressure in the charging pipeline.
As soon as the pump starts running the pressure relief valve with the help of pressure
gauge must be set at the required pressure. This pressure setting must be
maintained all the time until the pump is running.
If the pump after the start-up does not run properly it must not run longer than half of
minute. New attempts to run the pump may be re-taken with the intervals about one
minute and together with these attempts it is necessary to increase the tension of the
pressure relief valve. If this does not help that means that something is faulty and the
fault must be found and eliminated prior to start up the pump. See section
Troubleshooting".
291
292
Spare parts
Pump part
Item
Q-ty
1020
112
202
1
1
1
Pump size and type

25-2 NC
32-2 NC
32-2 NC
NC/60
NC/60
NC/60
1)
08 126
08 128
08 130
Assembly only Assembly only Assembly only
122
124
1
1
07 745
02 695
07 857
02 696
07 746
02 697
401
5010
502
1
1
1
07 665
07 667
02 734
07 852
07 850
02 739
07 719
07 717
02 739
Seal O-ring
Retaining ring
Back cover (valve
cover)
Connection element
Shaft seal 50G-NC
Shaft seal 50G-NC/60
Rotating sealing ring
O-ring for 50G-NC
O-ring for 50G-NC/60
Other parts
Valve elements
O-ring gasket
Sealing washer
Pin
506
514
480
1
1
1
01 679
07 749
07 669
01 681
02 715
07 669
01 683
02 717
07 720
556
509
509
509A
511A
511A
1
1
07 735
2)
07 919
08 132
08 627
08 141
08 142
Assembly only
07 735
07 920
3)
08 133
08 628
08 143
08 144
Assembly only
07 723
07 921
08 134
08 629
08 145
08 146
Assembly only
605
607
613
1
1
1
01 667
01 100
02 727
01 667
01 100
02 727
07 748
07 858
02 728
Valve piston
Valve spring
Pipe connection
elements
Suction flange
assembly 64G
Connection element
only
Charging side flange
64G
Connection element
only
614
615
1
1
07 672
07 736
07 672
07 736
07 722
07 724
416
07 756
08 116
08 116
418
01 845
01 803
01 803
427
07 756
07 756
08 116
428
01 845
01 845
01 803
When ordering, specify:

Ordering examples:
Size & Type

1)
25-2 NC
2)
25-2 NC
3)
32-2 NC/60
Name
Rotary assembly
Working rotor
Cap
Idle rotor
Front bearing
Ball bearing
Retaining ring
Pump body
Pump body
Front cover
Pin
1
1
Name
Rotary assembly
Shaft seal 50G-NC
Shaft seal 50G-NC/60
293
P/N
08 126
07 719
08 133
Regulating capacity
If the pump supplies more lube oil than it is required the excess lube oil may be
returned to the suction end of the pump through the pressure relief valve. To do this,
the pressure relief valve is unloaded until it opens sufficiently enough.
The pressure relief valve may handle the whole lube oil flow in the pump without
harmful pressure increase. If the whole lube oil flow is directed through this valve the
lube oil is heated. It is necessary not to let a continuous run of the pump at
completely closed charging pipeline as this will result in excessively high lube oil
heating that may cause the aggravation of the lube oil quality and the damage of the
pump.
Capacity regulation must not be carried out with throttling in the suction pipeline.
Suction height
IMO pump has a very high suction capacity and at a normal operation it provides a
reliable throughoutput when installed at the units requiring significant suction height.
The necessary conditions are a properly selected suction pipeline size, full opening of
the installed valves and correct mesh size of the filter as well as their noncontamination. Also, it is very important that the pumps are tight as air intrusion is not
allowed.
Maintenance and handling
Being correctly installed and started up, the IMO pumps does not nearly require any
maintenance. If it is not dictated by any abnormal circumstances, their operation and
maintenance do not differ from the same of the other pumps
Nevertheless, the lube oil filters must be disassembled and cleaned periodically. The
schedule is established based on the experience of operating pumps. The
vacuumeter installed in the suction pipeline between the lube oil filter and the pump is
a very important indicator in this connection as its readings indicate the level of the
contamination. When cleaning lube oil filters, it is recommended as well to check the
pump operation, shaft couplings conditions as well as defect signs such as leakage,
incorrect pressure or abnormal sounds.
IMO pumps series ALD are equipped with journal bearings not requiring any
lubrication other than the one of the pumped liquid. IMO pumps series ALD are
equipped with thermally stabilized ball bearings with sealing discs serving as
lubricator. The ball bearings are filled with the grease when supplied by the
manufacturer but after the first start-up of the pump, the grease must be replaced
after one running hour (See grease gun item 473, Picture 4). The grease
replacement must be performed only in the operation mode.
Type NC
The pump model designed for the lube oil temperature up to 90 .
294
At the normal operation conditions i.e. at 60, the grease in the pump must be
replaced every 6 months. At higher temperatures, the intervals between greasing
must reduced in half per each 10 of the temperature increase. At 90, it is
recommended to grease up each month. It is recommended to use one of the
following brands of the grease:
British Petroleum Energies LS2"
Caltex Rigal Starfak Premium 2"
Esso Bikon 325"
Shell Alvania 3".
Type N0/60
This pump model is equipped with a shaft sealing made of Viton rubber designed for
the lube oil temperature exceeding 90.
It is recommended to use synthetic grease according to booklet TSP-5345 of SKF
company. The intervals between greasing are up to 6 months at 100 and to be
reduced in half per each 10 of the temperature increase. At 130 , it is necessary
to grease up every month.
Preventive maintenance
For the IMO pumps, the repair is not usually required. Being properly operated the
wear of the IMO screws is very small. Nevertheless, if lube oils or other fluids with
high abrasive properties are pumped, the preventive maintenance may be performed
in order to make sure that the worn parts are duly replaced. The intervals of this
maintenance are established based on the experience of operating pumps. The IMO
pumps with ball bearings must be inspected every 20,000 running hours, when it is
recommended to replace the ball bearings. Usually, the shaft seals must be replaced
due to aging approximately every 3 6 years.
Troubleshooting
In most cases, the following failures may be handled easily:
Incorrect rotation direction
In three-phase motors, it is necessary to change two connecting wires.
Too low lube oil output
Shutoff valves at suction or charging pipelines are not completely opened.
The pressure relief valve is set at too low pressure.
Clogged filter or other obstacles in the suction pipeline restrict the lube oil flow
in the pump.
Too low pressure
The backpressure in the charging pipeline is too low.
Pressure relief valve tension is not sufficient. (When two or more pumps run in
parallel, all pressure relief valves must be set at similar opening pressure).
The pressure relief valve got jammed.
The pump is worn.
295
Problems with starting driving motor or it has a trend to stop when the motor
overload safety device trips.
The backpressure is too high.
The lube oil is too cold and consequently has a viscosity higher than required.
If the pressure relief valve is set at low pressure, the power consumption for
actual pumping is reduced.
This reduces the load to the motor and thus it is possible to avoid motor
overloading due to the high-viscosity lube oil. When the lube oil temperature
comes to normal again and that is why it flows easier, the pressure relief valve
may be set back to normal pressure.
The motor power is insufficient for the conditions predominating in such cases.
Too low settings of the motor overload safety relay.

The pump runs with abnormal noise (cavitation noise).
The lube oil flow to the pump is insufficient.
The suction pipeline is too long or has a small diameter for a given lube oil
volumetric flow and viscosity.
Clogged lube oil filter or closed valve in the suction pipeline. Check with the
vacuumeter connected to the pump inlet.
Evaporation at the suction chamber of the pump when pumping petroleum fuel
oils with high temperature and too low pressure at the inlet.
Suction height is too big.
Air leakage in the suction pipeline. (NOTE! Sometimes, a too high wear of the
pump may become a reason of the abnormal noise).
Lube oil leakage through the shaft sealing
Sealing capacity reduces due to the incorrect contact between sealing

surfaces. The reason may be shaft bending due to the misalignment between
the pump and the motor, old rubber parts or damages to the sliding surfaces
due to contamination in the lube oil or running dry.
Wear and vibration in the shaft coupling
Incorrect alignment between the pump and the motor. (The lube oil on the
rubber parts of the coupling reduces the hardness and service life of the parts
and promotes their wear).
The pump may wear if it was used for an inappropriate fluid, for light or contaminated
lube oil or at excessively high working pressure. The lube oil temperature exceeding
90 may as well result in damaging pump, if it is specially modified for operations at
high temperature conditions.
If due to a serious wear, the pump must be overhauled, it is necessary to replace the
IMO screws and that part of the pump that serves as a bearing for these screws.
Shaft sealing
The sealing is of axial type in the IMO pump and designed to prevent fluid leakage
along the drive shaft of the pump. Seals are purposed for mineral lube oils and
similar fluids. In order to assure the wear resistance of the seals when running, they
must be lubricated with the pumped fluid. Consequently, a minor leakage may take
place and corresponding measures must be taken to accumulate this fluid.
296
Mechanical seals type 2/W (manufactured by Brein company See Picture 4 b).
The rotating seal (509) rests against the collar ring (112) at the working rotor (1020).
The seal (509) due to the traction of the rubber bellows (509) related to the shaft
rotates together with the working rotor. The rotating sealing ring (509) made of
carbon is pressed slightly with the spring to the immobile seat (511) in the front cover
(501) of the pump. The pin (502) prevents rotating seat together with the seat.
The bellows (509) provide the sealing along the shaft and against the rear side if
the rotating sealing ring (509). The pressure of the rotating sealing ring (509) to
the immobile seat (511) creates a reliable sealing between contact surfaces of these
two components. The ring gasket (511) creates a sealing for the front cover (5010)
that is for the pump body.
Assembly/Disassembly
The dirt particles in the pumped liquid or inappropriate handling during the
disassembly and assembly may result in damaging contact sealing surfaces. That is
why jobs on disassembly and followed by the assembly of the seals must carried out
in the conditions of extreme cleanliness and carefulness and all endeavors must be
taken to avoid contacting sealing surfaces with the fingers. The carbon ring must be
handled with care and it is important not to touch them with the grease.
When doing maintenance if the shaft sealing or when replacing it, it is necessary to
take the following measures using the below-mentioned tools and materials:
Bearing installation tool, tubular tool for the installation of the ball bearings in
the following pumps:
Setting screw with threaded neck complete with a nut and a washer for the
installation of the ball bearing:
5 x 45 for the pump size 25-2,
8 x 50 for the pump sizes 32-2 and 38-2.
Nut wrench and screwdriver
Plastic hammer
Retaining ring pliers (for inner and outer rings)
Light lube oil and grease

