WARTSILANumber 48668 Installation ZELENODOLSK 262 Engine type WARTSILA 6132 Engine number PAAE036473 Specification 23187 This manuals intended forthe personal use of engine operators and should ways be at ther disposal. The content ofthis manva) shall nother ba copied ner communiested toa trird person “sone WARTSILA INSTRUCTION MANUAL© Copight by Wartsta Finland Oy All eghtseoservd No pt af this booklet may be repraduced oF coped i ‘any form oe by any meats flectte, mechnical. graphic. phaoepving Fecordng, taping or exer information eetrival spc) iat tht Br sweten permission ofthe etic owner TIVE InPORMATION WiTH REGARD TO THE SUBJECT-NATTER COVERED na WAS HvALABLe ar-Tie TIME OF PRIVTING. HOWEVER, THE PUSLIGATION DEMS Ww CoMPCIcATeD TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN ne ted Ano Toe oesion or THe SuasECTPRODUCTS gUBZECT TO REGU ‘hose Shown In Ts PUBLICATION TwE PURuISHE ano COPYAIGHT OWMER ENALL Uneh NO Cineumstances Be MELD LIARLE TOR ANY FINANEIAL CON SEQUENTIAL DAMAGES OM OTTER LOS, em aj OTHEM DAUAGE-OR INJURY. Surreneo ay any Panty maxing USE O18 PUGLIeATiON OM THE INFORMCONTACT WARTSILA \ ae oe Wartsila inland Oy, Services Services Office Vaasa Services Office Turku Tathaajantie 2 StAlarminkatu 45 F-65380 F-20810 Vaasa Turku P.O. Box 252 P.0. Box 50 F-65101 F-20811 Finland Finiand | ae Phone +358 10 709 080 | 24hrs Phone +358 10 709 090, Fax +358 70 709 1380 | Fax -+358 10 709 3410 ‘Switchboard +358 10 709 0000 (Office hours 7.30-16.30) E-mail service.solutions@ wartsila.com Homepage www.wartsila.com/services Lasbeol-o -a}-7 | fs [al-ol.a|-s | | tea ales oa lee oz o0 oe lerolerterd “© WARTSILA32-200328-03, Contents, Instructions, Terminology 00 00. Contents, Instructions, Terminology 00. 00.2 Contents of the Manual ‘This Manual contains data and instructions fr operation aiid mainte. nance of the engine as well as instruction for handling, personal protection and frst aid when feb, lubricating ls and cling wate ekiives are handled anny narmel operstion nd maintetuance work. Basie general knowledge has not been entered, Consoquenty itis nastimed that the engine operation and maintenance stalF is wel infarmed of the eare of dissl engines, ‘Wiirtsild rosorves for itself the right to minor alterations and improventents owing to engine development without. being dhliged to enter the corresponding changes in this Mami "The diesel engines wil he equipped as agroed wpem in tho sales 8 Hw wm ew op MO TOYO W Ie Fig 02-1 soe Example: A fuel oil with a viseosity of 380 St (A)at 50 °C (B)or 80.1 ‘at 50 *C (C) must be preheated 19 112 - 126 °C (DB) before the fuel injection puimps, to 97 °C (B) atthe centrifuge and to minimum 40°C (G) in storage tanks. The fast oil may nok be pumpable below 6 °C (HD. Toobtain temperatures for intermediats viscosities, draw a tine from. ‘the known visoosaty temperature point in parallel to the nscirestViscos- ity/temperature line in diagram. Example: Known viscosity £0 St at 50 °C (K). The following ean be read along the dotted line: Viscosity at 80 °C = 20 eS, lemperture at fut injection pumps TA 36°C, cencrifaging temperature 86 °C, mini- sur storage tank lemsperature 28 °C. ‘Couversion from various current and obsolete viscosity units to cent stokes ean be made in the diagram, Fig 02-2. The diagram shouldbe ‘used only for ennversion of visensities at the same temperature, The same temperatures should then be used when eatariug ehe viseo- sityltemperature point into the diagram, Fig 02-1. W270 /w32/W46, 32, 321N 02-3“Miscoslly conversion diagram Contisiokes Fig 02-2 een When converting viscosities from one of the units an the abscissa t0 centistokes or vice-versa, keep in mind that the result obtained ts valid only at one and the same temperature, When converting the viscositin any unit ata given temperature to 0 visosity at another temperature, fa viseosity-temporature diagram anconversian rule must be used, 2.1.23 Viscosily control An automatio viseosity controller or viscosimeter, at lenst, should be installed in order to kee) the correct viscosity ofthe fuel bofore the fuel conters the engine fuel system. ‘w20/W32/WAd, $2, S2UI6pm UNTO 02.1.3 Maximum limits of fuel characteristics “The diesel engines WARTSILA® Vasg 32 & 32LN, WARTSILAY 20, WARTSILA® 2, and WARTSILA® 46 & 46P are designed and developed for continuays opexation, without reduttion oéthe rated, ‘output, on fale with the fallawing propertios: Redwood No.l scat 100°F | 7200 “Romario wsconty 51 af engine nist ef, aim’ ot 15° 91 alin’ ot 15°C ro16! vor 10 | Pourpolnt = Toto Scent Potentit mow 10 The limits above also currespand to the demauids + 180 8217:1996(K), ISO-F-RMH 55 and RMA + BS MA 100:1996, RMH 55 and RMK 55” * CIMAC 1990, class H 55 and pve the fl tote assem can remove Water asl Four types of fuels are defined for the WARTSILA Vasa 92 & SOLN, WARTSILA? 20, WARTSILA® 32 and WARTSILA® 46.& 46F engines: + HPO 1, heavy fuel oil of normal quality + HPO 2, heavy fuel oil below normal standard quality e + 100, close el ar LFO, lig fe ol + CRO, Crude oil. (Not approved for WARTSILA™ 46F), ‘Tho maintenance intervals are decided by the characteristics of the cused fuel, see Chapter Di Maitonance Schedule ‘w20/w32/W46, 32, 32LN 02-502-6 "Te difexences between HPO 1 and HO 2 ae seen belove: Suphut ‘As Vanadium Sealum ‘Sodium, bef. ‘Alurinis + Soon ‘tnnium + Sleon. bet Crane moe mou moo mg moro mass mas % ‘Cenradion Carbon Residue ‘Asphatenes ‘CCA Foreign substances or chemical waste, hazardous to the safety of the installation or detrimental to the penfornnce of engines, should not be contained in the fuel KS" Note! If-any of specified tuel properties exceed HFO 1 maximum value ‘tno uel should be classiied os HFO 2 02.1.4 Commonts on fuel characteristics BBE The viecosty isnot a measure of the fuel quali, but detemaines the {Ontong aang pst, hy fel hs tobehesia teach aviosty of 18-24 ct atthe pat ont. At low visnm the ow past the tinge the section pp case Ths ads toa dacronse in teem of injetad at which ‘ttba cans gt mal napa o reach il engine op "ho standard engine fel ys eta out fora, 99 ¢3¢ 28 100°C fuel apton 73D coe 30°C spre. 7200 Hadwoad NT Scotts a 400" The densty infuencs mainly on the fuel separation. Separator Femave wor and sy extent si parties from fats hag Sonate of to 991 kgm at 15°C, There are ls separsiga on the Inari shat an clean fl vith denston of up to TOID Kn at 15 ‘Tae eepartorenpsbity must he checked before purchasing a fel with avery high enady, asa seperation wl Jed to abacemnal oar de tovuntemoved parties and waterThe separator dite must be chsh conning Vote fel density Ad Coutlont Fusis having a low vacosty in combination with a high density Usually have bad ignition propedias! w20/ws2/W4d, $2, 92LN200549-01 oom ating ing e Ignition quaily. Heavy fuels may lave very tow ignition quality. This may cause ¢rouble at stazt ated low load operation, particularly if the fengane $8 not sufficiently preheated, Law ignition quality may also result ina Jong ignition delay and eun cause a fast pressure rise and very high maximum pressure This inerenses the meekaical load and fan even damage engine components such as ef. piston rings and Ieavings severely. Deposits on the piston top, an the exhaust valves, in the exhaust system, and on the turbine nozzle ring and turbine blades ‘can also be expected. The turbocharger fouling will lead to decreasod ‘werbocharger efficiency, and increased thermal load, ‘A symptom of low ignition quality is diesel knock, ie. hard, Bih pitched combustion noise. The effects of diesel knorking ars increased ‘mechanical load on components surrounding the combustion space, increased thermal load, as well a incroased lubicating oil consump tion and contamination oO CutiontAtthough iow ignition quay produces long ignition delays, ad- a ancing ine gon ting maces hangs ony worse he ts ni be"injected ol a lower compression temperchure. and ths wll produce cn even longer igntion dele! Ignition guality is not dofined, nor limited, in marine residual fuel standards. The same applies to ISO-F-DMC marine distillate fos. "The ignition quality ofa distillate fuel can be ceterminéd according tosevera mtn, Dive Index, Cetane Ives, an Ceane Num “The ignition quality of « heavy fuel oil can be roughly determined by calculating the CAT (= Caleularsd Carbon Aromaticity Index) from the viscosity and density of a fuel, Determining of CAL oO coal where p= density kg/m’ nt 15 °C) ‘c= hinematie visosity (cSt at 50°C) 81-147 logiclogio Ox + 045) I= Nota! An increased CCAI value indicates decreased ignition quality! CCAT can alse be determined (but with Limited accuracy) by the romogram, see Fig 02-8. ‘Straight rin fuels show CCAT values in the 770 - 840 range, and are vory good igniters. Cracked residues may run from 810 to over 900, ‘while most bunkers remain in the 840 to 870 range at prasent. w20/ws2/W46, 32, 32LN 02-7"The CCAL is not an exset tool for judging fuel ignition properties allowing rough guidelines can however be giver: Engines ranning at constant speed and load aver 50 %ecan without difficulty use fuels with CCAL-values of up to 870. ‘+ Engines running at variable speed and load can without difficulty run on fuols with CCALvalues up t0 860, ‘To avoid difficulties with poor ignition quality fuets the following should be noted: + Sulficient preheating af the engine before start + Proper fanetion ofthe inverse cooling system. + Proper funotion of the injection system, especially the injection nezale condition must be good, Nomrogram far deriving CCAL i woo a oe 0 w20/W32/Wad, 32, 920TE IT The water content of heavy fuel oils varies widely, Water may come fom several diferent sours, tean ether be fresh or salt Trea also oxiginate frome condensation inte installations hunker tanks “+ Te the water is sweet and very well emulsified in the fuel, the cfoctive energy content of the fuel decreases with inereasing ‘water enatent, leading to an increase in fuel consumption, + Uf dhe fuel is contarninated with soa water, the chlorine inthe salt will etuse enerosion af the fuel handling system, inluting the Injeotion equipment. The effects of sdiaus tht also originates fiom sat, ave described more in desal below ‘To avoid difficulties in the engine fuel injection system the water content must be reduc to um of 0. % prior ta the engine BBE the sutphur in the fuel may cause cold corrosion and enxrosive wear, Cepetllyat-low fads, Sulphur leo conerbates to deposi formation {nthe cahaust system, normally together with vanadium andlor 2 e dum in the fora of sulpates, The deposits ean also ‘use high Vemperstare corraion, a8 described below Abigh ash content nay hedetrimentalin several ways. Disfeentash components ean eause diferent problems + Aluminium ond sicon oxides originate From the refining process, andcan cause severe abrasive wear mainty ofthe injection pumps fand nozzles, but also of eylinder liners and piston rings. An ‘ifiient fuel separation is must for minimising wear Oxides of vanadium ond sodium, rainy sodium vanadyl ‘vanadates, are foriaed during the combustion, and mix br react With oxides and venadates of other ash components, eg Bickel, Cale, silicon and sulphur. The sticking temperature of the mixture may be rch, that a deposit is formed on a valve in the ‘exhaust as system, or inthe turbo charger, This deposit highly orzoxive in the malien state, destroying the protective oxide lave ‘nevg-anexhaust valve, andlending toot carrosion anda bred ‘ive: Deposits and hot cnerosfon in the turbocharger, especially e on the nozzle ring and turbine blades will cause « decreased turbocharger efficiency. The gas exelamge will be distarbed, I tir flows through the engine, and thus the thermal Toad on the engine increnses, The deposit formation increases at inereated temperatures and engine ouepute ‘To avoid the above mentioned problems when running on high ash fuels, itis important ton, + Have an efficient fuel separation + Clean the turbocharger regularly with water, soe seetion 15.3. + Have a strict quality contol of the bunkered fuel, i. to see that the amounts of ash aa dangerous ash constituents sta’ low. + Maintain loan ne fiters and charge ait coolers by tegula clean ing bared on pressure drop monitoring [FBI High carbon residue conient may load to deposit formation in the tombustion chamber andinthoexhaust system, expecially at ow loads we0/w32/Wab, 32, S2LNE 02-9OAT ‘= Deposit formation on injection nozzle tips will disturb the fuel atainisation and deform the fuel sprays, decreasing the combs. tion process efficiency, and