Contents, Instructions, Terminology 00 a | Main data, Operating Data and General Design 01 Pl Fuel, Lubricating Oil, Cooling Water +O2 _ Start, Stop and Operation O03 Maintenance Schedule O4 a Maintenance Tools O5 _ Adjustments, Clearances and Wear Limits O06 Tightening Torques and Use of Hydraulic Tools Q7 > Operating Troubles, Emergency Operation 08 Specific Installation Data O9 a Engine Block with Bearings, Cylinder Liners and OilSump 10 oO Crank Mechanism: Crankshaft, Connecting Rod, Piston 1 1 i Cylinder Head with Valves 12 Camshaft Driving Gear 13 D Valve Mechanism and Camshaft 14 Turbocharging and Air Cooling 15 _ Injection System 16 fe Fuel System 17 Lubricating Oil System 18 pps Cooling Water System 19 wn Exhaust System 20 a Starting Air System 21 — Control Mechanisn 22 Instrumentation and Automation 23 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 1732-200251-05 Fuel System 7 17. Fuel System 17.1 General description The Wartsila”32 Common Rail engine is designed for continuous light or heavy fuel duty. The engine can be started and stopped on heavy fuel provided that the fuel is heated to operating temperature, the fuel feed system is pressurized to stated value and the jacket water is preheated to described temperature, see chapter 03. ‘As the fuel feed system can vary widely from one installation to another, it is not described in detail in this manual, Read the installation specific instructions for further information. A pump (11) delivers the fuel pressurized to the engine through afilter (17). The pressure in the engine system is maintained by an adjustable throttle valve or a pressure regulating valve (13) The fuel is circulated through the engine high pressure pumps (18), back to the deaeration tank (10), see Fig 17-1. It is of great importance that the fuel treatment before the engine is done properly. The lifetime of the high pressure pumps, the injection valves and other fuel injection parts depends highly on the fuel filtration efficiency. The performance of the engine is also dependent of the condition of the fuel injection equipment. Worn pumps decreases the power output and increases the ther- mal load of the engine. The fuel feed pressure and temperature are monitored on the Local Display Unit (LDU) located on the engine. Clean and dirty leak fuel oil is collected in separate enclosed systems. The clean leak fuel can be reused. The dirty leak oil system collects waste oil from the top level of the engine block as well as fuel and water arising e.g. when overhauling cylinder heads. ‘The high pressure fuel oil system with high pressure pumps, accumulators and injection valves, are described in chapter 16. ‘COMMON RAIL 7-17 Fuel System 32-200251-05 Fuel oil feed system 7 3. Adjustable orifice or pressure regulating valve 4, Pressure sensor 5. Temperature sensor 7. Fuel feed pump 8, Pressure regulating valve 9. Safety valve 10. Deaeration tank 11. Circulating pump 12. Safety valve 13, Pressure regulating valve 14. Valve 15. Valve 16. Valve 17. Filler 18, High pressure pump 20. Heater 21. Flow Control Valve 22. Accumulator 23. $8V-valve 24, 3-way valve ' 101. Fuel inlet 102. Fuel return, 103. Leak fuel drain, clean fuel Fig 17-1 sorror2n02s9 17-2 COMMON RAIL32-200251-05 Fuel System 17 17.2 Maintenance 17.3 When maintaining the fuel feed system, always observe utmost cleanliness. Pipes, tanks, pumps, filters, heaters and viscosime- ters, included in the engine delivery or not, should be carefully cleaned before taken into use, Run the engine for a while on light fuel oil before doing any maintenance to the fuel oil system, if the engine has been running, on heavy fuel oil ‘The fuel should always be separated and it is recommendable to install an automatic filter in the fuel treatment system. Always when the system has been opened, it should be vented after reassembly, see section 17.3. For maintenance of the fuel treatment equipment not mounted on the engine, see separate instructions. Venting 17.4 Start the fuel feed pump if the static pressure from the day tank is not sufficient. Always vent the filter housing after changing cartridges in the filter. Adjusiment of fuel system Check the adjustment at intervals recommended in chapter 04. Adjust the valves at normal temperatures with an idling engine. [1 Adjust the fuel system before engine according to the in- stallation specific instructions or by following steps 2 to 5. 2| The fuel feed pumps (7) maintain a system pressure of 3-4 bar. The pressure is adjusted on the pressure regulating valve (8) when the valve (15) is closed. 3| The safety valves (9) on the fuel feed pumps should be adjusted to 12 bar and locked when the valves (16) are closed. The purpose of the safety valve is only to protect the pump. [4] The fuel circulating pumps (11) keep the fuel in constant circulation and maintain a system pressure between the circu- lating pumps and the pressure regulating valve (13). Adjust the opening pressure of the pressure regulating valve to 10 bar. 5| The safety valves (12) on the fuel circulating pumps should be adjusted to 12 bar and locked when the valves (14) are closed. The purpose of the safety valve is only to protect the pump. COMMON RAIL 17-37 Fuel System. 32-200251-05 These adjustments should be carried out rapidly as the pumps may run hot if the system is closed for a lengthy time. 6] The pressure regulating valve/adjustable orifice (3) should be adjusted according as follows. Raise the pressure in the system slowly by closing the valve/ orifice (3), until the pressure reaches the value stated in chapter 01 7| Adjust the other engines according to workstep de- scribed above. 8] Check that the fuel oil pressures in all engines are ac- cording to chapter O1., section 01.2. 17.4.1 Preheating of fuel oil Preheating of the fuel oil is needed to achive correct viscosity of heavy fuel oil. The fuel system is preheated as follows: [1] Switch on the fuel feed pump and the booster pump. 2| Switch on the fuel heater (20) and check that the fuel oil temperature monitored on the electric control unit display starts rising. The Flow Control Valve (21) mounted on one of the high pressure pump is at this stage fully opened by the WECS engine control system to enable circulation through the pumps (18), the accumulators (22), the SSV-valves (23) and through the 3-way valve (24) 7-4 COMMON RAIL