Tool size
Pump type
Max. outer
diameter
Min. inner
diameter
Length
25-2 NC
27.0
17.5
45
32-2 NC
30.0
20.5
45
38-2 NC
35.0
25.5
50
297
Two wooden planks

Tanks for cleaning removed parts in kerosene, white spirit, etc. and for
accumulating waste oil.
Dismantling (See Section view, Picture 4a on page 7)
Remove the front cover (5010) of the pump together with the working rotor
(1020) and the shaft sealing. Put the cover on the wooden planks with the
shaft end facing upward.
Pull out the retaining ring (124). Knock slightly the shaft end with a plastic
hammer until the working rotor disconnects from the bearing (122).
Pull out the rotating sealing ring (509).
Push out the rotating seal (509) from the working rotor (1020). Due to the
presence of the rubber bellows (509), it is necessary to apply some force
while pushing out.
Knock slightly the immobile seat (511) with its O-ring gasket (511A) and knock
it out of the front cover (5010) with the help of screwdriver and hammer.
The ball bearing (122) is released when required with the removal of the
retaining ring (514).
NOTE! The ball bearing always must be rinsed in pure white spirit. Be very
careful while handling ball bearing as the contaminated thinner may contain
dirt particles that cause the contamination of the ball bearing race during
cleaning the parts of the pump.
Assembly
The assembly is carried out in the reverse order.
When the ball bearing (122) is released, it is necessary to install it into the
front cover (5010) turning the retaining ring with some grease outward. Lock
the retaining ring (514).
Whip the outer surface of the immobile seat with its -ring gasket (511/511 A)
with light lube oil and push the seat into the front cover. Check the contact
between the parts 502, 511.
Clean the working rotor shaft (1020) and whip the shaft with light lube oil (not
grease). Install the rotating seal (509) with the removed seal ring (509) onto
the rotor shaft.
Check that the bellows is pressed against the spring setting ring. Keep the
seal pressed in such position for a half of a minute until the bellows get at their
position.
Install the rotating sealing ring (509) in such a way that a smaller surface is
faced upwards and make sure that the grooves in the sealing rings are
situated in the same plane with the grooves the retaining bushing.
Install the front cover (5010) at the working rotor shafts end, put the bearing
retainer at the ball bearing race and install the setting screw into the central
hole of the shafts end.
Move the nut and the washer of the setting screw to put the ball bearing inner
race at the shaft. Lock the ball bearing at the working rotor with the retaining
ring (124).
298
Install the cover assembly complete with the rotor at the pump body (401) not
forgetting the O-ring gasket (506) providing sealing between body of the pump
and front cover. Fill the ball bearing with the grease. Prepare the pump for
testing. Later, follow the instructions specified in the section Start.
Maintenance
The seal is a self-adjusting sealing and does not require tightening-up later. This
series of the pumps has a threaded connection with a normal pipe thread Whithworth
3/8 (for shaft sealing). The drainage pipeline must be connected for the
accumulation of the lube oil being pressed out from sealing during operation. .
This drainage pipeline in case of pumping petroleum fuel oil must be short in order to
prevent clogging. If a major leakage takes place this is usually a sign of the wear that
may be result due to such causes as inappropriate start-up, dirty lube oil, poor
alignment or running without lube oil.
0610
JSC IMO - INDUSTRY
Address:
PO Box 42090, S-126 12 Stockholm 42, Sweden
Telegraph: Imoindustry
Telephone: 08-19 01 60
Teletype:
199 47 IMOPUMP-S
299
19.
19.1
Description and operation

The water cooling system has two loops and consists of high-temperature circulation
raw water system for cylinder and turbocharger cooling and low-temperature system
for heat exchangers cooling i.e. for air cooler, lube oil cooler and raw water circulation
cooler.
19.1.1
Raw water circulation system (high-temperature)
The engine must cooled with the raw water which must be treated according to the
recommendations specified in section 02, sub-section 02.3 to prevent corrosion and
deposition.
The raw water circulation pump (6) driven by the engine or independently charges
the water through the system. From the pump, the water comes to the distribution
channel molded together with the engine block of a single-row engine. In V-shape
engines, the water is distributed to the cylinder rows through the tube molded
together with the pump crankcase cover. The water while being distributing to the
cylinder cooling cavities through the space between the molded casing and the lower
part of the cover enters the cylinder head where the flow is directed by the diaphragm
and circulates along the fire bottom, passing along the valves and goes up along the
nozzles cooling intensively these components. From the cylinder heads, the water
flows through the tube to the manifolds.
A portion of water parallel to cooling cylinders goes as well to cooling turbines of the
turbocharger (2). From the manifold, the water flows to the raw water circulation
cooler (10) installed separately or erected at the foundation frame. Than, the water
flows back to raw water circulation pump. The thermostatic valve (9) maintains the
water temperature at the cooler outlet and consequently at the engine inlet as
constant as possible (See section 18, sub-section 18.6 Thermostatic valve).
The expansion tank (1) must be connected to the system directly before the pump
(6). Also, there is a common pipe connection (16) which is designed to bleed off the
air from the manifolds and the turbocharger cooling system. The air outlet pipes must
be run with a raise to the expansion tank.
The temperature control may be carried out with a local temperature gauge at the
engine inlet and outlet as well as at the turbocharger outlet. The temperature
specified in section 01, sub-section 01.2 must not be exceeded.
300
One high temperature transducer (13) for the raw water circulation at the engine
outlet is connected to the automatic warning system and the other transducer (12) is
connected to the automatic shutdown system in case of a further temperature
increase (the settings are according to sub-section 01.2 of section 01). The pressure
gauge (14) at the instrumentation panel indicates the water pressure at the engine
inlet. The pressure depends upon engine speed. As an additional instrumentation, a
low pressure water transducer may be supplied. Such transducer is connected to the
automatic warning system (See section 23.).
In case if the water may freeze, it is necessary to drain the cooling water from all
cavities. Avoid replacing cooling water. It is recommended to save the drained water
and reuse it again.
Cleaning system see sub-section 19.2.
There is an option to connect a preheater. For preheating water, the system must be
is equipped with nonreturn valve to create the circulation of the preheated water
through the engine.
19.1.2
Low-temperature system
Low-temperature cooling system is basically provided in two different ways: directly

with sea water or with raw water cooling system which is cooled with a centralized
cooler as well.
The air cooler (4) and lube oil cooler (11) which are usually installed at the engine are
connected in series and in case if the raw water circulation cooler (10) is installed at
the engine, it is connected in series after the afore-mentioned coolers. In V-shape
engine having two air coolers, the cooling water passes through both parallel air
coolers at first and then this water comes to the lube oil cooler.
The pressure gauge at the instrumentation panel indicates the water pressure at the
engine inlet. The local temperature gauges indicate the temperature at the inlets of
each cooler and at their outlets.
19.1.2.1 Sea water cooling

All pipes are manufactured of a special brass, the valves and cooler body covers are
made of bronze, the pipe bundles are made of copper-nickel alloy.
The pump may be driven by the engine or have an independent drive. The engine
driven sea water pump design-wise is similar to the engine driven raw water pump
but all its parts contacting sea water must be corrosion resistance (See sub-section
19.3).
301
The sea water system must be arranged in such a way that a portion of the warm
water is recirculated at the suction end of the pump to maintain the temperature at
approximately 25. The easiest way to achieve it is to install a thermostatic valve
(3).
The sea water pipe at the engine inlet must be is equipped with a mesh (7) having
mesh size 1.6 2.0 mm.
In case if the system was idle for a long time, in order to avoid deposition
accumulation, it is recommended to damp the sea water from the coolers.
Cleaning system see sub-section 19.2.
19.1.2.2 Raw water cooling (centralized cooling)

All pipes are steel and the tube bundles of the coolers are made of a special brass
alloy.
The pump may be driven by the engine or have an independent drive. The engine
driven raw water pump design-wise is similar to the engine driven raw water
circulation pump (See sub-section 19.3).
19.2
Cleaning water cavities
In completely closed system, a minor contamination takes place if the cooling water
is treated according to our instructions in section 02, sub-section 02.3. Depending
upon the cooling water quality as well as upon the treatment efficiency, the level of
the contamination of the cooling water cavities differs a lot. Especially quickly, the
contamination may take place in the coolers supplied directly with the sea water. The
depositions in the liners and cylinder heads as well as in the tube bundles must be
removed as they may affect the thermal exchange with the cooling water and thus
result in serious damage.
The necessity to clean must be studied especially during the first year of the
operation with pushing out one cylinder and inspecting both liner and cylinder head
for dirt and depositions. The cooling cavities of the cylinder heads may be inspected
with unscrewing lower big plugs from the cylinder head side. The turbochargers may
be inspected through cooling cavity hatches and the coolers may be checked with
removing body covers from the water inlet side.
The nature and composition of the depositions may be very heterogeneous. They
may be basically removed with a mechanical and/or chemical method as described
below. More detailed instructions on cleaning coolers see in section 18, sub-section
18.5.
302
a.
Mechanical cleaning
Most of the depositions consist of sediments and solid particles that can be removed
with a brush and flushing water.
In easy accessible places, for example, in cylinder liners, solid depositions are
effectively removed with mechanical cleaning.
In certain cases, it is recommended to combine chemical and mechanical cleaning as
sometimes only a partial solution of the depositions happens during the chemical
cleaning.
b. Chemical cleaning
The chemical cleaning is used for the water cavities that are difficult to access (for
example, cylinder heads or coolers). Sometime, if the depositions contain grease, it is
necessary to degrease the water cavities (See section 18, sub-section 18.5).
The chemical treatment using acid solution removes easily depositions consisting of
calcium carbonate. The depositions containing calcium sulfate or silicates may be
hardly removed with the chemical method. Nevertheless, the treatment may create
some thinning effect which if the access is easy may facilitate the removal with the
help of a brush.
There are a lot of suitable products based on acid solutions that are available at the
market. (See examples in section 02, sub-section 02.3).
It is recommended that the cleaning agents have the additives (inhibitors) preventing
corrosion of the metal surfaces.
In order to achieve the best results, the recommendations of manufacturers must be
always followed.
After treatment, flush thoroughly the system to remove the residuals of the cleaning
agent. If it is possible, use a brush as well to clean surfaces. Flush with the water
again and with 5 % natrium carbonate solution to neutralize the acid residuals.
19.3
Water pump
19.3.1
Description
The water pump is a centrifugal type pump driven by a tooth gear from the side
opposite to the drive end. The shaft is made of acid-resistant steel; the impeller (2)
and the sealing ring (3) are bronze and the other parts are made of the cast iron.
303
The shaft is installed on two ball bearings (11) and (12) lubricated with the lube oil
spray coming through the port (20). The radial seal (13) prevents the lube oil leakage
and the dirt intrusion and potential water penetrating inside. This is provided as well
with the axial seal (14) with the help of which the outer side of the seal (13) is sealed.
The pinion gear (24) is connected to the shaft with the help of tapered rings (25).
When making-up bolts (21), the rings create a pressure between the pinion gear and
the shaft. Due to the traction, the force is transmitted from the pinion gear to the shaft
of the pump.
The water end of the pump is equipped with a contact sealing ring. The ring (8)
rotates with the shaft sealing with the rubber seal O-ring (7). The spring (5) presses
the rotating ring to the immobile ring (9) sealed against the body with the rubber seal
O-ring (10). The potential water intrusions at the seal may be diverted through the
hole (15).
19.3.2
Maintenance
It is necessary to check the condition of the pump within the timeframes as