even leading to locally inereasexl thermal loads, + Deposits in the piston ring grooves and on the rings wil hinder the movement of the rings, causing 4.0, inereased blow-by of combustion gases dawn to the crank ease, which in turn increases the fouling of the lubricating oi. + Deposits in the exhaust gas system and in the turbocharger will disturb the gas exchange and increase the thermal load. High asphaltene content may contribute to deposit formation in the ‘combustion chamber and in tho exhaust system, especially atlow loads. ‘Aphaltenes are complex, highly aromatic compounds with high molecular weight, that usually contain sulphur, nitrogen ad oxen, a well as metals Hike vanadium, nickel, and iron (sve “Asi” above). A high asphaltene content indicates that a fel may he difficult to ignite tnd that it burns slowly. If the fuel is unstable, the asphaltenes may precipitate from the fuel and block filters andlor cause deposts in Une fuel system, as well as expensive centrifuge sludge, Alow flosh point (high vapour pressure) is often seen especially for care oils, ‘The low lash point wil not iafluenee the combustion, hus the fel pointis high, andthe fuethas tobe heated proof equipment and separators ean be used in extreme cases A high sapour pressure Qow flush point) can also give cavitation and sis peckets in the fuel pipes. Thess ean be avoided by using anlevated pressure in the fuel handling system: Tris to be noted thst sons insurance cow fuels having a flash point nigher than 60 °C. janies demand the use uf HIE The pour point tells below which temperature the fuel does not flow, fand determines how easy it will be to hauls the fuel. The whole fuel handling system, including tanks and pipes. must be heated toa temperature atleast 10-15 °C above the pour point. Total sediment potential tolls something about the fuels stablity. IF the TSPis high, the danger of sediment and sludge formation in tanks ‘and fuel handling gystems increases, as well asthe probability fo flter loging. ‘TSP can also be used esa check for the compatibility of wodlferent Sols: The two fuels are mixed, and ifthe 'SP far the mix seoains low, the fuels are compatible 02.1.8 Measutes fo avold dificultios when running on heavy fuel Toor fuel quality will infuence on wear, engine part lifetime and ‘maintenance intervals adversely wa0/ws2/Wa8, 52, 321NInorder to obtain maximum operating eooreuny it is zecommendable: BI ot maximum continuous output mich as apersting cond tioosallow fel olrown napocied io have high vanadimcontent (above 20 pp and sedis content. [59 10 limit low load operation as much as operating conditions allow iftvel i hnown or suspected to have high ephur content {above 4 minsa-%,exrbon content (Conrudeon carbon above 12 mace %) andor asphaltene content Obove 8 maoe-%). ‘Operstingbelow 20% rated cts oli tomas: 1OOours continuoely, by loading the engine above 10% orate load for er tere confining the lw oad operon o shutting down the engine Tiling Gx. main curiae dcuiched, generator ect caconnecied) should belimited ws much as possible, Warm-up ofthe engin at ion for ore than 3-5 minutes before nding, na well a ding tore than Santee td topan ts nnetesary an a sted. 02.1.6 General advice ‘Toavoid stability and incompatibility problems precipitation of heavy componente in the fue), avoid, if possible, blending of fuels from different bunlcer stations, unless the fuels are fnowa to be compatible stability and compatibility problems occur, never ada distillatefuel, 1 this will probably inerease precipitation. A fuel aciitive with a highly peworful disporsing characteristies can be of help until a new fue delivery takes place. ‘The characteristics of heavy fuels hended from residuals from mod cern refinery processes Ike eatalytie cracking and visbreaking may Approach at east son ofthe limits of fel characteristics given mn the chapter 02, sect 02.1.5 Compared with “traditional” heavy fuels blended from stenight run residuals, the “modern” heavy fuels may have reduced ignition and combustion quality Puels blended from catalytic cracking residuals may contain very abrasive eatalytc fines (si¥eon and aluminium axis) which, if al lowed to enter the injection system, may wear down injection pumps and nozrles in a foo hours ‘Some of the difficulties that may oecur when operating on heavy fuels Dnlended from ergcked residaals cun be avoided by + Sufficient centrifuging capacity. Tho best and most disturbance. free results are obtained with the purifier and clarifier in series, Alternatively the main and stand-by separators may be ran in parallel, but this makes heavier demands ea correct gravity dise choice and constant flow and temperature control to achieve optimum results. Flow rate througit the centrifuges should nat exceed the maximura fuel constamption by more than 10 %. + Sufficient heating capacity to keep centrifuging and injection omperatures at recommended Jevels. Tt is important that the weo/wsz/Wad, 32, 32LN 2-1re 02.2 temperature Muctuations are xs low ax possible (12 °C before centrifuge) when centrifussng high viscosity fuels with densities approaching or exeveding 991 kyl? at 15 *C Sufficient preheating of the engine and the fuel systems before starting the engine Keeping fuel injection equipment and the invee in good! coadition, ‘See also section 02.2.7, Handing of oil samples cooling system Lubricating oil 02.2.1 System oil characteristics Viscosity, Visosty ease SAE/40.In WARTSILA™ Vasa enginetyec @ also the use of SAI: 40 class lubricating ol is lowed Viscosity Index (VD. Min.5s Alkalinity (BN). The requited lubricating ail akaliniy is tid to the fuet specified for the engine D | GRUBER x It is recommenced to use in the first place IBN 50-85 fubricants when ‘operating on heavy fe. This recommendation is valid especially for fengines having yet lubricating ofl sump and using heavy fuel with sulphur contents above 2.0°% mass. BN 40 ubrieants ean he used when ‘operating on heavy fuel well experience shows thatthe lubricating ol BN eguilibriuns romaine at an secoptabic level BN 30 lubricants are recommended ta bo used only in special eases, such os installations equipped with ar SCR catalyst, Lawer BN prod. ucts eventually have a positive influence on cleanliness of the SCR catalyst, With BN 30 ils lubricatinigoil change intervals: may be xathor short, but lower total operating costs may’he achieved brenuse of hettor plant availability provided that the maintenance intervals of the SCR ‘catalyst can be increased W20/W32/W46, 32. 32.NPOE CSI BN 20 oils are also a recommended alternative when operating on ernde oil, Thovgh crude oils many times have low sulphuroratent, they ‘ean contin other aed compounds and thus an adequate alkali reserve igs impartant. ‘Adafives. The oils should contain additives that give good oxidation stability, carrasion protection, laad carrying capacity, neutralization of acid combustion and oxidation residues, and should prevent deposit formation on internal engine parts (piston coeling gallery, piston ring zone and bearing surfaces in particular). Foaming characteristics, Fresh lubricating oil should moet the fallow: ing limits for foaming tendoney and stability (according to the ASTM. ‘1D S90-92 test method): ‘Sequencs I: 10010 ral # Sequence Tl: 1900 ml # Sequence IIL: 1000 ml In this testa certain amount of airs blows though the lubricating oil sample. The first number in the resulta is the foam volume after 1 owing period af 5 erinutes ane sould be less than or equa to 300 ‘The second number is the foam volume after a settling period of 10 miuases and should always be 0m Sequences [ and IIf are performed at a temperature of 24 °C and sequence IT at a temperature of 93.5; 02.2.2 Lubricating qualities Lubricating oil is an integrated engine component and thus the quality of it is upmost important. il lubricating gils, whieh have been approved for uge in WARTSILA™, Vasa 32, WARTSILA® Vasa a2LN, WARTSILA® 20, WARTSILA® 82, WARTSILA™ 46 and WARTSILA® 468 engine types, have gone through an approval test according to the engine manufacturer s procedure "The use of approved Tubricating oil qualities during the warranty period is maniatory and is also strongly recommended after the ‘warranty perio. ‘The list of approved lubricating oils eaa bo found in the ond of this chapter J-= Note! Never blond diferent ol brands unless approved by the oll supplier. ‘and during the warranty period, by the engine manufacturer. JS Note! Before using a lubricating ll not listed in the fable, the engine manufacturer must be contacted. Lubricating olls hat are not ‘Gpproved have fo be tested according fo the engine manufac {urer’s procedures. ‘w20/W32/WA6, 32, 32UN 02-132-14 KS Netal Ay cain Ire 02.2.3 Maintenance and control of the lubricating oil Centrituging of the system oil is recommended in order to separate water and jnsolubles from the oil. Water must noc be added when ceatafuging (ashing). The oil should be pre-heated to 86 - 95 °C. ‘Many oil manufacturers recommend a separation temperature of 99-95 °C for an effective separation. Pleasw check with dhe supplier cof your lubricating oil what the optimal temperature is. Use the highest recommencied temperature, For efficicnt centrifuging, use only about 20% of the nated flow capacity of the separator. Bor ‘optimum conditions the centrifuge should bo eapable of passing the fentire oil quantity in cireulation 4 - 5 times every 24 hour st 20% of rated flow. Gravity dise should be chosen acc. to ail density at separation temperature, Follow the operation instructions given by the separator manufacturer for optimal perfamruanes of the separator, The lubricating oil separation etfciency influences the condition of the lubricating oil and the change interval of the lubricating off batch. Depending on type of application and from the different lubricating ol system arrangements point of view, the following separation routines are adviced: = Continous running of the separator(s) when the engine(s) is run- ning, recommended in the fist place. Petiodical separation of auilary engine in stand-by of runnin ‘mode in installotion equipped with one oF more separators), whic fneas lubricating oll of more than one engine. Defects on automatic, “self-cleaning” separators can quickly in- ‘crease the water content of ihe oll under certain circumstances! he woter control vaive tails) During the fist year of operation itis advisableto take samplosofthe 2icating oi at 500 opernting hours intervals, The sample should be ent to the oil supplicr far analysis. On the basis of the results itis possible to determine suitable intervals between eilehanges. Frequent oll analysis at 500 - 1000 operating hours intervals is also recom mended after the first voar af operation 1oensuro aufeengine operation, ‘Soe also section 02 2.7, Handling of al samples. Whenestimating dye condition of the used oi, the following propexties should be observed. Compare with guidance values (type analysis) for ew oil of the brand used. Viscosity. Should not decrease by more than 20% and not rise by more ‘han 2586 above the guidanre value at 100°C, Should not decrease by more than 25 % and not vise by more shan 45% above the guidance value at 40°C. Flash point. Should not fall by more than 30 °C below th value. Min, permissible flash point 190°C (open cup)ansl 170 up) At 130°C rink of erankease explosion dance (closed W20/W32/WA6, $2, 32LNe ‘Water content. Should not exceed 0.5%, A value higher tha. 0.3% can vcctor nt mass ba ie ciao care Bios ane oTuentegory A and Tie lt allowee BN valu af «us 50% te ronda enone + Fudntowis Can Thermos valu ed ils BN 20 seln The ny el ee rns ata. To i ater outshine Vice nts eae Neila cal ratenoa A aus ilar das int tedden pe item nts changin heal ieebeter winston tan theses eae e avn Be te aay tt sharma open of the Compensate for ol consumption by adding max. 10% new oil at a time, Adding larger quantities can distush the balance ofthe used oil cattsing, for example, precipitation of insoiubles, Measure and record the quantity added Attention ta the rieating oil cansumnption may give valuable infor sation about the engine condition, ’\cantingous inerease may indicate that piston vings, pistons and cxfuser liners are getting worn, and a sudden increase motivates ruling the pists, ito other reason is fond Guidance values fr oll change intervals. are tobe found in chapter (4. Intervalshetween changes areinffuenced by sytem siz ovolume), ‘operating conditions, fuel quality, centeifuging eciency and total oi tnsumptan, Efficient contrifgng and Lange yetems (dry ump opera tion) genera allow for long intervals hetwern changes tis recom nen to flea up tht the BN vale of te lubricating keeps within O° engine manufacturers mits during the whole ol change interval, When changing ot! the following procedure is commended: Hh Empty ot system white ol is sti hot Be sure tat i filters ana coolers er als opted 1 ciean oi spaces, inviting ters ondcnnshatcompartret. In port new Eten eartrgon Fila small quantity of new ol intheoilsumpandeineulatewith the yelubrieating pump. Drain! Ei Fit required quantity of ol in the system, nse chapter 01, section Out Oil samples taken at regular intervals analyzed by the oil supplier, and the analysis results plotted as a function of operating howrs isan ffcient way of predicting ol change intervals ‘Seuul or ask the oll supplies to send coptes of oll analyses to the engine manufacturer who will then assist in the evaluation. w2o/ws2/was, 32, 32UN 02-15Dy cowiont EO ing oi foaming, deposit forme- tiny, blocking of lubricating oil filters, damage of engine components, se, tho folowing procedure should be followed when lubricating oil brand is enange from one to another: « Ifpossible, change the lubricating oil brand in eoxiection with an tengine (piston) avorhaul. ‘+ Drain old lubricating oil from the lubricating oil system, + Clean the lubricating il system in easo of an excessive acrount of deposits on the surtanes of engine components, like crankease, ‘camshaft comparizacnt, ete. + Fill the lubricating ol system with fresh lubricating oil If the procedure described ahove is not followed, responsibility of possible damage and malfumetions enused by lubricating ail change Should always be agreed between the ol company and custome, 92.2.4 Lubricating oil for the governor ‘See the Insteuetion Bonk for the governor, attaehod, Ancil of viscosity lass SAI 80 or SAE 40 is suitable, and the same oil ean be used a8 in the engine. Turbocharger oil ean also be used in the fovernor. In Jow ambient conditions it may he weccssary to uso multigeade oi SAE BW40) to yet good control duzing. start-up, Oil change inter see maintenance schedule chapter 04 ‘Condensed water, high tempurature or leaking drive shaft seal may ‘eause the ail te detevinrate,or inturnalaurfaces ofthe governor toeollect deposits. Ifthe reason cannot be clarified anid rectified, a shorter oil change interval or change of all type should be yonsidered The governor should be Nushed Wath the oll inne oF gasoil ifheavy contamination ofthe oll is evident ‘Bxamples of auitable ibrieating ois for governor cast be found from ‘the end of this chapter, where the lists of approved lubricating eis for fan engine and turbocharger are available, + Ifthe aysiom is equipped with a start booster, then this should also be emptied when changing oil: «+ In installations whereby the actuator is equipped with a filler, t bane to be cleaned when clzanging oi += Depending on the governor type, oil should be separately emptied from the poster eylinder. This is done by removing the plug in the bottom of the power cylinder. + Sone governors are equipped with a magnetic oil plug, this plug shoul he cleaned tn connection with an oil change. I turbine oil is used in the govemor, iake care not to, mix it with ‘engine lubricating oll Only a small quantity of engine lubricating oll into the turbine of may cause heavy foaming. wa0/WS2/W40, 32, 32LNFS Note! 9 oils for turbochargers Please note that different types of turbochargers enn be used for the figine, The lubricating system is different for the different tasbo- charzer, One typeof chargers husacommion lubrieatingall system with the engine, soo chapter 15, while tho other type of changers has an internal lubricating system: for the benrings, abe chapter 15, See the Instruct Book for the tsbachsyer, attached ihe ABs seshabochargrtn ue caynelcloweton lipreating ois is srongly recorm ‘Re engine ond the {ubocharger menutactuers Oil easnge interval 81500 h seaviee for special mineral oils amd 2500. sorviee for synthoti lubricating oils Take care that the turbine oll is not mixed with engine lubricating cll. Only @ small quantity may cause heavy foaming. The list of approved lubricating oils for the AIBB VTE. series tusbo ‘changers eam be found in the end of this chapter, These luhricating oils are, regarding viseosity and quality, aeenrding t9 the recommenda tions, 02.2.6 Lubricating It is recommended to use EP-gear oils, visensity 400-500 eSt at 40 °C=I80 VG 460 as lubricating oils for the turning device ‘The list of lubricating oils for the engine turning device approved by the turning device manufacturer can be found inthe end afthischapter 02.2.7 Handling of oil samples ‘When taking uel oilor hubricatingoil samples theimportanceof proper sampling can not be over-emphasised. The aocuraey of the analysis results is significantly dependent on proper sampling and the results wwillonly be as good as the quality of the sample. Use elean sample containers holding approximately 1 litre. Clean ‘sample containers and accessories (ATA enrton boxes for transporta tion, ready made address labels, ete) are available for example from ‘Wirtsila local network offic. Rinse the sampling line properly before taking the actual sample. Preferably also rinse the sample bottles with the oil a couple of times before taking the sample, especially if "an Jnown" eample bottles need to be used, Close the bottles tightly using the serew caps provided. Seal all bottles and record all the separate seal numbers carefully. Put the bottles to be sent for analysing in Ziploc” plastic bags to prevent any spillage. Gently squeeze the"Ziploc™ |w20/W32/W46, 32, S2LN 02-17‘bag to minimise any air content prior to sealing, "The backround information for the Fuel oiVTubvieating sample is as important ns the sample itself, Oil samples with no backgroutc infor ration are of very limited value, The following data mie essential to note when talking the sample + Installetion name + Bngine type and number + Engine operating hours + Lubricating oll brand/fuel oil type + Lubricating oil operating hours » Where ia the system the lubricating ol/uel ell sample was taken Sampling date and seal number of the separate sampies if seals fare available ‘= Reason for taking and analysing the sample ‘© Contaet information; Name (of the person who wok the sample), telephone, fax, e-anail, te Use for example the ready made °Oil Analyse Application’ form, see Thustrction Manual attachments Observe personal sofety precautions wher taking ard handling fuel oil ‘and lubricating eil samples. Avold brezthings of fumes and mest, se ruspirator if necessary. Use strong, heat und hydrocarbon resistant ‘loves (ntrte rubber for example}. Wear eve gogaies if spac risk xis, Wear facial screen and proteting clothes if hot product is handled. 02.2.7.4 Lubricating oll sampling Luhrienting oil samples should be taker with the engine in operation imenediacely after the lubricating oi [ter an the engine Albenys take tubieating ol samples before adding fresh oi tothe system, 102.2.7.2 Fuel oll sampling Fuel oil samples ean be deassn from dliffevent places in the fuel oi system, Fuel samples “as bunkered’ or “before the engine” (after fuel oil separation and filtation) are perhaps the most cominon sample types. From the engines point of view the most inapoctant fuel oil sample is naturally the one which enters the engine, Le. taken after fuel oil separation and filtration. But if for example fuel oil separator efficiency neces tobe checked samples should be tuken just hefore and afterthe separator, tisnotadviaable to takesnmaples from tankchottom drain valves, since these will probably contain high levels of water and sediment and thus the spl will no! Be rpresentative of he hulk phase. 02.2.8 Dispatch and transportation Pace the bottle with the “Ziglo” bag inside the LAT carton bax and fold the box according to the assembly instructions given’ on the bos Enclose a copy ofthe "Bunker Receipt”, if available, hefore closing the Inst flap on the [NTA carton, w20/W32/WA6, 32, 32UNeEre Trac Perl Check the DNVPS Ai Courier Directory and use appropriate label for the IATA earion box to ensure that the sanmple is forsanded tothe ‘nearest DNYPS laboratory. Complete the courier dispatch instructions 6 the side ofthe LATA carton, Fill in the DNVPS universul uecount ‘nuwnber (950 590 010) to prevent rejection from the courier company (DHL), Complote he Proforma Invwice Form and tape it tothe outside of the LATA ear, Call the air owarier directly at the number as indicated in the Air CCoutier Diredtary and request urgont pick-up, ifmeeessary. When the ‘courier arrives you will ned to complete an Airway Bill, tis recommendable to nandle the dispatching of the fuel oil and lubricating ol supe at size. The results will he achieved faster when the dispatchingis handled at site and additionally its legal to carey fue al samples as personal ugsaye on normal aeroplanes. Support with merpretatinn oF the analysis rosults and advice on possible corrective actions is available Som Wairtsil, if needed, wa0/W32/WA6, 32, 321N 02-1902-20 Ay oie! Ay cote! Ay carton A Wom In order to prevent carrsion, scale deposits or other deposits in closed circulating water systems, the water must be treated with additives, elore treatieent, the water must be limpid and meet the specfien tion found in Yhe end of this chapter. Farther, the use of an approved voling water additive or treatment aystem is mandatory: Distilled water without adaltives absorbs carbon dioxide from the if, which Involves great isk of corrosion, water will eause severe corrosion and deposit formation even if plied to tho systom in small amounts, water hax high oxygen and carbon dioxide content: spt risk ‘of corrosion; unsuitable ae cooling water risk of frcting occurs, please enntact the engine manufacturer for tose of anti-freeze chemicals Fresh water generated by a reverse osmosis plant onbosed often has fa high chloride content (hisher than the permitted 80 mg) causing The use ot glycol in fhe cooling water is not recommended, fits not necessary. Siice alycol clone does not protect the engine ‘agains! corrosion, adetfionally an approved cooling water odtive must always be sect 02.3.2 Additives As additives, use products fom well-known and zeluble suppliers with vast distribution nets. Follow thoroughly the instructions of the sup- plier The use of emulsion cil, phosphates and borates (sole) is not accepted. Inan emergency, ifepmpountied additives are not available, trea the cooling water with sodium nitrite (NaNOs) in portions of 5 kfen?. To obtaiir a pH valuo of 9, add eaustic soda (NaOH), if necessary Sodium nite is toxic. wa0/W32/WA6, 32, 321NPe ° Coes te Corrosion rote as 0 hinetion of nitite concentration Nitrite oxidation curve ‘To give full protection the Nitrite level should be kept above X ppm. The ‘actual concentration is active ‘supplier dependent ‘permanent lower level wil leat 12 ‘anacoelerated corrosion rate, w20/W32/WA6, 32, 32LN ee ‘ via XXhpm Nite Concentration Fig 02-4 an Nitrive based eouling water additives are socalled anodie inhibitors and require proper dasing and maintenanee in order to serve as intended. ‘The nitrite of the additive is as such a salt and it will inerease the condhctivityof the watet, The condictivity is on the other hand one of the main parameters affecting the corrasion rate once carosion proctss gots started, the higher the conductivity the higher the eorto Ifthe conditions (nitrite level, chlorides, pH, ete) in the aystems are such that the nitrite based auditive is no Langer ably eo protect the ‘entire surface a the aystem there may cect a rapid, local corresion ia the areas that are not protacted. The corrosion rate at the attacked teas will even be much greater than it would be with no additive at all present in the system, soe schematic graph of the corrosion rate as a function of the nitrite dasage in Fig 02-4, Observe that the position fof the curve peak on the x-axis dangerous condition for corrosion) is not stable, but will shift depending on temperature, pH, chlorides and sulphates contents, ete, in the colin water ‘The table below shows shows examples of the mast common col wwator additive types.ONT | _Advantages “gooderticency. absoge tr contraiog caren Sodium | “gros detve quantias. Bos by mos - cheap Disadvantages suitgoie os ocatve except ‘hereon Haat ex sage suttaces 7°" {St epot conosion when ‘oa low concenietion norsecae kof cones NMinite | enocabus forthe sn orate Sodium silicate = hat