recommended in section 04 or immediately in case if a water or lube oil leakage is
detected.
a.
Removal and installation of impeller
Remove the casing after having undone the nuts (17).
Remove the key and undo the nut (1).
Remove the impeller with the help of extractor for gear wheels 837012. See
Picture on page 19-52.
When installing the impeller tighten the nut to the torque level specified in
section 07, sub-section 07.1, item 25.
Lock the nut with a stainless steel new cotter pin.
When installing the casing, make sure that it is intact and the seal O-ring (18)
is correctly positioned. Check that the casing is at the correct position. When
installing the pump at the engine, the port (20) must be faced upwards.
If the casing is incorrectly installed, the bearings (11) and (12) will not be lubricated.
Prior to install the pump at the engine, it is necessary to add the lube oil into the
body (20) of the pump, until the lube oil starts leaking through drain hole (25).
304
b. Dismantling and assembling contact seal ring

-
Remove the impeller according to item 2a.
Remove carefully all parts of the seal. Sealing rings are very easy to be
damaged.
Pay special attention to preventing damaging sealing surfaces as even a minor

scratch may affect the sealing capacity.
It is necessary to replace sealing completely if it leaks or if the sealing surfaces

are corroded, uneven or worn. Avoid touching sealing surfaces with your
fingers.
Bear in mind that the sealing capacity of the seals depends upon the rotation
direction due to self-locking pressure spring at the pump. For right-hand
engine the spring must be left wound (vise versa for the left-hand engine). A
loose spring may become a cause of unsynchronized rotation of the ring (8)
and the shaft resulting in the wear of the rubber seal O-ring and its gradually
leaking.
Assemble the parts of the contact sealing ring in a corresponding sequence

and then install the impeller according to item 2a. Do not forget to install the
thin washers (6) between the spring (5) and the ring (7).
c.
Bearing replacement
Remove the pump from the engine.
Remove the impeller and the contact sealing ring according to items 2a and
2b.
Remove the diaphragm (19) with undoing bolts (16).
Undo the bolts (21) and remove the cover (27).
Remove the pinion gear by-hand. If the pinion gear does not get loose hit it
several times with a hammer.
Using extractor may damage the shaft (causing axial scratches).
Remove the washer (23) and then remove the shaft with the bearing. At that,
the seal (14) will get loose as well.
Check the seals (13) and (14) as well as bearings for wear and damage. See
item 2d.
305
Remove the bearings.
Put the bearing (13) on along the inner race with the help of a suitable pipe.
Grease up the shoulder prior to install the bearing. See Picture on page 1953.
Check the shaft as according to picture on page 19-53.
Install the spacer and grease up the shoulder.
Put the bearing (11) on along the inner race with the help of a suitable pipe.
See Picture B on page 19-53.
Rotate the bearing housing as according to picture on page 19-53 and

lubricate the outer surfaces of the bearing. Press the shaft into the housing
along the inner and outer race of the bearing (11) with the help of a suitable
pipe.
Install the washer (23).

Before the installation of the pinion gear, all contact surfaces must be cleaned
and lubricated.
Install the tapered rings (25). See Picture on page 19-52.

The tapered rings must be easily lowered down to their place and do not jam.
Install the cover and the bolts.
Tighten up the bolts slightly and make sure that the pinion gear is at the
correct position.
Tighten up the bolts to the torque value as indicated in the item 23 A of subsection 07.1 of section 07.
Install the seals (13) and (14). See item 2d.

Install the diaphragm (19), the contact sealing ring, the impeller and the casing
according to items 2a and 2b.
d.
Replacing radial seal
The easiest to replace the radial seal is during the replacement of the bearing. If the
seal due to any reason leaks but the replacement of the bearings not required, it is
necessary to carry out the following:
Remove the casing and the contact sealing ring according to items 2a and 2b
as well the diaphragm (19).
306
Remove the seals (14) and (13) using the appropriate tools for cutting seals
but avoiding scratching shaft.
Check the shaft. If the shaft in the vicinity of the seals is worn more than
0.5mm in the radial direction, it must be replaced as according to item 2c.
Lubricate new seal and install it pressing it against the shoulder.
Lubricate the axial seal (14) with the grease and install it with the help of the
extractor for gear wheels 837012. See Picture on page 19-52.
Install the diaphragm, the contact sealing ring and the casing according to
items 2a and 2b.
19.4
Raw water circulation cooler
Raw water circulation cooler is basically similar to the lube oil cooler and the cooling
water side must be inspected and cleaned as according to sub-section 18.4 of
section 18.
The contamination of the tube bundle from outside where the circulation raw water
flows is not important in case if the water is thoroughly treated. In case of the
contamination, clean similar to cleaning general water system.
307
19-51
308
19-52
309
19-53
310
20.
20.1
Description (Picture on page 20 51)
The gas exhaust manifolds are molded of special the special cast iron with ball
graphite and have individual sections for each cylinder.
Steel multilayer expansion joints compensate the thermal expansion between the
cylinder heads and the manifolds as well as between the turbocharger and the
manifolds.
All connections between manifolds, expansion joints,
turbocharger are flanged and sealed with special steel rings.
cylinder
heads
and
The manifolds are supported and fixed with the bracket (5) but may move in the axial
direction in the support frame (3). The disk-type springs (2) provide the positive force
between the bracket and the manifold.
The whole system in enclosed in an insulated housing of the box shape made of
steel plates and elastically installed at the engine. The mineral wool is used for
insulation.
The temperature of the exhaust gas may be controlled with temperature gauges
installed at the outlets of each cylinder. There is an option to install the sensors for
remote gauging of the exhaust gas temperature (or for the engines automatic
warning system) at the outlet of each cylinder and at the inlet and the outlet of the
turbocharger.
20.2
Expansion joint replacement
a.
Remove the cover (4) of the isolated casing to access the expansion joint
between the exhaust gas manifolds and the cover.
b.
Remove the covers (6) for accessing expansion joint between the manifolds
and the turbocharger.
c.
In order to avoid the influence of the transversal forces to the expansion joints,
make sure that the retaining flanges of the expansion joints to the exhaust gas
manifolds are parallel and aligned.
20.3
Isolated casing suspension
The isolated casing is installed on elastic shock absorbers (1) protecting it against
vibration and thus safeguarding isolation. Replace the shock absorbers if required.
311
20.4
Exhaust gas temperature deviation by cylinders in engine types "Wartsila"

Vasa 8R22 and 16V22
The exhaust gas manifolds are designed based on the principle of the pulse purging
with two pulse manifolds for each turbocharger. The pulse manifolds supply the
exhaust gas to the turbocharger through two gas outlets. The exhaust gas manifolds
are shown at the page 20-52. The engine type 16V22 is equipped with two similar
manifolds. This system of turbo charging provides the best aggregate efficiency of
the engine. The exhaust gas temperature of two cylinders the closest to the
turbocharger is higher due to the gas pulses from the other cylinders connected to
the same gas outlet. The picture on page 20-53 shows a typical deviation of the
exhaust gas temperature by cylinders of a right-hand engine. The temperature
deviation by cylinders depends upon the engine speed and load.
Based on the experimental and theoretical study, we found out that the thermal load,
for example, of the cylinder outlet valves where the high temperature of the exhaust
gas is recorded does not exceed the thermal load of the other cylinder valves (See
page 20-54).
When assessing the operation of a cylinder based on the exhaust gas temperature at
the normal operating conditions, it is necessary to use for the reference the
parameters recorded in the factory test certificate. The deviation up to 50 from the
specified values is allowed if the environmental conditions and the fuel oil quality
correspond to the ones listed in the factory test certificate.
The temperature deviation by cylinders cannot be balanced with adjusting high
pressure fuel pump fuel racks positions. This causes the uneven load distribution by
cylinders. The fuel oil rack deviation by cylinders must not exceed 1 mm.
312
20-51
313
314
315
316
21.
STARTING AIR SYSTEM
21.1
Description
21.1 Description (Picture, page 21-51)