tee Ress to hana Sodium molybdate rganie | -nottode andinor- ‘ecnic syn- is ergisic 02-22 __|_torete sipnates} Tendency to attack ane (Coverings and sof soso fi Home: ethol dosage 3-4 Seinite oo 49 fe FtB6t conoson wen Taw concentration _ ‘ol active when woes Weiocy excueck Sp -cSrnarca produce ory PERES wo esonon En tpoteoreson fied toby ~inergexpensve hon Fie adits -iyetoared of concson, ifunsiteenty dered - coneouse depot ‘soto “imovicltes con cotect to ‘more expensive than som fen ‘atts ond moiyodate posed, ‘oscitves «(big active quanttves by ‘w20/W32/Wao, $2, S2LN5S Note! 02.4 wa0/wsz/wa6, 32, 32LN CNET 02.3.3 Treatment ‘Wher changing the additive or when entering an ative into a system where unerated wator hasbeen used, the complete stem must be cleaned {ebernially) andrinsed hcfore fresh treated water is pouredintnthesyster, IE, gant our ncomacwadations, an emulsian ofl as been used, the complete systom must he absointaly cleanest fil and greasy deposits. Evaporated water should be eompensated by untreated water, if treated water is used the content of additives may gradually become {eo high. To compensate for leakage or other losses, ndd treated water. Tn connection with maintenance work calling for duinage of the ‘ator system, take care of and reuse the treated water "The hist of approved cooling water additives and treatment eysteme can bo found in the end of this chapter. ‘Ask the supplier of the tteatment product for instructions about treatment procedure, dosage and concentration control, ‘Most suppliers wil provide a test Kit for the concentration eouttal Additionally a frequent laboratory analysia of eating Water at 3 months Interval is tecommended tp. ensur eats eine operation Injection water (DWI-engines) 02.4.1 Water quality Water sed for Direct Water Injection DW has to falfil the following, requirements: 59. x. 10 ‘max 80 max $0 na. 60 mae 80 sc Tresh water to be used, se alto eection 02.3.1, ‘The water must not be contaminated by oi, grease, surfactants or sina impurities. These kind of impurities may cause blocking of the Blters or other malfuneticns n the divect water injection system, 02-2302.5 02-24 Water quality requirements for Wartsil WETPAC™ system Water quality used for Wartsiki WTPAC Homidification of inlet aie systom (WETPAC™) has to fulfill the following zequirements: Property Maximum val Unit pH 4 os. Hraness oa (Chlerces Ct 5 Sssnenced Solids 5 Temperature before pump | ro Inevdler to achieve a safe operation of the Wetpac™ syston sad the fenggine, water procuced with a fresh water generator / distiller has to be used, The water must not he contaminated by ofl, yrease, surfuctants or silat impurities, These kind of impurities way cause blocking ofthe filters or other maifwnctions in the Wetpae™sytor ‘w20/W32/W46, 92, 32LNoe Gaposton | REQUIREMENTS & OIL QUALITY wife | “Ee ae ite a ——Trr Jenova [1 ali nan 4.2.5 REQUIREMENTS AND OIL QUALITY. ‘SYSTEM OIL REQUIREMENTS AND QUALITY FOR WARTSILA 32 ENGINES. Viscosity Viscosity class SAE 40. Viscosity Index (VI) Min. 95, Alkalinity (BN) The required lubricating oi alkalinity is tod tothe fuel specifiod forthe engine, which is shown in the table below. FUEL STANDARDS AND LUBRICATING O1L REQUIREMENTS a8 : Fuel standard Lube STEN, ASTM D O7507, ‘GRADE NO. 7-0, 20 A BS MA 100: 1996 | DMX, OMA, 10-30 IMAC 2003 DX, DA 1S0 8217: 1996(E) _| 1SO-F-DMx, DMA - BS MA 100: 1996 [DMB B CIMAC 2003, ba 18-30 1S0 8217: 1996(6) _| 1S0-F-0Me ASTM D 975.01, ‘GRADE NO. 4D ASTM 0 396-04) GRADE NO. 5.6 © BS MA 100; 1996 | DMC, AMATO-AMKSS | 30-55 IMAC 2003 0c, A30-K700 180 8217: 1996(€) | IS0-F-DMC, RMATO- it MKSS. BTeRUbE Git CRO) Songs It is tecomeended to use in the frst place BN $0-55 lubricants when operating on heavy jel. This recommendation is valid especially for engines having wel lubricating oll sump and using hoavy fuol with sulphur content above 2:0 % mass. BIN 40 lubricants can be used when operating on heavy fuel as well # experiance shows that the lubricating oll BN ‘ecullbrium remains at an acceptable level BBN 30 lubricants are recommended to be used only in special cases, stich a9 installations. ‘equipped with an SGR catalyst. Lower BN produrts eventually have a positive influence on cleanliness of the SCR eatalyst. With BN 80 oils lubricating of chanyo intervals may be rather chert, but lower total operating costs may be achioved because of botter plant availabilty provided that the maintenance intervals of the SCR catalyst can be increased.BN 30 oils are also a recommended alternative wen operating on crude oil having low sulphur content, Though enue olls many times have law Sulphur content. they can contain fother acid compounds and thus an adequate alkali reserve is important. With cre oils having higher sulphur content BIN 40)— 55 lubricating oils should de used. It both distilate fuel and residual fucl are used periodically as fuel, hubricaing ol quality nes to be chosen according to instructions being vals for resicual fust operation, Lo. BN 30 is the minimum. Ofzimutn BN in this kind of operation depends on the length of operating Deriods on Bath fuel cuales as wall az of sulphur content of fuels in question. Thus in ppanicular cases BN 40 or even higher BN lubricating cls should be used. ‘The intervals between lubricating oll changes may be extended by adding oll daily to keep the off level constantly case te the maximum level. ‘An example of BN depletion curve with diferent BN lubricatiay as is chown bolow. i : T 1 condoning tnt 20mg Kong | CH Voune: 06 Ki (et Bump) 5 ASE NUMBER fg KOM) 8 « 2000 000 00 000 scso SERVICE HOURS Additives The ols should contain adaves that give good oxidation stability, corrosion protection, load eauying capacity, neutzalcatien of acid combustion and oxidation residues and shouki preven! depesit formation on intemal engine parts (piston cooling gallery, piston ring zone ‘and bearing surfaces particule’). Foaming characteristics Fresh lubricating oll should moet the folowing limite tor foaming tendency and stability, according to the ASTM D 882-42 fast mothod! sequnoet 1000 ri ‘Sequence Il: 10010 mi e Sewencehi: 4000Use of vigin base stocks only is alowed, ie, recycled or re-refined base ole aro not allowed, CONDEMNING LIMITS FOR USED LUBRICATING OIL When estimating the condition of used lubricating oil the folowing properties along with the corresponding limit values must be noted. Ifthe limits are exccoded, measures must DS taken, Compare also wth guidance values for fresh lubricating ofthe brand used, ‘max. 25% Increase Property nit Tint ‘Test method Viscosity cSt ata" | max. 259 decrease | ASTID 445 ‘max. 45% increase Viscoatly ‘SLA TOTS |max. 20% decrease | ASTID 445, Water ev max 0.30 ASTM Sard 174 Baso Nanber | ma KOH ‘min, 20 in HFO operation, | ASTM D 2896 ‘max. 60% depletion in LFO operation. TasoUbles Femim max. 2.0 ‘ASTUND 8936 p-Pontane - Flash Pot, PMGG | "C Tin 170 ASTIN D oS Flash Point COC | °C sin 190 ASTM D 82. CHANGE OF LUBRICATING OIL BRAND. In order to minimize the risk of lubricating oll foaming, deposit formation, blocking of lubricating ol fiters, damage of engine companents, et., the following hencedure should be followed when lubricating of brand is changed fram one to another ‘+ If possible, change the lubricating oi brand in connection with an engne (piston} @ 7 sinast ‘rai cid lubricating ol from the lubricating ol systom + Clean tn hibricating oll systom in case of an excessive amount of deposts on the surfaces of engine component, ike crankcasé, camshaft compartmant, a 4+ Fill he lubricating oil system with fresh uorneatng oil If the procedure descrized above is rot followed, responsibilty of possible ¢amage and malfunctions caused by lubricating oil change should always be agreed between the oll company and customer. APPROVED LUBRICATING OIL QUALITIES FOR WARTSILA 92 ENGINES ‘Should unapproved lubricating olls be used during the engine warranty period, and there ‘exist no agreement with the engin manufacturer about testing, the enue guerantee does eu-™_aveeno64s GAS OIL AND MARINE DIESEL OIL OPERATION It gas oll or marine diesel oll is used as fusl, fobécatiny oils wih a BN of 10:25 are recommended lo be used. Also BN 30 lubrivaling ls inchided in Table 3 can be uced in ‘94s oll and marino diesel ol fuelled engines. Toble 1. Approved system: cils~ fuel catagories A and B, cecommended Inthe firt place in gas oll or ‘magi dasa cl installations SUPPLIER BRAND NAME ViscosnY [BN [FUEL CATEG. _ we Energol HPOX 40 THEW [A Castrol HLX 40 SAEW [12 [A MHP 154 saci |1s AS ‘Seamax Extra 40 sacao |15_ | AB Chevron (Texaco | Delo 1000 Marine 40 SAE4O | 12 + Caltex + FAMM) | Delo 2000 Marine 40 saeao | 20 Tero 12 XD 40, SAE4O 12 Taro 20 DP 40, SAE 4020 Exxontabit Mobilgard ADL 4 SAE40 | 15 Mobitgard 412 SAE40 15 Mobilgard 1 SHC SAE 4015 Tadian OF ‘Servo Marine 1040 ‘SAE 4010 | Corpevation Servo Marine 2040 SAE 4029 = Petrobras arbrax CCD-410-AP ‘SAE 40/12 Marbrax CCD-415 SAE4) 15 Harbrax CCD-420 SAE #020 Shell sae ao 12 ‘State - SAE40___ 108 Total /Lubmerine | Disola M4015 ‘SAEAO [14 Disola M4020 SAE 40 |20 HEAVY FUEL AND CRUDE OIL OPERATION Today's modarn trunk piston diasel engines are strossing the iubsicating oils heavily due fo 2.0. low specific lubricating oll consumption. Also ingress of residual fuel combustion Products into the lubricating oll can cause deposit formation on the surface of certain engine components resulting in severe operating problems, Due to this many hibsicating of suppliors have developed new lubricating oll frufations with better fuel and lubricating oft compas ‘Approved system lls - fuel categories C and D, recommended in the first place when ‘operating on heavy tusl and or on crude ofl having high sulphur content in order 10 reach fll service intervals. BN 50-55 lubricating ols are proferred in the fist place@ 50 sar085 ‘SUPPLIER BRAND NAME VISCOSITY | BN | FUEL CATES. oP Energol I HEX 408 SAE4 [40 [C.D Energol IC-HFX 504 sae4o [50 | co Castroi TLX Plus 404 SAE 40 TLX Plus 504 SAE 40 TLX Plus 554 SAE 40 Cepsa “Troncoll 4040 PLUS ‘SAE 40 ‘Troncoil 5040 PLUS SAE 40 Ertoil Koral 4040 SHF SAE 40 Ertoil Koral 5040 SHF__| SAE 40. Chevron (Texaco | Taro 40 XL 40 ‘SAE 40 + Caltex + FAM) | Taro 50 XL 40 SAE 40 Delo 3400 Marine 40 SAE 40 — Delo 3550 Marine 40 SAE 40 Chinese ‘Marilube Oil W 404 ‘SAE 40 Petroleum Maritube Oil W 504 SAE 40 Corporation _| a ENIS.pA. im 400 § SAE 40 ‘SAE AG Cladium 500 $ SAE 40 | SAE 46 Gladium 550 SAE 40 | SAE. 40 Exxontiobi Exxmar 40 TP 40 SAE 40 Examar 50.7P 40 SAE 40 Mobilgard m 440 SAE 40 Mobilgard M50 SAE 40 Fuchs in PSW 40 SAE 40 ‘SAE 40 L tan PSW 58 SAE 40, SAE 40 Taian OF ‘Servo Marine K-4040, "SAE 40 Corporation ‘Servo Marine K-5040 SAE 40 ‘Servo Marine K-5540 SAE 40 | Pertamina Martron 440 SAE Martron 450 SAE 40 ‘Salyx 440 SAE 40 Salyx 450 SAE 40 Petrobras Marbrax CCD-440 ‘SAE 40 Marbrax CCD-450. SAE 40, i in Petromar XC 4040 ‘SAE 40 Petromar XC 5540_ SAE 40 Repsol YPF Neptuno W NT 4000 SAE @0_| SAE 40 Neptuno W NT 5500 SAE 40_| SAE 40 Shell ‘Argina X40 ‘SAE 40 ‘Argina XL 40 __| sae 40 Total Lubmarine | Aurelia XL 4040 SAE 40 | Aurelia XL 4055 SAE 40S01 aysen06ts Approved system ails - fuel categories A, B, C and D. Lubricating ofs with BN 30 included In Table 3 are designed to bo used wien operating on crude oll wih low sulphur content (< 1% mim} and in sposial cases wien operating on heavy fuel, e.g. in installations equipped with an SCR catalyst. ‘SUPPLIER BRAND NAME VISCOSITY] BN ] FUEL CATEG. BP. EnergoliCHEX Soa | SAE 40 30_[AB,C.0 Castrol LX Plus 304. “SAE 40 '30_| AB,C,0 Cepsa Troncoil 3040 PLUS | SAE 4. 