The engine is started with compressed air with maximum pressure not more than 30
bars. The Minimum pressure for the start-up is approximately 11 bars depending on
the number of cylinders and the power plant type. The air pressure before the main
starting valve is read out with the pressure gauge (15).
The inlet air pipe from the air cylinder to the engine is equipped with the nonreturn
valve (13) and the filter (20). The unloading valve (3) is before the main starting
valve. The control main starting valve may be performed either with the help of the
handle (1) at the manual start-up or with the help of the integrated solenoid valve (8)
at the remote or automatic start-up.
When the main starting valve opens one part of the starting air is supplied through
the flame arrestor (16) and the other part goes through the interlocking valve (23).
The interlocking valve does not let the control air when the hatch cover is opened for
the flywheel rotation.
The air distributor distribute the control air by the starting valves in such a way that
they open and let the starting air go to the cylinders during a certain preset time.
The four-cylinder engines are is equipped with a pneumatic starter rotating the
crankshaft with the ring gear at the flywheel until the engine reaches the RPM value
required for starting.
V-shape engines are equipped with starting valves in the row only.
21.2
Main starting valve (Picture, page 21-51)
21.2.1
Description
The engine starting air is supplied to the cavity (12) and to the backside of the valve
through valve ports (11). Due to this the piston is usually closed.
During the manual start-up, open the valve with bringing handle (1) down. At that, the
pin (3) shifts the valve (11) and the starting air enters the cavity (5) to which the
distribution pipe and the air distributor are connected.
During the remote or automatic start-up, the solenoid valve (8) opens the accessway
7) between the rear side of the valve (11) and the servopiston (6) which with the help
of the rod (2) and the pin (3) shifts the valve (11) to the left. The solenoid valve opens
receiving working pulse. When it closes, the air from the space behind the
servopiston (6) is released through the nozzle (9) and the starting valve closes.
317
21.2.2
Maintenance
Usually, the main starting valve requires low maintenance. If an inspection is

necessary, open the valve in the following sequence:
a.
Remove the valve from the engine after having removed the starting air pipe,
the pipe between the valve and the interlocking valve and the bracket with the
starting handle. In V-shape engines, uninstall as well the tubes connecting
pressure gauges from the instrumentation panel and remove the
instrumentation panel and the bracket complete with the starting handle. Then,
the valve may be uninstalled from the butt end cover.
b.
Open the plug (10) for inspection. Clean the valve (11) and its seat. Do not use
hard tools.
c.
Check the mobility of the pin (3) and the servopiston (6). The servopiston may
be removed undoing hexagonal head bolts retaining the cylinder.
If it is required, replace the seal O-rings
d.
Lubricate the parts before the assembly. Fill up the lubrication grooves of the
servopiston with "Molykote Paste G" compound.
e.
When installing, make sure that the seal O-rings are intact and correctly
positioned.
f.
Cover the contact surfaces of the rod (2) with "Molykote" compound.
The solenoid valve (8) does not basically require any maintenance. If the coil is
faulty, for example, due to the overvoltage, replace the coil. If the valve is suspected
to be dirty it may be carefully disassembled for cleaning. Make sure that the sealing
surfaces are intact. Put all parts together in the correct order. If the problems with the
valve still exist, replace it.
21.3
Air distributor (Picture, page 21-51)
21.3.1
Description
The air distributor is of the sliding valve type. The sliding valve of the air distributor is
governed by the cam (19) situated in the end of the camshaft. When the main starting
valve opens, the distribution sliding valve (17) sets against the cam and the cylinder
sliding valve being at the starting position opens the passage for the control air to the
working piston (22) of the starting valve. The starting valve opens the passage for the
compressed air to the engines working cylinder. This process repeats until the main
starting valve is open or until the engine attains the speed required for combustions
to take place.
318
When the main starting valve closes the pressure drops and the springs (18) push
the sliding valves from the cam. Thus, the contact of the sliding valves and the cam
and the subsequent wear take place only during the starting process.
21.3.2
Maintenance
Usually, the air distributor wears slightly. If it is required to open it for inspection and
cleaning, it is necessary to take the following measures:
a.
Do not allow damaging sliding surfaces of the sliding valves and their ports in
the body of the air distributor.
b.
Sliding valves are fit individually and not interchangeable. Use the cylinder
identification numbers stamped at the socket ends of the control air pipes.
c.
Before the assembly, lubricate the sliding surfaces of the sliding valves and fill
up the lubrication grooves with "Molykote Paste G" compound. Make sure that
the sliding valves do not get jammed.
d.
After the installation of the air distributor at the engine but prior to connect the
control air piping, make sure that all sliding valves work properly, for example,
connecting the compressed air hose to the starting air inlet in the air distributor
and rotating crankshaft. At that you may check if each sliding valve moves
when the cam shifts.
Warning: If during testing the control air pipes are connected the crankshaft
rotates.
21.4
Starting valve in cylinder head
21.4.1 Description
This valve is installed in an individual body and consists of a stem and a spring
loaded control piston. The valve may be replaced as an assembly.
21.4.2
Maintenance
Check and clean the valve if required with removing cylinder head.
a.
Remove the flange and pull out the valve.
b.
Undo the lock nut (21) and remove the piston (22).
319
c.
Check the sealing surfaces of the valve disk and the valve seat.
d.
After having assembled piston, stem and springs, check the free motion and
complete valve closing.
e.
While installing valve at the cylinder head, check if the sealing ring is intact
and correctly positioned.
d.
Tighten up the valve to the torque value specified in section 07, sub-section
07.1.
21.5
Air cylinder and pipelines
The starting air system must be designed to prevent explosions.

The supply pipe from the compressor to the air cylinder must have the lube oil and
water separators. A drain valve must be installed at the lowest point of the pipeline
system.
Prior to start, drain the condensate from the air cylinder through the drain valve.
The pipelines between the air cylinders and engines during their assembly and
installation must be thoroughly cleaned. Later, they must be always protected from
the dirt, lube oil and condensate.
The air cylinders must be inspected and cleaned within the timeframes specified in
section 04 with (if it is possible) inner coating with anti-corrosion agents. Enough time
must be let for their drying.
Simultaneously, the air cylinder valves must be inspected. The excessive torque of
the valves may result in damaging seats and air leakage. Leaking and worn valves
including the safety valve must be machined and worked over. The safety valves
must be pressure tested.
The filter (20) at the engine must be inspected and cleaned within the timeframes
specified in section 04. Drain the condensate from filter through the integrated drain
valve.
21.6
Starting air system with pneumatic starter
21.6.1
Description
In order to provide the automatic start-up regardless from the position of the
crankshaft the four-cylinder engines are equipped with a pneumatic starter rotating
320
crankshaft with the ring gear at the flywheel until the required engine RPM is
achieved. The starting air pressure is maximum 30 bars. Minimum pressure for the
start-up is approximately 15 bars but it may vary for different power plants.
The engine is equipped with an additional device preventing the unintended start-up
when the crankshaft rotates. The air is supplied through the interlocking valve
preventing the control air to pass when the hatch cover is open for the flywheel
rotation.
If the engine is started by-hand, the starting button must be released straight after the
engine start-up to avoid the excessive wear of the starter.
21.6.2
Maintenance
Periodically, it is necessary to check that the lube oil level is between the maximum
and minimum limits.
Use one of the following lube oil brands:
Gali HI 33 EP
Shell Turbo Z7
Castrol Huspin 80
BP Energoil HP 46
Mobil Detergent Light
If it is necessary, use the same lube oil as in the engines lube oil system.
321
21-51
322
22.
CONTROL GEAR
22.1
Description (Picture, page 22-51)
The engines speed is regulated during normal operation with the governor (18) that
adjusts the volume of the injected fuel oil according the load.
The regulating motion is transferred at first to the fuel supply regulating shaft (10)
through the elastic rod (16) allowing to transferring stopping or limiting action to the
fuel supply regulating shaft regardless the position of the governor. In V-shape
engines, the fuel supply regulating shafts of both cylinder rows are connected with
the rod for synchronization of their operation.
The motion from the fuel oil supply regulating shaft is transferred to the fuel oil racks
(1) of the high pressure fuel pump through regulating lever (4) and the spring (3)
pressing the pin (2) at the end of the fuel racks to the regulating lever. The rotating
spring (3) allows shifting fuel oil supply regulating shaft and consequently the other
fuel oil racks to the stop position even if one of the racks has got jammed.
Accordingly, the rotating spring (5) allows rotating fuel oil supply regulating shaft to
the fuel oil supply position even when one of the high pressure fuel pumps is jammed
at the zero supply position. This may be very important in emergency cases.
The engine may be shut down with the shutdown handle (6). When the shutdown
handle is put at the stop position, the lever (8) operates the lever (7) and the fuel oil
supply regulating shaft shifts to the stop position.
The engine is equipped with the independent limit switches: electro-pneumatic limit
switch tripping when the RPM exceeds the rated value by approximately 15% and a
mechanical limit switch tripping when the RPM exceeds the rated value by
approximately 18%. The electro-pneumatic limit switch puts the fuel rack of each high
pressure fuel pump to the stop position with the help of a pneumatic cylinder. The
pneumatic cylinder governs the fuel rack (1) and the mechanical limit switch governs
the lever (14) and puts the fuel oil supply regulating shaft to the stop position. Both
electro-pneumatic and mechanical limit switches may be controlled by-hand. See
sub-sections 22.5 and 22.6.
When starting up engine, the fuel oil supply limit switch limits automatically the
motion of the fuel oil supply regulating shaft to a certain degree. The pneumatic
cylinder limits the motion of the lever (11). See section 22, sub-section 22.7.
The load indicator (12) indicates the position of the high pressure fuel pump fuel
racks.
The RPM regulator is equipped with a switching solenoid valve with the help of which
the remote engine shutdown is available.
323
The solenoid valve is connected as well to the electro-pneumatic running-in

protection system and the remote engine shutdown system tripping at the minimum
lube oil pressure and the excessive raw water circulation temperature increase or at
any other condition requiring engine shutdown.
Next to the governor, there is a mechanical support through which, the lever (13)
governs directly the fuel oil supply regulating shaft.
22.2
Maintenance (Picture, page 22-51)
It is necessary to pay special attention to the operation of this system as its failure
may result in the engine running-in with the serious consequences or in the
engines failure to take the load.
a.
The system must operate at the minimum traction force. The fuel oil
racks, the bearing assemblies (including the self-lubricating bearings
(9)) and the ball hinges must be periodically cleaned and lubricated.
b.
The air gaps in the system must be minimal. Check the air gaps at all
connections. The aggregated free motion may not exceed 0.5 mm. This is
identified by the fuel racks of the high pressure fuel pump.
c.
It is necessary to check periodically (see the recommendations in section 04.)

the adjustment of the system: the stop position, the limit switches,
the fuel oil supply limitations when starting-up. See sub-section 22.3.
d.
When assembling the system, make sure that all parts are correctly installed,
the nuts are tighten properly with a recommended torque (if it is specified) and
that all retaining accessories: pins, rings, plates are installed properly. Check
as according to items a b.
22.3
Testing and adjustment (Picture, page 22-51)
22.3.1
Shutdown handle at the stop position
a.
-
Testing
Put the lever (17) of the governor to the maximum fuel oil supply position and
the shutdown handle (6) to the stop position.
Check that the fuel oil racks of all fuel oil pumps have a play not less than
5mm.
324
b.
Adjustment
Put the shutdown handle to the stop position and check that the required
contact of the lever (7) to the lever (3) is provided. With the help of the
governor it is possible to create a small torque which nevertheless must not be
very high as even a minor twist of the shaft is not allowed.
Adjust the positions of the high pressure fuel oil pump fuel oil racks to 4 mm
with the help of the setting screws (20).
22.3.2
Governor is at stop position
a.
Testing
Put the handle at the run position.
Put the governors lever at the stop position.
Check that the high pressure fuel pump fuel oil racks are set at 4 mm.
b.
Adjustment
If the position of the high pressure fuel pump fuel oil racks differs, carry out the
adjustment as according to item 1 b.
Adjust the elastic rod in such a way that the positions of the high pressure fuel
pump fuel oil racks are set at 4 mm.
Governor replacement. See sub-section 22.4.
22.3.3
Mechanical limit switch
Check the stop position
Put the shutdown handle at the run position and the governor lever to the
maximum fuel oil supply position.
Do the manual tripping of the limit switch.
Make sure that the high pressure fuel pump fuel oil racks are set at least at
5mm
325
b.
Adjusting stop position
At the stop position, the limit switch is set by the manufacturer and
interlocked according to the stop position of the shutdown handle. In case if
there is any misalignment, check the handle fixtures and wear.
c.
Checking and adjusting limit RPM values
See sub-section 22.5
22.3.4
Electro-pneumatic limit switch (Picture, page 22-53)
a.
Checking stop position
Put the shutdown handle at the run position and the governor lever to the
maximum fuel oil supply position.
Do the manual tripping of the limit switch.

-
Make sure that the high pressure fuel pump fuel oil racks positions are less
than 5 mm.
b.
Adjusting stop position
The electro-pneumatic limit switch does not require any adjustment.
If setting the fuel oil racks at the position lower than 5 mm is impossible, it is
necessary to check them for wear.
c.
Testing and adjusting RPM limit values
22.3.5
Starting fuel oil supply limit switch (Picture on page 22-54)
Checking limit position
Put the shutdown handle at the run position and the governor lever at
position maximum fuel oil supply.
Connect the compressed air to the tip (5), and then the cylinder (2) of the limit
switch will rotate the fuel oil supply regulating shaft to the limit position.
Check the positions of the fuel oil racks. The corresponding fuel oil supply
depends upon the engine purpose. Usually, the position is approximately
18mm.
326
Adjusting limit position
Connect the compressed air the tip (5).
Undo the retaining bolt (3) of the limit switch lever.
Turn the fuel oil supply regulating shaft to the position at which the fuel oil rack
setting corresponds to the recommended fuel oil supply value.
Turn the limit switch lever to the piston (1) of the limit switch. Tighten up the
retaining bolt in this position.
Check as according to item a.

.
Function test
b.
Load indicator
Make sure that the readings of the indicator correspond to the fuel rack position. In
case if an incompliance has been found, undo the retaining bolt and put the indicator
at an appropriate value.
22.4
RPM regulator (Picture, page 22-51)
22.4.1
General
The engine may be is equipped with the regulators of the various types depending
upon the purpose of an engine. See the instructions on the regulator at the end of
section 22.
22.4.2
Hydraulic regulator drive
The regulator is driven by an individual drive which at its turn is driven by the
camshaft with the help of the screw pinion gears. The regulator is fixed to the drive
and connected to the driving shaft with a slotted connection. Thus, there is a
possibility to install and uninstall the regulator complete with the drive or to replace
the regulator without dismantling drive.
The pressurized lube oil is supplied through the holes drilled in the bracket to
bearings and nozzles for toothed gear lubrication. The gear and the slotted
connection bushing are installed at the shaft under a pressure and fixed with springloaded retainers.
327
It is recommended inspecting periodically:

radial and axial air gaps in the bearings;
air gap between pinion gear teeth;
cleanliness of the lubrication ports and lube oil nozzles;
reliability of the fixation of the gear and the slotted connecting bushing to the
shaft.
Worn parts must be replaced.
22.4.3
Dismounting regulator
a.
Disconnect the regulator lever (17) and the regulators electrical cabling.
b.
Undo the bolts (19) and remove the regulator vertically upwards. Do not let the
regulator to fall or its placing at the driving shaft.
22.4.4
Mounting regulator
While mounting the same regulator, it is necessary to make sure that the mark at the
lever (17) corresponds to the mark at the shaft. Check the installation as according to
sub-section 22.3.
The sequence of the mounting is the following:
a.
Install the regulator at the drive.
b.
Turn the regulator lever to the stop position (counterclockwise from the drive
end).
c.
Put the regulator lever (17) as according to the following parameters (See
Picture on page 22-51):
UG8 single-row engine: at the horizontal direction
PG16 V-shape engine: 30 upwards at the horizontal plane.
d.
Lock the retaining bolt and mark the position of the regulator lever according to
the mark at the lever.
e.
Put the shutdown handle to the stop position. (Position of the fuel oil rack is
5mm).
328
f.
Adjust the length of the elastic rod in such a way that it enters the gap between
levers (17) and (15). Do not forget to lock the nuts.
g.
Check according to sub-section 22.3.
22.5
Mechanical limit switch (Picture, page 22-52)
22.5.1
Description
The mechanical limit switch is of the centrifugal type. It trips at the moment when the
engines RPM value exceeds the values specified in section 06, sub-section 06.1.
The tripping mechanism is connected directly to the butt end of the camshaft. When
the engines RPM increases the centrifugal force of the tripping mechanism increases
as well and when the predetermined tripping RPM values are achieved thus force
overcomes the one of the spring (1) and the weight (2) is moved aside making lock
(3) turn thus releasing stem (4) loaded with the working spring (5). V-shape engine is
equipped with two working springs. The force is transmitted to the fuel oil supply
regulating shaft with the help of the lever (6) and the jaw clutch of the he fuel oil
supply regulating shaft and bringing the last to the stop position.
There is an option to perform the manual tripping of the limit switch with the help of
the lever (7).
The next engine start-up is impossible until the lever (6) is not moved by-hand down
until the lever (3) catches the piston rod (4).
The supply package may include the sensor (8) warning about the limit switch
tripping.
22.5.2
Checking limit RPM values
The limit RPM values must be checked when the engine runs idle with increasing
speed above the rated value with a quick turn of the speed regulating handle.
Then, turn the handle approximately to the original position and return by-hand the
limit switch working spring to the original position with the help of the lever (6). Use a
steel bar or a steel pipe with the outside diameter not more than 22 mm, for example,
lever 22 x 550mm 844001.
The RPM value must not be increased by more than 60 rpm above the limit value.
329
The limit RPM must correspond to the values specified in section 06, sub-section
06.1.
When checking the RPM limit settings of the mechanical limit switch, it is
necessary to switch off the electro-pneumatic limit switch as it trips at lower RPM
values. Do not forget to switch it on back later.
22.5.3
Adjusting RPM limit values
a.
Remove the plug (9).
b.
Rotate the crankshaft until the regulating nut (14) is positioned straight against
the hole.
c.
If it is required to increase the RPM limit value the spring is to be pressed with
tightening nut and if it is required to reduce the RPM limit value the spring is to
be loosened with undoing nut.
d.
Make up the plug (9) and check the RPM limit values as according to item 2.
e.
If required, the spring may be replaced through the hole in the plug.
22.5.4
Maintenance
Uninstall the tripping mechanism undoing bolts (11).
Remove the stem (4) with the piston and the spring (5).
The spring (5) must be carefully removed. Use the tool 837015.
Check all mobile parts for wear and replace them with new one if required.
Make sure that the drain hole (12) is not clogged.
It is necessary to replace the self-locking nut (10) each time when it is found
that this nut got loose.
Tighten up the bolts (11) to the predetermined torque value while reassembling and lock them with the lock wire.
Tighten up the bolts (13) to the predetermined torque value.
330
Use the tool 837015 to reinstate the spring.
Check the RPM limit value as according to item 2.
22.6
Electro-pneumatic limit switch (Picture, page 22-53)
22.6.1
Description
The electro-pneumatic limit switch has the electric control. The starting air is used as
a working agent. The starting air pressure must not exceed 30 bars. See the RPM
limit values in section 06, sub-section 06.1.
The air connection socket is situated straight behind the nonreturn valve (1) in the
starting air pipe. The air is supplied through the second nonreturn valve (2)
preventing air leaking in case if the air pressure decreases due to one or the other
reason. For the same purpose, the system is equipped as well with separate air
tank (4) having the volume sufficient for the engine shutdown.
The three-way solenoid valve (5) receives the shutdown signal from the system of the
RPM electric measurement. Plus, the solenoid valve is connected to the safety
system.
When the solenoid valve opens, the air is supplied to the pneumatic cylinders for
each of the high pressure fuel pump. The Piston (7) of the pneumatic cylinders
actuates the pin (6) of the fuel oil rack and shifts it to the stop position.
The shutdown signal is usually on long enough until the complete shutdown of the
engine. When the pulse ends, the air is bled off through the three-way valve and the
piston returns to the extreme position by the fuel oil rack.
Also, there is an option to control the solenoid valve by-hand.
22.6.2
Testing and adjusting of the stop position
See sub-section 22.3, items 4 a and b.
22.6.3
Checking RPM limit values
The RPM limit values must be checked when the engine runs idle with increasing
speed above the rated value with the help of the RPM regulating handle. Turn the
handle approximately to the original position prior to restart the engine.
The RPM value must not be increased by more than 60 rpm above the limit value.
331
The RPM limit values must exceed the rated value by 15% (by 13% at 1200 rpm).
See section 06, sub-section 06.1.
22.6.4
Adjusting RPM limit values
The RPM limit values may be adjusted in the RPM electronic measurement box. See
the instructions on the RPM electronic measurement system in section 23.
22.6.5
Maintenance
a.
General
It is necessary to drain periodically the condensate through the drain valve