30 [ AB,C.D Ertoil Koral 3040 SHF__| SAE 40 30_|ap.co Chevron (Texaco Taro 30 DP 40 ‘SAE 40 30 [A.B.C,0 | + Caltex + FAM) | Delo 3000 Marine 40 __| SAE 40 so | ABCD oO Chinese Marilube Oi W304 SAE 40 30 | AB.C.0 Petroleum Cladium 3008 SAE 40 | SAE 40 30_[AB.C.0 Exxmar 30 TP 40 ‘SAE 40 30 [ABCD Mobilgard M430. SAE 40 30_|AB.CO Servo Marine K-3040 | SAE 40 30 |A.B.C,0 Martron 430 ‘SAE 40 30 [ABCD Salyx 430 SAE 40, |30__|a8.c.0 Marbrax CCD-430. ‘SAE 40 30 [ABCD etromar XC 3040 SAE 40 30 [ABCD rz ‘Argina T 40 SAE 40 30 [ABCD Total /Lubmarine | Auretia XL 4030 SAE 40 30 AB.6.0 Before using a ibicating of no sted In Tebles 1-3, he engine manutacturer muat na @ Conrad Lubscting of tha ae nol approved have to bo tested according Ws erghne ‘manufacture procedures. APPROVED LUBRICATING OILS FOR ENGINE TURNING DEVICE It fs recommended to uee FP-gear oils, viscosity 400-500 cSt al 40 °C = ISO VG 460 as lubricating ols for turning device.Te) aveoHO6A5 ____ LUBRICATING OILS FOR ENGINE TURNING DEVICE ‘SUPPLIER BRAND NAME [VISCOSITY | VISCOSITY] VISCOSITY nas | eStat 40°C | eSt at 100° | INDEX (Vi) oP, Energol GRXP460| 425 270 | 88, Castrol [Alpha SP 460 | 480 30.5 95. Chevion (Texaco | Meropa 460 460 318 100 + Caltex + FANN) | ENIS.p.A. Basia 320 —300 230 Exxonvfobil Spartan EP 460 ‘460 30.8 Mobilgear 634 437 278 Sheil ‘Omala Oit 460 460 30:8 Total Lusmarine | Epona Z 460 470 303) LUBRICATING OILS FOR GOVERNOR / ACTUATOR ‘An oll of viscosity class SAE 30 or SAE 40 is suitable and usually the saire oll can be used as in the engine. Turbocharger oll can also be used in the govemor. In low ambient Conditions it may be necessary to ue @ multgrade oll (0.9. SAE 5W-40) 'o get a good Control during start-up. Oil enange interval: 2000 service hours.yet ee) ©_| © wensiasnum0y | RAW WATER QUALITY AND APPROVED WARTSLA, Ferd | COOLING WATER ADDITIVES: ‘ite coon a lemiee aoe YDocrvenns [rev | “on Be sesen [sees | 1210808 se [aveanores | Sr RAW WATER QUALITY AND APPROVED COOLING WATER ADDITIVES FOR WARTSILA® VASA 3232LN, WAKTSILA® 20, WARTSILA® 26, WARTSILA® 32, WARTSILA® 38, WARTSILA” 46, WARTSILA® 46¥, WARTSILA? 64, WARTSILA® 3209, WARTSI,A” S0DF AND WARTSILA® MSG ENG! RAW WATER QUALITY Raw eater quality to be used the closed euoling water iris of engines has 0 meet the following specifi Property [Tinie ll Hardness [ma 10" ——] ‘Chlorides max, Song Sulphates [ana (50 mg For raw water eviporate! water anda good quality tap water are nontlly recommended. Ya reverse ‘osmosis procons rests in water quality speifid above, that can be used as well, Unreate sea wate tend es ater us wells ain war are nwitale nw water qualities APPROVED COOLING WATER ADDITIVES Manih ave name 5 Havoline XLi Teelmolaicpark-Zvijnaarde 2 -9052.GhemiZwijnasee Belgium | Asti! Spectsty Chemical Drevs Indira (ne Drew Pla ‘Ashland Specialty Chemical DEWENC power Drow Marine Liguidewt Oe Dew Pla Masigard Beaton, NJ 07005, USA.(Of ° Nanofaetarer [Additive name GE Bota Europe Consild NT 4293 Tnterleuveniaan 25 1.3001 Heverle, Belgium Gr Bete Con Shield NT 4200) 4536 Somerton Rod “Trevose 1 19053, United Sates _ | Houseman Lad Chakra OT The Priory, Burnham Slough SLI 7LS, OK Kuwait Feibleun (Damark) AS ‘Gi Tresiontahibhor Longs Lite Hameactatvei) 29 | DK-2830 Virur, amark eee a ‘Martsch AB SiarsoT CW Box M3 Oo s stianstad. Sweden ‘alee Chemical Company Taleo 39 (One Naleo Centre Naleool 2000 Naperville, lino 366-1024 USA Nalflet Marine Choiical Talent 2000 PO Box Il Nailer EWT 9-108 Winningion Avenue, Noshwich Cheshire, CWS 4DX, UK RDiT RDIIM. 52s 1 Kecstop KY 77570 Jap, Faland ‘Gevron obal Lubneans vate e 6101 Botingse Canyon Roa San Ramon, CA 91583 Foi Wisp Diamant 8 16, ed a Républiqne 50923 Pars La Dstese Code. Fance Chitor ASA Diesclguad NB P.O. Sox 300 Skayen Rocor NB liquid N-0212 Osto, Nowa Conlieat AL ‘Vecom Holding BY Vecom CWT Devel G2 PO Bos 27 3140 AA Muassluis, The Netherlands In onder to prevent corrosion in che cvoling water system, the instructions of right dosage and concentration of active corosion ihibitvs should always be Followed. ‘Te information can be found inthe table below. ex pam o @ [isles [3 Product designation Dosage per Tv of system capaci ‘Concentration of active corrosion inhibitor Corshield NT D9F ‘Conhield NT 4200, TO tees ‘870 — 1008 ppan as NOs Drswgar 4100 Tes Loe pa NO DEWTNC power 3 aSkg 1300225 ppm as NO> Drew 409 16-30 thws | 640-1200 pms NO Lauidewt B-iDliees [470 7D ppm > Makar 16 0lins | 640 = (209 ppmas NOs Cosa 1 Sis 300 7pm «NO; (5 CorsosiorTahibvor —]50= 100TH 8 87 Br ative compos Lone-tite smeared with 9 spies eracincter Maccol CW oie O00 = 1500 pp as Naleo 390) 16-36Tins 350-1200 pas NOs Nino! 2060 2cakiines | 1000-151 ppm m8 NOx @ |sainesetwro. ios [235"3.ttices [690-1009 ppmas NO. | Rosiop KV 30-35 lines [120-130 ppm os Mo ROUT RDIIND sk 1380 ppm as NO; RDS Salis 710 poms Mo Tlaotne XT 50-T00TIRS [18-37 Uex® ofaane compas sneaned wih supplier sree WHS BOCTOOTRS 18-37 Trix of active compous sucasued with a supplier's rleaconieer Dissiguad NE 50-8 Tao 210 pps NOT Recor NB Liquid 952 tues | J000~2400 ppm se NOs Coole AL $0-t00limes | 188-27 Bra’ of active compounds imenoned wih «suppl refaconeter [Wem wT DAT OCT [OTs 1500-2500 pus NO Note Iz Tow tiny prot he rsommende nin and mixin mis are Hed inthe be athore. Sime the amount of active cocsion inhibitors copay nits, i decreasing e drng the sevice of engines, the engine manuatre recommen to tat he dow om the upper eve of indicated range. Note:The nitrite coatent of trite-hosed cooing water additives tends to decrease in use. The sk cf local vorzasio inerewses subsantally when ntete content goes below the socommended Tin Note 3: Cooling water ative manufacturers eam fadieate the required tite content messed ther 2 Sodiune site NaNc NaNO; owe nite, NOs, L-mgll a NO equals to 1.5 mgfl asLe [essence [>] e USE OFGLYCOL Ita frecring vik exist, glycol nocd to be add to cooling water. Sipe plyeol alte does nat pret the engine and cooling water sstent against corrosion, aldtonally en appeoved sucting. water additive must always he used. Aff approved cooling water akitives age compatible ith give). the moot of glycol in closed cooling water system shall akways be minimized since heat wane of ‘ware containing glycol as deteriorated signficaaly, Engine ype specific cexuirements have 10 be always taken into account and in some cases dering of engine auipu is needed ia igh amount of lyeol is ade fo closed cooling water system. Thee are comercilly available two types glycol ‘lalities, monopropsfene glycol (MPG) and monocthyleneziyeot (MEGI- So called industrial qualities of both glycol types can be used, hut MPG is coasidened 1 be x more environmental ternative.32-200402-08 Stan, Stop ond Operation ee) ° 03. Start, Stop and Operation 03.1 Turning of crankshaft ‘Turning is peeformed by means of an electrically driven euening dloviee built othe engine. 03.1.1 Electrically driven tuning device The tuning device consists ofan elettie wot which drives the twening gear through a gear drive and a worm gear. There is 8 ‘ontol box available, inloding cable, which allows the Ping e robe accomplished from any positon near thee. The turnin speed ofthe fiywhcel ts abou 0.6 RPM. "Te engaging arid disengaging ofthe tar gwar is made by the fever (I) th ello ball ob. The Curing gear Is sping ‘outwards inorder to prevent it fram meshingwith the yet wher ‘operation “The turing device is povided with a start lacking. valve which prevents starting In eau he turing year fs engaged See chapter ty seetion 21. For careful adjustment of the erat postin there is hand wlael @ with whieh is possible to perform marl ming. Electrically driven tuming device atin e 1 5 Fang no s.came aes e Fig 037 asi WARTSILA 32 03-103 Stari, Stop and Operation Start 1. Remote stars 2 Lovall start &. Emergency start (salenold valve) 4, Emergency start (starting valved) Befure starting the engine, heck that f the lubricating oil level is correct the fuel system is in ruinniog order (correct profeating, correct pressure, sufficient precireulation to beat the fuel Injection pumps) * both cooling water system circuits, LT and HT water circu fare in cunning order (correct pressures, elrculating water preheated aint pre-cireuated sufficiently to heat the engine) » the oll level in the governor Is correct the starting air pressure exceeds 15 har ‘the starting air system is drained of condensate «= the drain pipe of the air cooler easing Is open, no leakage «stop lever is in Work position * peshubicaing oll pump is cunning ond prssune 5 over ‘turning devioe fs disengaged ‘Indicator valves are elased ‘that the aucomation system indicates ready for start All covers and proteeting shields are r0 be mounted and elased before starting the engine. Covers shoufel be removed er apened ‘occasionally only for measuseraents and checks, and they must be immediately mounted agin. Note! Never leave the engine running when covers are removed, 03-2 WARTOILA 3232-2004N2-04 WARTSILA 32, Note! Siart, Slop and Operation 03 03.2.1 Local start 1) stat the pretubricoting oil pump vo obtain Tubsicating ail gressure, oer 0:3 bar 2) Open the vaive in the stating air suppiy systom anc drain condensate via the blow-off valve. Close the blow-off valve vlan there is no mare condensate [3] Tum the crankshaft either two revolutions iy using the Taming device or tn the engine on stating at at some reve Iutions hy pressing the button on the salened valve and keep i the stop lever In stop position (red Dall Knol) and the indicator valves open, In doing 50 the risk of water lacks Is elinated, After Blawing, close te indicator valves [4] Disongage the tuming gear from the flywheel (yellow ball Kot), [5) Check start blocking on the LDU. Remove blackings and Feturn fo the main pope. 6) Check thal the automation system indicates. realy fo 7) Check that the stop lever is in werk position |B) LocalfRemote switch in local postion. 9| Push the stattbution. If cic engine does not start after Starting sequence, de reason shouldbe checked [i0| Cheek that the automation systom indicates tbat the engine fs unmng and thatthe running parameters are nos mal The stating at supply should be open when the engine & running, ofnerwga the pnoumaaic slop moy not work, 03, Remote and automatic start See installation specifi instructions, 03.2.3 Emergency start Emengenty siewation engine san alsobe start. manually by push Ing the batton on the starting solanod or main starting valve 03-303 Start, Stop and Operation '32-200402-04 03.4 03-4 Caution! Stop 03.3.1 Manual stop 1 tale the engine 1 min before tapping 2) Stop the engine by moving the stop lever nto step post tion ac by pressing the stop bution (LCP). The time Gf slowing own offers good opportunity to detect posse (0) Belongs to complete too! set, cod ROODI6. "nvaro200 ‘vesfols7 vars avesr0ies vesraise ‘verve, 2vesrOI8? 2vesF018 waeywa4sews2/wsasc. 05 sont sean eae bessipion — —prangNs, 0018 Ute vasFDIS6 ROOMS Asem ra) ‘vasr0z38 099 —Suppod ct svasro2a SEOIOE_ Mounting sige (> 2veo19! sq0101 _eantngslocge CD avast 200102 suppotam 27830369 200107 _ Protecting deve for connacting rod svaaro209 20108 suppor co avasronay 1) Belongs to complete toolset, coe HOORAE, 05-505 Maintenance Tools 32-200237 ‘Connecting Rod 110 8 sovesr axon Brawina No. ‘S0UIZOHyorec toa NaIRD Gy, naaING ROT ‘vsean2 a 200021 Stud mover MOTD <4vec00052 BOX? infor ightening of us 2A ‘AV8680231 {00053 _ High pressure pup (1000ba) (1) 2v86A0033 200056 _Flewtle nese S00 rm (D> 200057 Henle hore 1103 rm (1) 800097 _Dstonce seve M272 () Inehuctng quiek couplings 05-6 waa/wsasesree nem thantensnon eos Te oe | Piston 10 eo, Sede _Daseipon —— Drawing No. Sccn0T “Pong Si — nants feo? es ere ng sae ODI? Ungtoo! ch poses fox012 _Ungtool 2 Sera f00015 Contes or stnings et S018 Meco fosior ton ing ove 10H Spar te frpes tm. vc : {0140 Frou ck ring oon Fives e (0 Diesel engines ©) 96 engines ‘ws2/Ww3486 05-708 05-8 Maintenonce Tools Cylinder Head tase taepice — aang Urogtos ‘2vsx0011 ‘Mounting & demon tool for watos ‘ai0110 Tuming Foc or grncing of veves eco? yc toot 46 ().Incldrg EOOORE veel fing tol orm cides wares ign eresuse pane (0beH (1 — avesaosa ee wa Bey) Hyena etontor 1) svesenbsi Lance soove Ms ‘asc? {C0150 Eerocor tr yoko in coo | {00135 Exact fol fer cyind head deve _sves0075 00142 Limogiool@) T avescooes {48115 Valve clecrance gauge fooler forpce wale (065) 4va0067 {) Including quick coups @ SGeengines32-200237 Maintenance Tools 05 ws2/wsasc Cylinder Head 120 oo oui ae Q 7 Cade Daipion ii ‘000 Pore fr secu tha 00010 Sud ernover 520 00027 _ Removing tok torrjction & song wae venom 200080 _ valve lerence teeler op 800081 French for inciotor va O09 _ in fochahlaring of Ms AINE _lowbio nose 3050 rm cl) 002% Box wrenen hee 2¢enm faWNI26 _Extraston morctetfor wove guide Aplus Adler Me, avesn0s20 #22000 _Yoraue wrench 0-100 Nm AvV2KCOD :605,_Btereonbor 25°250 BRON Spore puy socket @) aviamrs 182007 Adjusng too tec prechomber vave @ vizio ATCE2 Pas tes device for prechombo! @) 2vi710%61 (1) Including quick couplings @SCengines 05-9.05 Maintenance Tools 32-200237 Intermediate Gear and Camshatt Tools 130 05-10 ing afruts 200069 Hgh eraser pin 100010 1) CUE eit newo U0 en (1) 200082 Mounting & removing tok 800059 Hyoroule extractor 800112 _Hyeaule tools VA ferinterm. gece.) 000113 _ Suppor fer yekoute too! 0124” Mounting and ternoving fosters 8 800125. Foseniag om 800150__ Mounting tool carat piace (0) Including quick couplings ao en aos Sree ina Saou a Wa3GOI66 e wa2/wsaseMaintenance Tools Injection Equipment 160 a SSR _Gincting ool Wacom “eset Errante recon wave "yan0116 frm sce wer Son sirens fu Faerur warn ripening afhscton pes dl in ANOS Bn secet waren eS forense conrad ‘aernoct {2080 ttt ockmoveres Sisco Fear ooo wotpbe toes aac fea Locing ac econ pare tape ‘3021 07) ing totes rectonpure arate e 07S Gounnglectersecarocelrtecionvcvo __ Deas? teams Tonio reno evexens? {00111 Means gator njecton puro torpet Sveents {00127 toate conactng lee urge stews sess 010 bios toro ecton pup terse! 282 fromm Torvo onc L20S00Nn ‘owen? HONG fer west for Georg to BOTS ‘esse? tastes Toate neclonsunotoarg sn wse/ws4sc 05-1105 Maintenance Tools ___ 32200237 a Turbocharger 372 e Dessipion ning To9e for naboonage ECT A ara 1B 200070 Took or nsbochargor EG} 297. 6h ond 12 800071, ook for iurbocrorger EST 35, LL WV cmd 1B 20007) Too for tutsachorger EST 357.8, A. 16V on 18 80007B_Taghtor Dacnarye TA 6, shone IV 800079 Fook tor urDocharger P45, 6k, IBV ant IBV 00079 Took fox ocnergerTPLA®, BL, 9, 18V are TE 05-12 ws2/ 348632-200287 Maintenance Tools wsa/wsase Miscellaneous Tools Das Drawing te, ‘X08 Mouning &remashg ol Ter commaH baaingbuh —_svBaHII67 £00085. Hyeroule exo 0) ‘SvacE0061 {800064 Checking fal or cyinder values igitnoss BO0O48 Detection nator nanos 200066 Locking piste or hyecton pimp tappst ese 200087 Sacurng nor wave Lapoot “460124 00089 Ling soo M12 00089 Ling ys or AN ‘ord _viencn for centgo) Mer venc00%9 800122 Eerate plo for nckver ot ihemestaie elomoni 48340480 00124 Maurtng tool for connection piece @) 1veas0se0 00132 _ Praumote tes! equipment ornyection pun Wwielois? 800151 Hrawntng tool or connection piece 2vee065s 227058 Siu torextoctr (water jection astem) ‘aveshosse O59 AMP hand ermeing to! veers 14197 _Steunting too Ter purnp cover when TC inthe fee end 1VBAG0K3 249061 Toaklocker ve0.c003 6A _ Ae vont Mowe for water Wjecton astern avarcoa (6) Including quirk conplings @ Only for V32 05-1305 Maintenance Tools 32-200237 ___ Miscellaneous Tools 900 = oy sro ‘Sede Dexetipiog —_________frawrato ‘0001 Removng tocar Ten valve, soe Gsocecton 12D Svaseuo02 200127 Toei tor comeciion piece tengo screw -3¥8060056 200131 Extocter ool for testa vows ‘vere 0014 _Toct or cyinder ner tempera sensor ‘svens00se 00180 Mountngtooter camshat ozo vascoi6e 802000 Hexagon bar Kw27 “ave00018 207063. Wrench fr Cynder pressure sensor ‘svacH0025 {520000 _Terque wrench 100200. 407240007 832010 _Lifing device for ce block 2vratoa72 1837055 _Emioctorfor water pump impeter svsxioi! @® 1844201 Tool fer speedsensoradstment “av7es0015 |84:008._ Bracket for PTOshoft sve40612 {44008 Bracket or PrOshott sveecosi1 1842005. Guldng pe forP10 aft _3veas0o10 1846206 _ Guiding ph fo domper svB4s0607 BABITE Woodwcrd 728 hance! -ave0L3974 860170 A operatedttyraute power pack 208080100 85202? Fusipump uing aevice ‘vaarco1? 05-14 wa2/wa4sMaintenance Toole 0 High Pressure pump 900 wes sm | = ono | > | | Dexctiplion ring Hh prose aur (1000509 a) vac Sen pats 200076, Fedaienoe 60mm (0 feta owe 3000 Aeabisheze 100mm #60180. tenomnatr aa vias 861018 Guexoouping, female = aan’ e110 Qickeouring. mde “AO S61\47 Fonte peso Dm e 61148 Rests ese 000 rm 51183 Rewcsahene 100 ren ws2/Ws4sc ) Tnetuding quick coupt32-200037 | Low Pressure Pump: 900 50 ese hoze $200 me) 860074 Seach mate sta avsaionss| B6M07s Qniek coupina, male, avageoo!2 860079. uck couping feraie ‘avser0oi2 8650080 Fee. Nowe 300 erm “aveeacns? (2) Inctuding gulek couplings: 05-16 wo2/wsdse32-200237 Maintenance Tools 05 ‘ws2/ws4se Tightening Tools 900 e@ Coge_Decipion —— —_—__——— rs owe 06000 0000 20002 2000 woos e000 e007 mone Toqua wrench Too a Howogen bar kW 27 Tercque wrench 0-100 rn Ratchet nonce 200 th 3 square dive tenet nana 125400 wih 1/2 square ve Speed brace 81251600 enon bar B12 51280 wh 1/2 square chive ‘Adopter socket wrench A225, 3/42" Tecqua wench 150800 ‘22K aveosan'8 “sye2nea0t ‘sional 0710207 05-1705 ~ Maintenance Tools 32200257 05-18 Hand Tools: 900 ave ei ss o~ fear oe Ee ee ae ae i ee ou cose oo feos ee = <= oa oo sss 606012 Key forhoxogen socket sow 4 200013 Key forhaxogen socket seen 5 806014 Key fornexagen socket tow 6 802015 Key ferhexoyen socket era B 822016 Koy forhenogen socket sre 10 802017 Key ferhaxogen socket saw 12 801018 Key forhexagen socket Sew 4 802019 Key forhexogen socket sey 17 208021 Br nexogon socket sew é wth |/2-squave dive VA0LON01 201022 BH hexagon socket screw 8 wth 1/2'squcie dive ‘aven.o001 202029 Bt, ewogon socket crew TO with I/2 eau sive 480\0001 506031 nexopon socket screw 14 wih 3/4'squave ctve ——_4A0L0001 202032 Br. newgon socket screw 17 wih S/a'squorecve _—_ve0\0001 201033 BIL Nexoron socket screw Din 3e'equore dive 80.0001 wsa/wsasePera aa Sateen foe poweren aI fan porwr Sty Sirah bovarncn 9d fine socereh oat fort, brdnowsorech 151 foul _eremurnnta fois _tngrocs wrens 17 nid teorourwrency 22 e tons _tgneenarener2t2) {Ome Inaronewnanen 0% fon _tuoerensnoh teat fomolt_tagrocswrencncoad Sod _ Cortncsarenreh A Sirs someon 267 ws2/wa4sc 05-19Maintenance Tools 92-200287 05 - 2 Hand Tools 900 Beoe 6 ad | ge = & 00017 "Socket wench 1OdZS wih 09012 “Socket wet 54126 thn 1/2 square the 808013 Socket wench I/xlZ swith I" sauore Sve aDROId Socket wonen 19125 with 27 sque aWS SORDIS Socket wrench 20125 wih 2" equa dre AUIGIC. Spoke! wroneh 274125 with I)? souare ve 809017 Leng socket wrench I8eT28L win 1/7 square ctive GORDI Long socket wrench 28412 th 1/2 square 0 Bo9n2) ong socket weench 2D0L vith 34 square ive 0023 Socket wlench 12Q0 wim 3/4 square ave wa2/wsdse.32-200237 a Micometetio piiening grooves Premure colerator-I bar. 25ber Waar FHequoncy gonerotee : avsgn0014 Toot tertming chock ‘2vestoot2 Too fo: mecs. boctdesh GGect cee fuel feed parm 3viTIOGN7 ocldam of rect ven woterparmpe AVISIC059 Toole forme Toolfortemovingisin AMP. connectes : [ANP band crimping foo, ‘avec Mitoreir (25 mm) E ons Gyinder gauges Endoscope Mecsurng rsrument ferpiston Qe. cal g2ug8) vine wsz/wa4se 05-21Measuring and tesling equipment 900 oe a SCO118 Laser temp eter Theme Hurt PIF {800119 Mutiiogp cotbrator Joti MLS {800120 Charger fer ore MIC 7010 Premise sensor tosor sven 148050. _Tocnometer 848081 _Tornparcte tarssuee’ cont equipment ‘058. Cyinder Fresare Inaoota. Scone Maciel 148034" Vatimeter 248035 _Volrneter.unieniol 848036 Oscloscepe 05 - 22, wa2/w3ase‘Adjustments, Clearances and Wear Limits 06 06. Adjustments, Clearances and Wear Limits 06.1 WARISILA 32 Adjustments Valve timing ‘The valve timing Is fixed and cannot be changed individually cylinder by cylinder: Valve timing we Inet vale ope Bihoust vaives cleses ? \ Inet vive ‘ono vee ‘loeae se oP Set values: Valve clearances infer valves 0.4 me exhaust valves 0.8 mm See test records Injection valve: 600 bac (ot Com ‘+ Fuel delivery commenceme + Opening pressure of fu mon Rail) Electro-pneumatic tipping speed (Sid engines): Nominal peed Wecsor Pont Relay Moc one 220 10; 24 10 Rem ORM 50. 10M 02 10M Tipping speed (Common Rail engines): Nominal peed wees 2000 wecs 7800 rege 8202 108M 8602 101M Heaton 602 10M fa. 1OreMd06 ‘Adjustments, Clearances and Wear Limits Clearances and wear limits (at 20°C) Normal pom mectuisg Boar ‘clearance (mm) Wecr limit (mm) 10 | Manboomg clearance 2250.46 (Gio tpetooibourng) Journal kenetet _ssoas oxen cutof crew aE Jour, topo _ ‘0.005100 an basing srl eine Secon Tfenotatrte toes : Tamm | _~ ans = Timust beara. cial ocrarics wom 080 Imstwaerticnass a uo Corset boning clearance puieon2e (camehot booing piece: 230mm) . lig ‘Corrshat booing cooronce: Bisonzs6 (CamshottBoaing pleco: 190mm) : Aasorbiecibeatrgjboe Vercaldeecton) 730.850 Corti ru nace. ackclecrance asoo 70 10 (camehott 230") 3 if ui ‘Correct ustbocring: ot ocrance assoodo (camshesS0r»m) Cyne iner, claret op: 320.80 is : | better 520 ‘rine cules oHIDE a5 TT Bigentbeciing Gerance - aso a Crank. ut ednhy = iis Gankpi. taper =i boss ito Boendbeatra del hice ‘ection Tetete te Tae Sire ee fioendbore aso ___ovety : ch ‘Asembledtoaing bore Rod asersted) _ 310.400 Gudgeenpinbourna clearence boos ‘Asembledbeaing bore si Conrectngrodaniicaaaicsingsion 5-1 ‘Seorance gudgecnin ton ‘posoa8a Berodarnstornpion ie pera Pejonting gep|lomped S20) br a stoning gooll(lamned #220) 13:16 tscepertng qa (Clamp 9320 12-15, 5 E Paton gheiht corn. Necrmpresiong (C82) 140185 28 Sager gE Biase ed Sirerormat Bons. 85 Faloninggoovehaig Groove! ax Sowell Bs0 soos 50. 05-2 WARISILA 92[(s2-200807-07 Aajstnenis,Clearonces and Wearlinils ry Sgulconrcs «BAD | comma ning ge octan oe @ Gerrit gr whnaciey fageiemmedi geatabool@ gba te | Snalingmectato goat wheal 7 somn i 025055 Ta Wow tappet, diameter losrancs 0/20.161 J[esndamete,.poe Beara clerance busilenpoi an | Batetnyio rs neste 18 voor Yoke bore ciarniotar i = ae. ee nossa 6 ce en wean Be eee eee Be | oz nesecte (DI, cs) 085-090 0.98 =a ‘ommeanan eae) a © BEEN semocee atm See neteen caer et va faite hoes oF a TD a Frettot ne igh eros Cnmmaniatergran ne ise a | Base longer verte oath spore 132 2027-61999“32 Normal polnecnancrert clearance (mm) Wear limit (mm) 16 labicatngolpumpbeoingdsaunss a 013-017 ‘O20 oe 3 19 as ieee ‘agideancs bao Backdae or ving gear Laz oe vin__02? O75 Base jongentionath Giving 0 SvertoutOloehy spond 1286.32 aha crerseven (oath pured Vie. 86 Foumeargeioumetcorgdesncs 42 DOI 010 Aéoieieronee 32 or- 018 N11 030 acoso eure gacre 13 Blo ap Ta Connor prose on Coron Ralengnee 200.225 pa Bact or const oun goat pss 07 ry 19 Water panpbackiah forcing g50r are roe 2 bw o Vo 033 008 : Base engentionaih over thos @)teoth spanned 61,990-62027, 72 [Beamgcloorncefergovercrawingshatt 0080.12) ae [asoiclexence D2 bs i [Bala fx diving gear be oa =a Contoisholl vers elegrance novo. 05 06-4 WARTSILA 32'32-200508-01 Tightening Torques and Use of Hydraulic Tools o7 07. Tightening Torques and Use of Hydraulic Tools 07.1 WARIS 32 Note! Note! Tightening torques for screws and nuts ‘ee section 07.3 for hydraulically tightened connections! ‘The position imbers in the tables below refer to the corresjencing figures A to J, which are located in che engine according to Fig 07-1 Always tighten to stated torque shown in the tables. 2 loosen scree ‘connect jght cause seriousdamagestturan injury: Threads and eontact faces nuts andscrow reads shoulbe led with Ibeleati dil unless otherwise stated, Note that locking fluids are used Molycoto or similar low friction tubricants must not be used for any screws of Muls. Great isk of over tensioning of screws, T Nem = 0.102 pen Tightering torques fig 07-41 07-1| 7 Tightening Torques and Use of Hydraulic Tools 32-200808-01 A: Crankshaft and tlywhoot Rote! Torque wrench settings must be recalculated if an other lool combination than Fig below is used for the split gear wee! Teo) 20720567 Trae wronen 721/89 Me Example o, Me 8 yh Te 25m Liem 07-2 WARISNA 3232.200508-01 Tightening Torques and Use of Hydraulic Tools o7 B: Intermediate year and camshaft See section 13.2 forintermediate gears and cannstiatt dave. WARTSILA 32o7-4 82-200508-01 WARTSILA 3232-200508-01 Tightening Torques and Use of Hydraulic Tools ‘WARTSILA 32 Cylinder head Fig 07-57 Tightening Torques and Use of Hydraulic Tools 32-20050u-01 or- D: Injection pump WARISILA 3232-200508-01 Tightening Torques and Use of Hydraulic Tools o7 tion pump, Common Rail WARTSILA 32 o7-7o7 Tightening Torques and Use of Hydraulic To Fig 07-8 a 2 Cakde 07-8 WARISILA 3232-200508-01 Tightening Torques and Use of Hydraulic Tools o7 E:Fuel injection valve 1 23 4 eae EES ® i Friction ting 1 af 3/4, 2 Fig 07-9 or Oo 2. ectenppocaprutiocamectonpiecd | ———S0:10 [3] connecton piece tenamenoiger | teas 2015 000 eras 1 elon pps espn otiecten pare 2| teetnebeccendioomneconsiecs [tae CCanocten pica tonezziahokdor at WARTSILA 32a jahtening Torques and Use of Hydraulic 1ools Fuel injection valve, bw '32-200308-01 WARTSILA 3232-200508-01 Tightening Torques and Use of Hydraulic Tools Cl WARISILA 32 E:Fuol injection valve, Common Rail Fig o7-11 oeTorques and Use o Hydraulic Tools fuse, DWI FLOW FUSE #5 FLOW FUSE #7 1 Fig 07-12 —@ or-i2 wApIsiLh 3732-200508-01 Tightening Torques and Use of Hydraulic Tools 07 igh pressure pipes, Common Rail Distances X for HP pipe ends (postions A-E) Fig o7-3 ‘woe ae 5 a ——| ms Roa tnghs danbasadrantieclcorce 4. Rall pb yarccurator © —_* Boe Sngie Blan fsatrendtoct cones 3) pug, | Apply engine of on tecads ‘A. Dstonce 00 Pipe enc Pow Steve (5). Apply Loctite 2701 ontieads. B._istance 09 ips enc -Powa Seve". Apply Loctite 2701 on ead. Note! ‘The high pressure pipes must be reUghtened according to Imeval sated ir chp OF and as descnbed in chapter 16 WARTSILA 32 07-13Toole _22-200508.01 7 Tightening Torques and use of Hydra ‘Accumulator, Common Rail Oe ASIA 2Piston of ype # Piston a ype 2 Fig 07-15, tonne WARISILA 32 07-15Gl Tightening Torques and Use vf Hydraulic Tools 42-200508-01 F:Pton View A ton with 4 scram Fig 07-16 erwarie 07-16 WARTSILA 3232-200508-01 Tightening Torques and Use of Hydraulic Tools 0 Oo G:Tubocharges fastening screws e Fig 07-17 ora e j e@ ‘WARISILA 32 1-17o7 Tightening Torquias and Use of Hydraulic fouls _42-200508-01 Hi. Engine driven pum| Fig 07-18 ‘ren Note! To avoid damaging the threads (Pos. 2 and 3), heat up the screws before loosening. 