(83).
Check if the nonreturn valve (2) is tight. If it leaks, it is necessary to remove it

and check the condition of the sealing surfaces of the seal O-ring. Check the
unrestricted movement of the valve element.
b.
Three-way solenoid valve
If the solenoid valve is out of order, replace it.
If the sliding valve does not move, it is necessary to clean all ports. Check the
condition of the valve piston.
If there are air leakages through the valve to the pneumatic cylinders, it is
necessary to replace the sealing.
c.
Pneumatic cylinder
Check the pneumatic cylinders for wear.
Check the in the cylinder is tight. If it is required, replace the seals with new
ones. Do not allow the excessive deformation of the Teflon ring facilitating the
seal O-rings work.
Lubricate the seals and the piston.
Make sure that piston is not jammed.
332
22-11
22.7
Fuel oil supply limit switch for the start-up phase (Picture, page 22-54)
22.7.1
General
Always, during each start-up (automatic, remote or manual), the volume of the
injected fuel oil is automatically limited by the limit switch.
Always, when the engine does not work and when the electronic control system is
switched on, the three-way solenoid valve (6) is powered connecting the starting air
distribution pipe to the cylinder of the limit switch. The main starting valve that opens
when the engine is being started let the air go through the nonreturn valve (8) the
starting air distribution pipe to the cylinder of the limit switch and the piston (1) shifts
and limits the volume of the injected fuel with the lever (7) installed at the fuel oil
supply regulating shaft. When the engine reaches 100 rpm one of the relays in the
RPM measurement system switches off the solenoid valve (6). The switching-off is
delayed by 2 seconds so that the engine reaches the rated RPM before the fuel oil
supply limitation stops.
The air pressure is bled off through the nozzle (5). For main engines that are used at
the RPM value below the above-mentioned one, lower RPM values may be allowed.
22.7.2
Checking and adjusting the limitations.
See sub-section 22.3, items 5 and b.
22.7.3
Function test
a.
Check that the fuel oil injection limitation starts at the moment when the main
starting valve opens.
b.
Check that the predetermined fuel oil supply limitation is achieved when the
engine accelerates.
c.
The limitation stops at 100 rpm from the rated RPM value with a 2 seconds
dwell time. This may be checked with the method of the slow RPM increase
beyond the limitations with the slow rotation of the RPM regulating handle. For
main engines, it is allowed to have the shutdown RPM values that are below
the minimum operating RPM values.
22.7.4
.
Maintenance
If the limitation is gradually decreased before the three-way solenoid valve (6)
bleeds off the air pressure through the nozzle (5). The causes may be as
follows:
333
Leakage at the piston (1). Replace the sealing with a new one. Do not allow
the excessive deformation of the Teflon ring facilitating the seal O-rings work.
Add several drops of the lube oil at the piston prior to assemble.
The nonreturn valve (8) does not close. Uninstall and clean the valve. If
anyhow the valve is not tight, it is necessary to replace it with a new one.
The three-way valve is leaking.
b.
If the valve does not get excited or excites at a wrong time, check the condition
of the control relays. See the circuit diagram and manufacturers instructions in
section 23.
c.
If the limit switch does not work properly, check the coil (6). If the coil (6) is not
damaged, make sure that the piston does not get jammed in the cylinder (2),
three-way valve (4) or nonreturn valve (3).
d.
Normally, the three-way valve does not require any maintenance. If the coil is
out of order, for example, due to the overvoltage, replace
the coil. If it is suspected that the valve is clogged with the dirt, it may be
opened for inspection under the condition of operating very carefully.
Do not allow damaging sealing surfaces. Consider the correct order while
assembling. If there are still some malfunctions, it is necessary to replace the
valve.
e.
Check according to items 2 and 3.
334
22-51
335
22-52
336
22-53
337
22-54
338
23.
INSTRUMENTATION
23.1
Instruments installed at the engine

(Picture, page 23-51)
23.1.1
Instrumentation panel
The instrumentation panel is elastically suspended at three shock absorbers at the

side opposite to the drive end. The panel includes the following measuring devices:
-
Pressure gauges:
for starting air at the engine inlet

for fuel oil at the engine inlet
for lube oil at the engine inlet
for high-temperature water at the engine inlet
for low-temperature water the engine
for charging air
for lube oil of the nozzle temperature regulating system
(with a double indication)
Tachometer
Running hour counter
The tubes connecting the pressure gauges are equipped with valves allowing
replacing pressure gauges when the engine runs.
The instruments do not require any maintenance. The instruments having incorrect
indication must be repaired or replaced with new ones as soon as possible.
The rubber shock absorbers of the instrumentation panel must be inspected after a
long-term operation and replaced if required.
23.1.2
Temperature gauges
for exhaust gas at the outlets of each cylinder (18);

for lube oil at the inlet (20) of the lube oil cooler and at the outlet (22) of the
lube oil cooler;
for high-temperature water at the inlet (2) of the engine and at its outlet (24);
for high-temperature water at the outlet (25) of the turbocharger;
for charging air in the receiver (17);
for low-temperature water at the cooler inlet (11), in the cooler_(29) and at its
outlet (30);
for lube oil of the nozzle temperature regulating system at the inlet (9) of the
engine and at its outlet (8) 1);
for fuel oil at the engine inlet (28)
___________________________________________________________________
1)
339
The incorrectly indicating or broken temperature gauges must be replaced with new
ones as soon as possible.
23.1.3
Combination differential pressure gauges and transducers of the engine

automatic warning and alarm system
23.1.4
.
for maximum allowed pressure differential at the lube oil filter (19). The
transducer-indicator is installed at each lube oil filter.
for maximum allowed pressure differential at the fuel oil filter.
The transducer-indicator is installed close to the filter (14).
Discontinuous action transducers

Transducers of the engine automatic warning and alarm system
The standard system of transducers for the engine automatic warning and alarm
system includes the following components:
single-position transducers:
for high temperature of the purging air (3);
for low temperature of the lube oil at the inlet of the nozzle temperature
regulating system (16)2);
for high temperature of the lube oil at the outlet of the nozzle temperature
regulating system (15) 2);
for low pressure of the lube oil at the inlet of the engine (4);
for low pressure of the preliminary lubrication lube oil (6);
for low pressure of the fuel oil (9);
for low pressure of the lube oil in the nozzle temperature regulating system
(10) 2);
for low pressure of the high-temperature water (7) (only for main engines) ;
for low pressure of the low-temperature water (8) (only for main engines);
for pressure differential in the lube oil filter (19) ;
for pressure differential in the fuel oil filter (14) ;
for low level of the lube oil (27).
Double-position transducers;
for high temperature of the lube oil (28) ;
for high temperature of the high-temperature water (26) ;
___________________________________________________________________
2)
340
b.
Protection transducers
The standard protection system includes the following transducers:

for low pressure of the lube oil (5)
for high temperature of the cooling water (23)
c.
Indicating transducers
The standard system of transducers includes the following indicating transducers:

for indication of the mechanical limit switch tripping (21).
Additionally, the following transducers may be supplied as well:
for indication of the load value: one or two transducers.
Due to the further improvement of the engine design, the transducer package may
differ from the above-mentioned.
d.
Other transducers
The pressure transducer in connected to the charging air receiver to control the
cooling system depending on the operational load. 3)
e.
Controlling transducers
The original setting of all transducers was carried out by the manufacturer.
All transducers must be function tested within the timeframes recommended in
section 04. If it is suspected that a transducer is improperly set or damaged, it is
necessary to check it immediately and, if required, adjust or replace it with a new
one. The pressure and temperature transducers may be checked when the engine
runs.
Temperature transducers
The temperature transducers are installed at the special seats due to which it is very
easy to remove them for an inspection when the engine runs. The control is carried
out as follows: the sensing element is submerged into a fluid, for example, lube oil
which is slowly heated up. At that, it is identified at which temperature the
transducers microswitch trips. Bear in mind that the two-position transducers must
be inspected by both positions. The recommended temperature is specified in section
01 and it is usually stamped at the transducer until it is not set to any other
temperature. It is necessary to uninstall and clean as well the seats when the
systems are drained due to any reason.
___________________________________________________________________
3)
341
Pressure transducers
The pressure gauge at the instrumentation panel may be used for the control as
follows:
Close the ball valve at the common pipeline of the pressure gauge and the
pressure transducer.
-
Disconnect the transducer from the connection nipple undoing carefully the
connection nut in such a way that the transducer sends a signal.
The transducer warning about the preliminary lubrication pressure decrease is set to
tripping at the pressure increase thus the aforementioned control method does not
provide the correct value. Nevertheless, it is possible to carry out a rough test bearing
in mind that the pressure decrease transducer unlike the pressure increase provides
the value less than 0.2 bar.
All pressure transducers may be connected to a separate testing unit.
Pressure differential indicator
The lube oil transducer must be disconnected from the filter and the fuel oil
transducer must be disconnected from the pipelines.
In order to determine the pressure when the transducer emits the signal, it is
necessary to connect the maximum pressure regulating accessory and the pressure
gauge to the transducers nipple before the filter (to the side with a higher pressure).
The pressure is being built up until the differential pressure gauge at the end of the
transducer comes up completely. The pressure must be 1.5 0.3 bar.
Other microswitches
The microswitches may be easily inspected when the engine is not running, for
example, as follows:
Do the manual tripping of the mechanical limit switch (See section 22, subsection 22.5). This must activate the alarm system.
-
Turn the regulator shaft until the load indicating transducer is switched on.
Check to which load the reading received during the test corresponds to.
Never switch off any transducer of the engine automatic warning and alarm system
or the protection system.
When an incorrect tripping of any of the transducers took place, it is necessary to find
out the cause and take the troubleshooting measures as soon as possible.
342
23.1.5
Remote measurement transducers
The engine is usually supplied ready for connecting following transducers:

.
Temperature transducers
The interconnection contacts are situated (if otherwise not specified) next to the
corresponding temperature gauges:
-
for air in the purging air receiver

for lube oil at the inlet and the outlet of the lube oil cooler
for the high-temperature water at the inlet and the outlet of the engine
for low-temperature water at the inlet of the engine
for exhaust gas at the outlets of each cylinders individually
for exhaust gas at the inlet and the outlet of the turbocharger
b.
Pressure transducers
The interconnections are situated at the tubes connecting the corresponding

pressure gauges installed at the instrumentation panel:
-
for purging air

for lube oil at the inlet of the engine
for low-temperature water at the inlet of the engine
for fuel oil at the outlet from the filter
for lube oil of the nozzle temperature regulating system at the inlet of the
engine 4)
for starting air
c.
Other transducers
turbocharger RPM transducer

transducer of lube oil mist in the crankcase (one for each cylinder)
load indicating transducer
The specification of the instrumentation supplied together with the engine

documentation contains the information related to the transducer locations and types
and manufacturers data of the transducers.
___________________________________________________________________
4)
343
23.1.6 Equipment for RPM measurement including relay control

. General
The engine is equipped with the electronic remote system (without mechanical drive)
designed for the measurement of the RPM value including the control relay for the
automatic control system.
An induction transducer is installed close to the crankshaft pinion gear tooth and
sends the pulses that are proportional to the crankshaft rotation frequency. The
measurement transducer converts this signal to the direct current voltage
proportional to the engine RPM value. The measurement transformer box is included
in the engine delivery package and usually fixed to the bulkhead in the Engine Room.
Usually, there is a possibility to connect up to five additional remote measuring
devices.
In main engines, the turbocharger RPM measuring transducer is included in the
measurement equipment package.
b. Maintenance
The measuring devices and relays are thoroughly adjusted by the manufacturer and
it is recommended not to adjust if there are no significant deviations from the actual
values.
See item 5 in sub-section 22.3 of section 22 for the inspection of the fuel oil supply
limit relay during the engine start-up.
See item 3 in sub-section 22.6 of section 22 for the inspection of the limit switch
relay.
Damaged or faulty components must be replaced with new ones. See circuit
diagrams and instructions of the manufacturer.
The induction transducer must be set at 1.5 0.5 mm from the crankshaft pinion gear.
Check periodically the elastic fixture of the measurement transformer box.
344
23-51
345
DESPEMES
Diesel Engine Speed Measurement System
346
1.
INTRODUCTION
2.
OPERATIONAL PRINCIPALS
2.1 Engine speed
2.2 Relay functions
2.3 Turbocharger RPM
2.4
2.5 Additional relays
3.
PRINTED CIRCUIT BOARDS

3.1 Power supply
3.2 Diesel engine speed transformer
3.2.1 Operation
3.2.2 Adjustment
3.2.3 Technical specification
3.3 Relay card
3.3.1 Operation
3.3.2 Adjustment relay
3.4 Turbocharger speed transformer
3.4.1 Operation
3.4.2 Adjustment
3.5 Relay II
3.5.1 Operation
3.5.2 Adjustment
4.
ENGINE SPEED TRANSDUCER

4.1 Description
4.2 Transducer installation
5.
TURBOCHARGER SPEED TRANSDUCER

5.1 Description
5.2 Transducer installation
6.
TROUBLESHOOTING PROGRAM
6.1 Power supply unit
6.2 Main engine measuring transformer with relay functions
347
6.3
6.4
6.5
Printed circuit board for relay functions

Turbocharger measuring transformer
Main engine speed transducer
Appendix:
A:
Assembly drawing 3V72H83
B:
Circuit diagram
348
1.
INTRODUCTION
"Despemes" is an electronic engine speed measuring system including the following

functions:
engine speed measurement;
-
four speed depending relay functions;
one or two turbocharger speed measurement;
place for three additional relays.
349
2.
OPERATIONAL PRINCIPALS
2.1
Engine speed
The main engine speed is measured with the help of the remote inductive transducer
installed at the close vicinity of the pinion gear teeth. The frequency of the given
pulse transducer is converted with the help of frequency/voltage transformer to the
direct current voltage of 0 - 10 V according to the main engine speed. This voltage is
increased before it is supplied to the analogue signal devices.
The voltage signal is sent further to four free-regulated comparators adjusted in
within the range 0 - 100%. Then, the regulated dwell time may be provided for the
relay functions. The relays have two switching contacts with the breaking capacity of
110 VDC / 0.3 or 24 VDC / 1 .
The turbocharger speed is controlled with a magnetic transducer installed into the
butt end of the turbocharger shaft. The output sinusoidal signal is amplified and
converted with the help of frequency/voltage transformer to the direct current voltage
of 0 - 10 V.
The speed is detected out as well as a sequence pulses that may be taken, for
example, by a frequency meter, (Nevertheless, the frequency and the digital speed
value are not identical; the coefficient ratios are stamped at the printed circuit board).
Upon special order, we are able to provide three voltage control relays. These relays
may be controlled partially by the engine speed, an outer source of the direct current
voltage or by a potentiometer.
350
3.
PRINTED CIRCUIT BOARDS
The speed control system includes the following circuit boards:

a.
Power supply, DC/DC

24 VDC or 48 110 VDC
C1
b.
Diesel engine speed transformer with relay functions
c.
Relay I. Three relay functions governed by the diesel engine speed value with
the optional dwell time function
d.
Turbocharger. One or two turbocharger speed value transformers
e.
Relay II. Three relay functions governed by the diesel engine speed value with
the optional dwell time function
5
3.1
Power supply SPA - ZU
Inlet voltage:
Outlet voltage:
Outlet amperage:
Outlet pulsation:
Allowed ambient air temperature:
Short circuit strength:
Isolation voltage:
Fuse:
C4
18 40 VDC rectified or 40 160 VDC

12 V 0.3 V
350 mA
100 mV
25 . + 71O C
5 sec
2 kV, 50 Hz, 1 minute; 5 kV, 1.2 / sec
500 mA, 5 x 20 mm
351
The power supply unit is equipped with the protection against short circuits and
against the overheat as well as with a green light diode indicating that the voltage is
supplied.
3.2
Diesel engine speed transformer with a breaking function

2V72H114
3.2.1 Operation
The pulse transducer installed in close vicinity from the pinion gear teeth sends a
sequence of pulses with the frequency that corresponds to the diesel engine speed.
The frequency / voltage transformer emits the direct current voltage proportional to
the input voltage. This voltage is amplified and then it may be supplied to a separate
device indicating the diesel engine speed. The relay is governed by the same
voltage. The tripping point of the relay may be set within the range from 0 to 100%
RPM with an adjustable dwell time of the relay.
The diesel engine speed may be controlled as well as an output pulse connected in
parallel to the speed transducer.
The preliminary calibrated inner testing function may be used for the function test of
the printed circuit board.
352
3.2.2 Adjustment
Analogue testing measurement voltage 0 10 VDC.
If it is necessary to adjust (the precise calibration was carried out by the manufacturer
according to the parameters stamped at the label), the adjustment may be performed
with the help of the 501 potentiometer (the leftmost). The voltage is increased when
the potentiometer is turned clockwise and it is reduced when the potentiometer is
turned counterclockwise.
Tripping point relay and dwell time.
If the tripping point that was adjusted by the manufacturer must be changed it is
necessary to take the following measures:
a.
Identify the amplification of the diesel engine speed printed circuit board
nmax (RPM) = Umax [VDC]
b.
Calculate the output voltage corresponding to the required speed value for the
relay activation:
n x [RPM ]
Ux [VDC] =
x Umax [rpm]
n max [RPM ]
c.
Adjust with the help of 502 potentiometer until reaching voltage of the
calculated value at the test point 4.
Example: VASA 32: The required diesel engine speed during the tripping:
620 rpm
a.
1000 rpm = 10 VDC
620[ RPM ]
b.
U620 =
x 10 VDC = 6.2 V
1000[RPM ]
c.
The voltage in 4 is adjusted up to 6.2 V.
The dwell time of the relay tripping may be determined with short circuiting at the
testing point and determining time before the relay switches on. The fine
adjustment may be carried out with the 503 potentiometer.
Testing points
1: the sequence of pulses from the transducer or calibration frequency while
short circuiting at .
2: frequency/voltage transformer outlet: direct current voltage from 0 to 10 V
depending of the diesel engine speed.
353
: starting oscillator for testing and calibration. The points are short circuited, for
example, with a small screwdriver (the contact to the transducer must
switched off preliminary).
4: voltage adjusted with the potentiometer 502. This voltage corresponds to the
required point of the relay tripping.
5: The voltage is adjusted with the potentiometer 502. This voltage corresponds
to the required dwell time.

Input:
Input frequency:
Power supply voltage:
Consumption amperage:
0 8000 Hz,
the peak 12 V, square wave
+ 12 V, 12 V, 0 V
maximum 40 mA
Output:
Output frequency:
Output voltage:
Non-linearity:
Temperature dependence:
the peak 12 V, square wave, protected from short

circuiting
0 10 VDC, 15 mA, protected from short circuiting
0.1%
0.03 %/K
Relay function:
Tripping point:
Delay time:
Contacts:
Breaking capacity:
0 100% of the controlled range

0 10 seconds
1 switching contact
110 VDC, 0.3 A, 24 VDC, 1.0 A
Testing:
Testing point:
Allowed ambient
air temperature:
approximately 80% of the full load

25 + 71O C.
354
3.3
C3 Relay card 3V72H115
3.3.1 Operation
The printed circuit board consists of three relays with two switching contacts each.
The output voltage of the diesel engine speed board:C2 is supplied to three
comparators in which the relay tripping points may be adjusted individually for each
relay with a freely regulated dwell time.
The relays may function either based on the working current principal or based on the
standby current principle.
The relays may be programmed with the dwell time for switching-on, switching-off or
without any delay at all.
The third relay channel may be programmed with the self-locking feature requiring
the confirmation from outside. Nevertheless, this function uses the switching contact
of the relay itself. The relay activation is indicated with the green or red light diode.
355
3.3.2 Adjustment relay

The relay tripping point is adjusted with regulating potentiometers. The corresponding
values may be taken at the testing points.
601, 1
602, 2
603,
relay channel 1
relay channel 2
relay channel 3
a.
Identify the amplification of the diesel engine speed printed circuit board:
nmax (RPM) = Umax [VDC]
b.
Calculate the voltage corresponding to the engine speed value when the must
trip:
n x [RPM ]
Ux [VDC] =
x Umax [rpm]
n max [RPM ]
c.
Adjust with the help of the channel potentiometer until reaching voltage of the
calculated value at the test point.
The potential delay time of the relay may be determined with short circuiting the
testing point at the diesel engine speed printed circuit board (2). The
corresponding potentiometers are 604, 605, 606.
NOTE!
If the adjusted relay tripping point is higher than the voltage generated by
the testing oscillator (), for the testing time, the tripping point may be
adjusted to the voltage required for testing.

Input:
Output voltage:
+ 12 V, 12 V, 0 V
maximum 40 mA
0 10 VDC
Output:
Three relays with two switching contacts each.
Tripping point:
Delay time:
0 30 seconds
Breaking capacity:
110 VDC, 0.3 A, 24 VDC, 1.0 A
Allowed ambient
air temperature:
25 + 71O C.
356
3.4
C4 Turbocharger speed transformer for one or two turbochargers
3.4.1 Operation
The sinusoidal signal coming from the magnetic pulse transducer is converted and
then as a square pulse voltage, it is transferred partially as a pulse signal and
partially to the frequency / voltage transformer. The output voltage of the transformer
proportional to the signal from the pulse transducer is amplified and may be detected
by an analogue voltmeter. The printed circuit board consists of 2 channels.
3.4.2 Adjustment
The analogue voltage at the output is regulated with potentiometers situated at the
left side of the printed circuit board.
P402 : Turbocharger 1 speed
P404 : Turbocharger 2 speed
If the analogue voltage at the output must be increased turn the potentiometer
clockwise and if this voltage must be decreased turn the potentiometer
counterclockwise.

Input:
Input frequency:
0 8000 Hz, > 100 mV peak-to-peak sinus

357

+ 12 V, 12 V, 0 V
maximum 35 mA
Output:
Output frequency:
Output voltage:
Non-linearity:
Temperature dependence:
3.5
12 V peak-peak,
10 mA, protected from short circuiting
0 10 VDC, 15 mA, protected from short circuiting
0.1%
< 0.03 %/K
C5 Relay II, 3V72H115
3.5.1 Operation
The card contains three control voltage relays with one switching contact each. The
relays are governed with the signal of the diesel engine speed from the printed circuit
board or with the outer direct current voltage. The relay switching points are adjusted
with the potentiometers situated at the front side of the printed circuit board.
358
3.5.2 Adjustment
See item 3.3.2.

Input:
Output voltage:
0 10 VDC
+ 12 V, 12 V, 0 V
maximum 60 mA
Output:
Three relays with one switching contact each.
Tripping point:
Delay time:
Breaking capacity:
Allowed ambient
air temperature:

0 30 seconds
110 VDC, 0.3 A, 24 VDC, 1.0 A
25 + 71O C.
359
4.
ENGINE SPEED TRANSDUCER
4.1
Description
The transducer is of the inductive, contact-free type and receives the power supply
from the speed measuring system with the voltage of +12 and 0 V. The third
conductor is the pulse output proportional to the engine speed value.
The electrical part of the transducer is molded in the threaded bushing made of nickel
brass, thread size 18 1.5 mm. Cable connection is provided with the help of the
four-pole contact device with the screw retainer ("Euchner BS4").
Picture. 4.1. View from the cable connection side.

1. + 12 V
2. Output
3. 0 V
4.2
Transducer installation
NOTE! The transducer turning-in when the diesel engine runs is not allowed. If the
transducer contacts the teeth during the diesel engine run, the transducer may get
damaged.
Picture. 4.2
360
The diesel engines crankshaft must be turned at such position that the tooth peak
should be seen in the middle of the hole for the transducer. The transducer is turned
in until the contact with the tooth peak and then it is to be turned approximately 1.5
turn.
Picture. 4.3
In this position the output signal at the testing point 1 must have the voltage of
12V. If the transducer is at the gear root between two teeth the signal has the voltage
of approximately 0 V.
361
5.
TURBOCHARGER SPEED TRANSDUCER
5.1
Description
The transducer is magnetic and that is why it does not require the power supply
voltage. The sensor element divided in two parts in the sensor butt end of the
spreader beam is integrated in the pipe with the thread 12 1.25 mm.
The turbocharger shafts butt end is made for the transducer of this type with
shoulders or hole as follows:
type RR:
VTR:
with 2 eccentric holes

washer with 6 holes
When rotating the turbocharger shaft and matching these holes with the transducer,
the direct current voltage of the sinusoidal shape is produced. The cable connection
is provided with the help of the four-pole contact device with the screw retainer
("Euchner BS4").
5.2
Transducer installation
NOTE! The transducer turning-in when the diesel engine runs is not allowed.
The transducer is turned in until it goes by-hand and then it must be screwed in
approximately 0.8 1.5 turn.
362
363
364
6.
TROUBLESHOOTING PROGRAM
6.1
Power supply unit Direct current / Direct current

START
Is green light
diode on?
Power supply
Terminals
29 + 30
Switch on the power

supply
Is the fuse intact?
Replace the fuse
Replace the printed

circuit board
Power supply available

Output voltage:
+ 12 V
Earthing
12 V
Terminal 24
Terminal 26
365
6.2
Main engine measuring transformer with relay functions

START
Is the output 010 VDC?
Replace
the board
Voltage
available?
At which RPM
does the relay
trip (light diode
is on)?
Is pulse input from

transducer or
oscillator?
Is the output 010 VDC? TP2?
Check & adjust if

required
Test program 6.1
Test program 6.5
Replace the
board
Short circuit of
lose contact at
the output?
Troubleshooting
The board works

Output frequency:
Measuring signal 0 10 VDC:
Pulse output:
Voltmeter VDC range:
Terminal 55 and 57
Terminal 25 and 26
Terminal 58 and 59
Transducer approximately 5.8V
Oscillator approximately 4.2 V
366
6.3
Printed circuit board for relay functions

START
Analogue
voltage output 010 VDC
At which RPM do
the relays work?
Test program 6.2
Replace the board
Check the relays

tripping points
Board is faultless
367
6.4
Turbocharger measuring transformer

START
Is the analogue
voltage output 0-10
VDC at the terminal
8 or 37?
Is the voltage
available?
Transducer i
Test program 6.1
Pulse output
terminal 12 or 41
Replace the board
Sinusoidal signal
from transducer
terminal 10 or 39?
Check the
transducers settings
Replace the board
The turbocharger
board is faulty.
Pulse input:
Pulse output:
Measuring signal 0-10 VDC:
Channel 1
Terminal 10, 11
Terminal 12, 13
Terminal 8, 9
368
Channel 2
Terminal 39, 40
Terminal 41, 42
Terminal 37, 38
6.5
Main engine speed transducer
START
Is pulse sequence
proportional to TP1
engine speed board?
Adjust the
transducer for
symmetrical square
wave: 12 V peak at
engines running
Is voltage
available?
Test program 6.1
12 VDC between 1
(+) and 3 (-) at
transducers contact
device?
Check
connection
Adjust as according to
Pic. 4.2
NOTE!
Max. 0.25 turn
Do transducers signals
change the condition
when the engine
crankshaft is turned?
Screw out the transducer

and put it on the flat metal
surface.
Transducers signal
changes depending
on the transducers
location
Replace the
transducer
Transducer is faultless
369
Install the
transducer back
13
12
11
10
9
8
7
6
5
4
3
2
1
Item
Rubber plate
Terminal number plate
Terminal
Board keeper
Washer
Slotted head screw
Nut
Slotted head screw
Thumbscrew
Board contact part
Main board
Steel guard
Steel body
Name
Drawing/Type
DESPEMES Speed measuring system.

Assembly drawing 3V72H83
370
Part number Q-ty
371
372
373

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OPERATIONS MANUAL

CONTENTS, GENERAL, DEFINITIONS

Contents of Operation Manual

MAIN CHARACTERISTICS, OPERATIONAL SPECIFICATION AND ENGINE

FUEL OIL, LUBE OIL, COOLING WATER, NOZZLE COOLING OIL

fuel oil treatment

recommended limits for fuel oil quality specification

comments on the fuel oil quality specification

measures when running on heavy fuel

specification of the circulated lube oil

lube oil maintenance and condition inspection

regulator lube oil

turbocharger lube oil

list of most frequently used cooling water additives

nozzle cooling oil

remote and automatic start

Maintenance during operation

after every two days or every 50 running hours

after every two weeks or every 250 running hours

after one month or every 500 running hours

Starting after a long shut-down

Starting after dismantling

PREVENTIVE MAINTENANCE SCHEDULE

Every second day regardless whether the engine ran or not

Every week regardless whether the engine ran or not

Every 50 running hours

Every 250 running hours

Every 500 running hours

Every 1000 running hours

Every 2000 running hours

Every 4000 running hours

Every 8000 running hours

Every 16000 running hours

Every 64000 running hours

Hand tools for cylinder heads

SETTINGS, AIR GAPS AND WEAR LIMITS

TORQUE AND THREADED CONNECTION REQUIREMENTS

Stud, bolt and nut torques

threaded connections hydraulic torque pressure

topping-up and checking hydraulic accessories set and bleeding-off air

undoing hydraulically torqued threaded connections

hydraulic tightening of threaded connections

TROUBLESHOOTING, EMERGENCY OPERATIONS

Failures, possible causes

crankshaft does not rotate during start

crankshaft rotates with air but no combustion in engine cylinders

intermittent combustions in engine cylinders, combustions are completely

engine runs intermittently

slaps or detonations in engine

dark exhaust gas

white-blue exhaust gas

abnormal high exhaust gas temperature of all cylinders

abnormal high exhaust gas temperature of any cylinder

abnormal low exhaust gas temperature of any cylinder

very uneven exhaust gas temperature

low lube oil pressure or no lube oil pressure

high lube oil pressure

high lube oil temperature