07-18 wawrsua 37'32-200508-01 Tightening Torques and Use of Hydraulic Tools| 07 1H, Engine driven control oll pump, Common 1 serow Fig 07-19 WARTSILA 32 07-19[or Tightening faqs andthe of ycrauis Took aeamoeeea | J: Free end of crankshaft Fig 07-20, poe We recommend the use of torque measuring ols alsa when tightening otter serews and cuts, The following corques apply to serews of the strength class 838: whin olled with luicating il or created with Loctite 07.2 Use of locking fluid Whew using locking ffuid (Loctite), clean parts carefully in de ‘greasing Mule anett then dry eampletely before applying locking, uid. 07-20 WARTSIUA 32[[ae-200508-01 Tightening orques and Use of yaanc Took | 07.3 Hydraulically tightened connections 07.3.1 Tightening pressures Hydraulically tightened connections ee Z J Fig 07-21 Pos. Screw connection 1) Gynderhoodscrena hon most ststoo Second step 2) Main boamng screws Wb two steps: “igen 5 5) toterclicewscfmainbear 1 seo second He. 2) Conractingodsceows Nipper andlowercen M27 two stops ‘tes Seconei dee 5) Ggyrtowochv rosa Fe str Sao 122 Gorewstampeu94 Hefteo i Stone 182 Gerenstampod56i fstten ‘Stoonda 3 Fngne festering screws 11 teectete goo MEX ee Ftp ‘Sacendsep ‘Max. hydraulic pressure (bar)| Hydraulic tightening loosening cylinder ee8224 sa 5a 500 28 veers aves 0 a 20 wien x0 cid m0 x0 vate 7m no a svaeare a0, 20 2 “aie 1g 70. 1) Pas. 6 stilt trons. WARTSILA 32. o7-217 Tightening Torques and Use of Hydraulic Tools 49-200508-01 07-22 Exception! Caution! “The atu bolts are tightened to the casting atthe following torques: Screws ace. to pos. 3 and 6. Pos. 3 see chapter 10, section 10.33. The scrows wil be overloaded if the maximum hydraulic js recommended to change the Screws if maximum hydrau- lic pressure is exceeded for Some reason a 07.3.2 Hydraulic Tool Safety Instructions Since the hydraulic tools aperote andes high prossure and pro: duce great fore, proper safety preeautions must be taketh © reduce the isk tury topersons ancl damage to materialdurlig ‘work atthe engine andl in the workshop. ‘There aretwotypes of hydraule tools for theconmectingrodshenk serous see PigoT-22, The sens and uns inthe tl Of new design Ghcheed in yer nt) sale red tre reac 1000 Icing ees, ke ang te peste to nova ‘value 1000 times) a ig The screws and nuts of previous design, sce Fig 7-22. sould be replaced etre reaching 250 ose Wehetydrolally tense ase esi canb tur ben the ‘maximum hydraulic pressure Is reheat check foe cori [n threads chek tox conten on ret ere WARTSILA 32'32-200508-01 Tightening Torques and Use of Hydraulic Tools o Hydraulic tightening tool for connecting rod shank screw - BS in “De Fig 07-22, ona Cylindrical hydraulic tool 1. yar 2.Pison, 3.sleove 1 2 3 Fig 07-23 ove 07.3.3 Filling, venting and control of the high pres- sure fiydraulié tool set ‘The hydraulic to! set consists ofa high pressure hanel pump with an integrated oll container, hoses fitted with quick-coupling’s and rhon return valves, cylinders and a pressure gauge mounted on the hand pump but not connected tothe pressure side ofthe pump, ‘The components are coupled in series with the pressure gauge being the ast cnptent ds cern tha every ier ie ‘with the earreet pressure WARISILA 32 07-23or Caution! Tightening Torques and Use of Hydraulic Tools 32.200508-01 ‘The non-return valves In the hoses are integrated with the “quick coupling’sanxl are opener by ‘the pins located in ehe centre ‘f the male and fenale pacts. IF these pins get worn the coupling Innis be replaced because af the risk of blocking, “+ In the high pressare hydraule tool set it is recommended ta Use a Special hydraulic wil or in any ease an oll with a viscosity af about 12eSt at 20°C |» During the filling of cho container of che high pressure pump it is recommendable to couple the set according to sehewe DB, Fig 07-24. Refare filing, open the retease valve (2) and empty che cylinders (4} by pressing the piston andcylinder together. Aer that, drain the oil and rel chroagh the fling plug (. ‘= After filling, vent the system by pressing in, with a nw the contre pin of the female part of the Last jack: coupe, the coupling being disconnected from the pressure gauge Keepon puriping until airfree of emerges ia che caper. ‘= Cheek the pressure gauge of the hydraulic tool set regularly. For this puiepose a comparison pressure gauge is delivered. This pressure gauge can be connected to the pt, hole (7), the outlet hose of the pump being connected direct to the pressure gauges, 7.3.3.1 Instructions for high pressure hydraulic tools Pay special attontion to cleanliness and carefuiness when Using and maintaining the hydraulic high prossure tools ‘¢ When the hoses mre pressurised, any maintenance, adjust: meats nor repairing are allowed, not even tightening of the ‘+ Before rising the pressure in the high pressure tae), all hydeaulle parts (pump. pipes, hases, regulating units) nas to he vented ‘+ The weakest parts maximum allowed pressure must not be exceeded, ‘+ Keap a logbook or similar of the hydeaulictoals WARTSILA 3232-2005D8-01 Tightening torques and Use of Hydraulic Tools o 07.3.4 Dismantling hydraulically tightened screw connections ‘warning! Do not stand absolute next to a pressurized hydraulic tool. || attach distance sleeves and hydraulic cylincers actaring (o Big 07-24 8, Serow on eylinders by hand, [2| Connect the hoses to the pump and cylinders sccording to scheme Fig 07-24°8, Open the release valve (2) and serevs cylinders clockwise direction ta expel possible ol [3] Sctew the cylinders in counter clockwise direction about half a revelution (180%), atherwise the rut is locked by the plinder and! impossible 0 Toasen, e 4) Close the release valve and pump pressure 10 the stated value, 5) Screw the nut in counterclockwise direction about half 3 revolution withthe pin. [5 Open the release valve and remove the hydraulic tot sot. (7) Serew ofthe nuts by han, ycrautc cylinder @ 2 couse , 2.Pughote Fig 07-24 rns WARISILA 32 01-25a 07-26 Note! Tightoning Torques and Use of Hydraulic Tools _$2-200608-01 07.3.5 Reassombli screw conn hydraulically tightened (Check tht the threads andl contact surfaces are clean and tree fram parses (1| screw on nuts and attach distance sleeves. § 6tlindees by hand |2| Connect the hoses to the pump and cylinders. Check that the Telease valve Is open and screw the eylinders In clockwise direeion to expel posse of, [3] Close the release valve and pump pressure to dhe stated valu (4) Scrow the nuts in a clockwise direction until in close con- tact with the face. Use the pin uateruded for this purpose and LUghten the nat as muchas passible without breaking the pin Keep the pressure constant at tise stated value, ['5' Openthe release valve and remove the hydraulic toolset. To.ensure that the mut vallbe properly’ tihtened, the pressure an be raised in twosteps Pump the pressure according to section 07.3.1 screw thera in aclockisise direction unt in close eoatct wit the face faezease the pressure further to the stated pressure, and ‘screw teri until i eave contact with the face again Thistle the taut shi save just Tinie angle be approximately the same angle forall nuts ofthe same kine! Selore the engine is started, ensure thal a screw connections that have been opened are properly lightened and locked WARTSWA 3232-200508-01 Tightening Torques and Use of Hydraulic Tools or 07.4 WARISILA 32. der Use of hydraulic extractor cyl For some power demanding operations a hydraulic extractor cylin ser (800003) Is used. In connection with this cylinder, the hydraulic high pressure hand pump is till, coupling sesine ace. to Fig ares. Hydraulic extractor cylinder _ Fig 07-25 ar According the design of the cylinder, the tr ier (1) rst tet be lan bu fhe ost ereated between the surfaces A ad “Te pisto.s prevented from running out ofthe cylinder by a expansion ring (2) The strength ofthis ings eed ads fetoramended 0 be careful shen operating at the end of the ‘stoke The effective area of the piston is 32,2 em® which gives the following relation between pressure and. force (arg, tol BVBSTOIAG), see Fig 728, (0) Inthe previowstol fired with 3V8360061) theeffectve area ofthe pistonis (442m Therelation between pressure andere isshin In Fig 07 28,2),¢ of Hydraulic Tools o7 Tightening terques and Relation between pressure and force ook Max prose lig oz SET em 07.5 Low pressure pump for lifting purposes in the crankcase special low pressure puinp (250 hat) 800 059 is delivered for Liting tools used in the erankease, Normal engine ofl, which is tused inthe engine lubricating system (sting) must be used in this Puunp because the drain ol forthe teas sled to the sump of the engine o7-28 WARTS 3232 700402-01 Operating Houbies mergency Operon oe | e 08. Operating Troubles, Emergency Operation 08.1 Trouble shooting Preventive moasures, see chapter 03, and 04. Some possible ‘operating troubles require prompt action, Operators shoul ac quire knowledge of this chapter for immediate action when needed. Trouble Posaesion. ©) Tuna doce conectes NOTEIErne connote stated when Marina dovcolsconoctod However Defer starting. ciwoys check thot Rin dove bdcornected. 1) Storing a press footw, shut. vee staring aint pipeclosed 9) Jamming ofsating wave ncyirdet hood wd, 211 au. 218. aia 2) Samming ofstaring cr ceo lon 213 €©) Jommringot biocing vole cn ring devin, jan 9) Staring ascend vawofouhy Jara 9) Hlteroxhoust vate jenmra when open. “Negative” wave dooranco Glengtorranobe). 12. Sem cmt 2 2 ©) Yookow s0t(10). 1») Automakesue down coulce énetin str poston 2. ©) toad ofeantalshat erat governcrissatatfoolow a value Hg? 6) Sorina uctiotar wrcoalyadhstod 2, €) So1ne por oye canto mechenien jarring and proventsfuslodmision 2. 9 Fustandirysctn syorinci vented pe comectosbctwecninjectonpumpsand 163, 17 vanesnerghianset ee os ©) Fast tite ou no engine clogced 1) vee way cock tua Mr werent vaveintuninet ripe ceo day toni Spy full puma! ie oe et > Stop levers postion > ey ow anctengre reuchregnteclctekng Wotan ncomecionwin 62) » Seder ey fate Funlewuticlenty prehectodor preheated 2,1 Figt2-1 D_Tookow rosso 9) Scopoint thik hdd 1) Recon purp contolrack wena adhe 2s ©) clan pare contldeew det ol mes porary css ovenpoo cece ity) ae | ee «etn pny rapes ce enti cay 16 aeligtesaeN ec bl ear ting WARTSLA 92 08-1[08 ~ Operating Teubies Emergency Opecion 3220000001 | |@) nfoction valve fauly: nels holes clogged % eee i 0 eee eee teerearinaneca en secre ee (Ree ees eee ea Uieesioes eine rae ers eae oral Seinen een ae s a sais daee tomer nearer ae {Governor agstment ety (nexmaky too low campensaten) 1) seopont 2 ©) Fuelteed presi tootow ove sop Dies esas aesrhe eet ) Londra autemetin ci no cg ae ©} Bigencibeaing cleciance co rg doove screws) ae a OP Voto prhasorjsctionpue lappet saingbowon |r. ©) Int oreshaastvabe jamming when opay | ) Toolageveive coorances os, 1224 ©) Ohecrmere oylndersbactyortoadea (8c) 1 Injection pump orvabe lappat aude back 169, datas 071 9) (ripen of piton sere 1) asntpetetnoctendroncaratcnvinttinrton arty fue wong, See pot 9. ©} Late njcten (mong set carat ove) 1, 1623, [Mize by Seerontsa6 cde ©) ascgnterexye arcresie: “Testeconk @ 162. one “Shore oa Ronse | 0s elt ee ical sae aeaat ©) Gonsienurcatracicomrrotarehs ks uatlowbypaiinagwonerlencl GBA8, 1133, 1) aunsiteh haut garesmay ccescnaly occur when endnehasbaen ding fora lSratiyirocralion’aneseniomparaure ororomenneattasateg ©) Goya emens pce cv 0 wotelockage om ext! bor, tubochoT 9) Engne boxy evericaded (chectnjocton rump rok postions) Test Records 10) Seepaintéc 8-2 - WARTSILA 3232-200402-01 peratiny Troubles, Emergency Operation Sea EEE) sane iertpec denen megiaaas ee eect ass ie Shiseameeseeate a8 eo ae ee wy oe | Bxhasigas ampere cone ender sboveromal tt Dery eter cat terre eer 8 ieeatte roe Ene ©. Fay nection ato, ‘gut rmensadonmencen Soka iotot sty Remsen @ © oer c100 61, 1623 9) Ristauppy haifcent iterclxgped) 7 1 ction pump kay, fuatracksbesno ln ich ‘o @)_Screwininectianpurmp ierloowe, checkhigt of sce tao ©) Faxstyexhaus ges lemperahresenscr b) Seopoinis ath 35.c.cb@ ©) Leaky fection pipecepioe sings 16s When 23 at ©) Seopont9a.c.e 1) oolow fyeeed promt, too sme troughinjoc on puro o12 Gsopontsdn's Ney etkes pack beridievence cehmeene fede cut ry ‘clon pump rockpeatiansare the sane ial Colca ighthonnal eicadinincvicual yin, ©) Seopoinis 1.40 @ 2 wheniaina toe ports ©) ihoasttipe cetubine nara ha party clogged 1 Apa 198-and i onder cngees. The cirence me*aastgastemperaiies tosh ying ern sa a2 ©) Fauitypresnre srr 2 1) Wiicatingotlevalinallamp toolow ona, 182 ©) unica a presse cont vtve ou of oat orang, aa @) \eotmgeintuexcating ot wctenpipe connections ia) ©) ubrlonting albadty dst wth cevatok vscosty of foolow maro2a 1. lubicatng ot ppesinacie enginelooseorbrcken 1. )_latsicatng afte clogged ra ee Lao e ©) Fauity nervemeter WARTSILA 92, 08-3[os ‘Operating Troubles, Emergency Operation 32-200402-01 b) Iutlent cocina wale flow tveugh olooke (uty pu. oF ase. vee wie © CRASS PaSRightenwcriempercnse. er CouNPANP-OF as" ©) Ol cooler clogged depostson tubes ae Feaity hemostatvave ice ae a2 9) One oftemperaturesensos foury 1) Grevising water coolerclogged depostsan ties ©) [rauficient tow ofcosing watce traughengine ouding wolerpumpfaury.arim | 193 Stem vawonclosed ae fie Bar )_‘Tharmestalvavoiauty Fal ‘230841 ©) lecteyolconiee 185 b)_ Foul ubrcating ci separator. Se sopexatorinsructon book! 223 155 @) Leaky coors 'b)_Condensation ios low cherge at cooing weer ompeatas) | oxarons2 ©) Frgre overloaded aturhertcreaie otfualayepyisrrevantadbyinemechoricd | 22.1. fi922-1 ) tre ve syeply prevail Bu 1) Soopoinis2e- bo. ©) Seaport {Shortage offue 20min 1) Aulomatestop dovice stoped 2928 ©) Fay govemer ocqmvernar dv 2. Fasty povex spr 4 atoms 2 ° np comet ark orgy ot 3.) Beet hltatppy nea tent ce poe (ey ie ee wc cock) Solr relring tu engrhokeuitmamtbe oeststondccccted rook ako 1b) Fauty sep autematon Stop by mecnsofstepkover 22a (©) The engi civeniby gonerator erpropoterer by another erie connected sama >) Teer certo propor oy cone 0) jectonpurypcontererse tery st hc) Lood he engine, Haossble. skstiiefanpy oa bysneornct hctMer ecw way eck b) Anoworspeadingengne ihoxtipstop.inteioe. checkroakatythecesimentiot 223 fecontalmactesum dhe ricchan fumprockpsaions ‘Sirestostiver bony Ns poshun ore overpeee hp device ben hitpadiond saeroccocwanen alia that, ‘Dadon evar ond Fe oeargyeou hnpbeng n workpation anche speed caemor stop pasion. Thsconial siti be dene clays when te contolmechanimarhe nyc parpshavn bono WARTSILA 32 8) .08.2 32-200402-01 Operating Troubles, Emergency Operation 08 Emergency operation 08.2.1 Operation detective air cooler(s) Ifthe water tubes of an air caoker are defetive, the cooling water tay enter the cylinders. If water oF watee mst flows out ofthe ‘deain pipe at the bottom of the evoler housing, check whether it Js raw water or condensate, If condensate, reduce cooling See chapter 03, Fig 03-2) IF raw water, stop the engine as soa as possible and fia spare cooter fw spare cooler is avallabie, the following ean be dane as an emergency solution: It theie isnot ime enough fo remove the defective cooler and repair it, hut off warer supply and retaen pipes. Operating with a partially plugged, shut-down or removed cit cooler. Engine gucput must be limited so that the normal full Joadexhause temperatures are not exceeded, The turbocharger may surge hefore tae admissible exhaust temperatures are reached. fn such a ease, engine load must be reduced further ro avbid continuous surging. 08.2.2 Operation with defective turbocharger(s) A defective turbocharger is to be treated in accordance jth the service instructions given in the turbocharger instruction book. (blocking of rotor blanking of turbocharger etc). See chapter 15, section 15.4 08.2.3 Operation with defective cams Irlye camshaft piece with damaged cams cannot be removed and replaced by a new one, the engine ean be kept running by the following measures: Injection pump cams: “Lock the Injection pup Lappet in upper position by a locking plate 800066 included inthe toolset. Attention! Goaceming fostonal vibrations and other vibrations, soo soc. WARTSILA 32 ‘When operating with a shut-off injection pump overlong period, the valve push rods of the inlet and outlet valves are to be removed, and the indicator valve on the respective eying ist bbe ppened once an hour to allow any aceumlated oll t escape. With one eylinder out of operation, reduce load to prevent exhaust (emperature of the remaining cylinders from exceeding, ‘nore ll ll temperatures,08 ‘Operating Troubles, Emergency Operon BE vaive cams Stap fuel injection to the cylinder concerned, see chapter 16. Remove the valve push reds and hang up the Cappet in zoe position by locking pins SO0G87 inure! in the tool set Mount ‘he tubes covering the push ods, Waringt Note with locked tappet in upper postion should the push rods be removed othorwise will he pision contac! with the valves. ‘Atfenticnt — Conceming torsional vibrations and other vibrations, see sec, 0625. Withoneeyltnder out of operation, reduce load ww prevent exharst reanperateees ofthe remaining eylindes from excooding full load teanperatares 08.2.4 Operation with removed piston and con- Recting rod Tf damage on pv, eonowctng soda igen! bsg cannot be ‘upaired, the ablowingean be dane 1 allow emergency apecation: [1 Remove the piston and the connecting rod. 2 Cover lubricating of bore in crank pin with a sultable those clip, andl secure [3) Fit completely ossembled cylinderhead but omit valve msi ods, [ 4) Provent starting ait entry to the cylindethead by re- roving plata pipe [5] Hang up te injection pump tappet aril ave sappots as decried insetton 0823 Aiention! Concoming tonional virtions and other vibrations, $90 see: Withone cylieder autofaperation, rece lor to prevent exhanst temperature of the remaining cylinders from exceeding nermal full load teroperarares. If the turhocharger(s) surges, reduce load further ¢ avoid con inuous surging, (Operation with semoved piston anel connecting rd, fro¥ one or more cylinders, should be performed only in absolute exeqgency ‘oniviones when there are no other means of proceeding uncer ‘own power WARISILA 3232-200402-01 ‘Operating Troubles, Emergency Operation 08 WARTSILA 32 08.2.6 Torsional vibrations and other vibrations When running the engine with one cylinder, aF more, out of operation, the halance of the engine is disturbed and severe, ar leven dangerous, vibrations may occur, The vibration conditions Aare, in practice, dependent an the type of the install ‘Asa general advice, when there ate cylinders out of order: «Reduce load as muuch as possible * Keap the speed in a favourable range (completely depending, ‘on the type of installation). ‘ I?one or several pistons are removed, lowest possible speed shoudl be usec 08-708 ‘Operating Troubles, Emergency Operation WARTSILA 32EE] Ena Q9. Specific Installation Data 09.1 General Marine installations + 09 is reserved for specific installation data, wending on installation, the specific installation data ean also be nd from separate binder, “Attachments” 09.2 General Power installations all ‘The reports and cer if installa 1es are collected in series 8 Quality records n data can be found from binder 7A 02 0,09-2 Pore)WARTSILA TEST PROTOCOL Project: Zelenodolsk 262 Number: PAAE036473 Type: wels2 Dates): 26.08.2008 27.06.2006 Class. Soc. RS2 WARTSILA ENGINE DATA Customer: Type: ‘Manufacturing number: Nominal output [kW]: ‘Nominal spoed {rpm Rotation direction: INSTALLATION Type: Name: Number LOADING: Type: ‘Manufacturer: Number: Current [Al: Voltage IVI: ‘Output fava Frequency [He]: “est protocol no PAREDA72 Report R086 Version: 30.03, Prted 21.06.2006, Installation Data weta2 PAAE036472 2760 750 Counterclockwise Main Engine Zolenodolsk 262 wo2ass, Alternator LSA 58UL12.8P LEROY SOMER 40957-1 4278 +1000 150 50 LUBRICATING OIL, ‘Quality: Shell Argina T 40e © ger oe . Tee: WARTSILA srimed °° zre8208 ‘Test Program for Zelonodolsk 262 Tost cell 03, Order number: mona Engine number: PAAEO3647 Engine type: wots Tost rundate(sy: 26.06.2006 27.06.2006 WTS 1780.5. 70-18-10 20 10-10-3020 1830-18 39 7838 a5 E86 105 3615-1970 7820-1940 740 20°01 SET 3085 50810) "ras [aS 2 1090, Pre [a7 zr 265, 40-1010 Seas [97 36] 2086 70 10-1030 7070 9651 1088 030-1050) seb [0555510 (oso“s¥10, 29 -s#0 "| 25 390 [03.88) ea (Check of veepeea aovees EIAPP-Certifeste tobe subitid.« @ WARTSILA TetproteatNe, prcmers Report Veron: 30.08 Operation Data 2 2008 aa steer saa < |B ‘esi yt oe Ee ne Ba Ba ancisot 2 Sea adveusasensseesssasasresquegegey,e@ Test Protocol No. PAACOREATS eport PADS Version: 3.004 Prainee WARTSILA ae Operation Data° @ WARTSILA Printed 2108200 Operation Data fay nin (Setsecstove tears sete re acs ee sddddddadaadsacadady 93 8 j esttiseesescuaeeness (freppesewe ness Ven bess neate © rrtecstto, pvepees WARTSILA Pred" 27052008 Operation Dataee ee r) ire ee rode WARTSILA ae Lod ADJUSTMENT OF STOP SWITCHES: “epang met ecole ve ‘clone rte ash a ADJUSTMENT OF FUEL PUMPS: Bea ine tm Rl OM" os os a 92 e 2 08 08 a 3 0s 08 8 ap a 08 88 0 4B Ccovernon Test Load appliaton: aac Redveton: % - % nema nemo dn sec = MAX M-tom dn see Amt oF THE TEST ‘The sim ofthe lst run parted was to check he general quay fhe producton and to prove hat ‘he engine pearance vos hile recroodtequrements PRESENT ATTHE TEST RUN ‘Warts Fintand 7 customers) Ve. @& WARTSILA pig qeip sero TN ‘Room temperature when valus were measured [°C Ine: Engine runing coninuosy before indicating IN: @ Tete etn stop and natn il Temperature of whcating ol Cy: ‘Temperature of cooling water before engine 'C) Crankshaft Measurements Forse op | “aka ny i Forse etacato jan L (Geena se 1 Wyeast _| | ‘Geers oo (Kaos yaa ——t — Deviation 00m @] _ essere ot raha stonment main sesembiy COLD ENGINE Room temperature when values were moasurea [24°C Inte iw (Rear si op i [rota ymaow | o | o | o | o | o | o Frearsde T T rakes is | ot | ot | ot | ots | 105 i (Baio T lanai [a fens | on te fies | ot I [Operating ade T T Ikaytesiute o | ss} 2 [as |g] | | (Operating se Tp rt [kaytosiaryinaats| +1 | 0 | +1 | wos] vs | 0 | L ead© WARTSILA Test protocol mo PAAEQSSA7S Report RALOB! Version: 2004 Printed 29.08.2008 Inspection of the Wartsila Engine Project Zelerodoisk 262 ‘Onder number: Meozsse Engine pe" wou Engine number Paaosears Claiteation society: RS. estrumdatets) 25062005 roe 2008 Inspection date: ra06 2006 Ithas boon agreed that he following openings and inspections are tobe cari out atthe livery test run attended by the buyer andor tho representative of Inspection ig end bearing No 65 Mam ean No ‘ ‘Tht Beary Yee Endoagpe apecton 2 Opening fevers Yes ‘Astona information: laesieaton society. ‘Changed, # 6 changed pin planed OX hanged #0 changos Ox or ok ‘Te flowing corrections should be made before delivery: ae Customete) :© WARTSILA, Test protocol no PAAEOSSA7S Re Ra.os2 Version: 3.004 Printed 2108 2008 Fuel Oil Consumption According to ISO 3046/1 Engine mante ‘Order number: Engine type: ‘Outpu00% ae: ‘Speed rp tatoo indicated power ower sjusment ocr aromas prossure dg tet (NP) rare a colt omperstue dng te] «-GY-G)-Gy -07*(8-9) rofererce charge ar cart temseratre [208K] Paacosee73 elon 262 ozas ey lower hosting vate oe ei ding test (el erga fe i 001) {too onsamoton acorn 180 fg /) S Simeis) EDP. = engine sen pum gk clei wih ‘seh EDP acoring tothe cae) ge = (SMES) 09 igs eRT PS 2 e0p = igi Be Mt eDP ig KH) @ wom eat ® oon ag eases 438 ie fe «= imagenes Sas Se = sae Sin SE arr Sono Eestenigtany Se wap a Sse a Apo not sous Actomerncessie ety de aes ng Cee: TN 5 38S GeeCGWECS CABINET WARTSILA L32) @ (MARINE) (alee aL om oO Noresito | WIRING DIAGRAM Fintond WECS CABINET vwRTsA ering i INSTALLATION: far 632 JO 5 Meolows ~ ws | ZELENODOLSK 261, 262 fue] zw 20 sL4070 7 Locvate PRIEST ror my WODeeD slr x seehacor 7 ott Peden leoln eva arioor 7 riya | | 109, DAAEO19072— a ST Pe FPS oT T eS AT RE PA Ae TOT“0402, _UI74, U518, x4] poles a Flies, Zhe ain caainer: 4B aes mun cassettes paoueros HF HBT 36 42 Fis Bot Sutte twee oy maw cones unit AN Re moue LOY L004 orstar ance KToe, ISQ.AION RLUPSerowareteet Xi, WS Comecron Fo tasovinGy StUs/Serelrgrtett Litin 2 poms cawectoereaue Livin XG Poweh PLY COBECTONVirrmayetteiitin 34 aun tas? tps riesivesteet, @ 122, ms errr e10 een es, 2 fist tarsutte te Diy 02 prarcrion ore /Sjodioe 2h 22 arisen FicteRAeLAM mtn S72? — srw cicuir estar Steptet Late LOCAL CONTROL PANEL LEP) HS721 (eh SAR! 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