Contents, Instructions, Terminology 00 a | Main data, Operating Data and General Design O1 qf Fuel, Lubricating Oil, Cooling Water + O2 _ Start, Stop and Operation 03 Maintenance Schedule O04 a Maintenance Tools O5 qf Adjustments, Clearances and Wear Limits O06 Tightening Torques and Use of Hydraulic Tools Q7 > Operating Troubles, Emergency Operation O8 Specific Installation Data O9 a Engine Block with Bearings, Cylinder Liners and OilSump 10 oO Crank Mechanism: Crankshaft, Connecting Rod, Piston 1 1 a Cylinder Head with Valves 12 = Camshaft DrivingGear 13 Valve Mechanism and Camshaft 14 O Turbocharging and Air Cooling 15 _ Injection System 16 oe Fuel System 17 Lubricating Oil System 18 jens Cooling Water System 19 wn Exhaust System 20 a Starting Air System 21 | Control Mechanism 22 Instrumentation and Automation 23 00 01 02 03 04 05 06 0732-200643-01 Tightening Torques and Use of Hydraulic Tools 07 07. Tightening Torques and Use of Hydraulic Tools 07.1 Tightening torques for screws and nuts Note! Note! See section 07.3 for hydraulically tightened connections! ‘The position numbers in the tables below refer to the correspond ing figures A to K, which are located in the engine according to Fig 07-1. Always tighten to stated torque shown in the tables, A loosen screw connection might cause serious damages/human injury.Threads and contact faces of nuts and screw heads should be oiled with lubricating oil unless otherwise stated. Note that locking fluids are used in certain cases. Molycote or similar low friction lubricants must not be used for any screws or nuts. Great risk of over tensioning of screws. 1. Nm = 0.102 kom all fel - cal Fig 07-1 sooroe01 WARISILA 32 07-107 Tightening Torques and Use of Hydraulic Tools 32-200643-01 A: Crankshaft and flywheel Fig 07-2 so7eas01 1.| Flywheel bolts, fitted bolts, M30. 600430 |__2.| Flywheel elongation botts, M30 1200+60 3) Spit gear on crankshaft, M20"190, 10.9 screws(Miz) [55030 Torque wrench setting (Mi) with tool comiaination, see rigibeiow. 488 Lubricate threads with engine lubricating oll. 4,) Spit gear on crankshaft, M20"120, 12.9 screws(vz} |600:30 Torque wrench setting (Mn) with tool combination, see Fig below. 's32 Lubricate threads with engine lubricating ol. 5.| Flywheel mounting bolts, M20 [390220 Note! Torque wrench settings must be recalculated if an other fool combination than Fig below is used for the split gear wheel screws. Tool 2V-126987 Torque wrench 721/80 Ma Example: 550 y=975 mm. 07-2 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 ] B: Intermediate gear and camshaft Fig 07-3 007049501 1.| Camshaft flange connection screws [290110 2.| Camshaft dtiving gear screws 290::10 3,| Governor gear wheel screws 11710 4,| Intermediate gear wheel screws 560130 Hydraulically fensioned screw, see section 07.3 | 5.) Flange fastening screws 8035 6.| Camshaft flange connection nuts [29010 Note! See section 13.2 for intermediate gears and camshaft drive. WARTSILA 32 07-3Tightening Torques and Use of Hydraulic Tools 32-200643-01 Governor drive Fig 07-4 soon sos [Lu Govemor WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools C: Cylinder head 07 Fig 07-5 0705 1.| Rocker arm console, fastening screws |40020 2,| Starting valve fastening screws [555 3,|_Nutforstarting valve spindle [3615 4.| Nuts for injection valve 125410 5,| Safety valveincyiinderhead, fosteningnuts [855 6] Fastening screws, cylinder heady/muitduct Notel ightening order. 195#10 Recheck the screws. ‘Apply Nova Lube of similar heat resistant grease on threads. 7.| Fastening screws for flange connections 7985) 8.| Fastening screws, mulfiduct/exhaust manifold [19510 9,| Fastening screws, mulfiduct/engine block 195410 10.| Fastening screws, rocker arms [300 WARTSILA 32 07-507 Tightening Torques and Use of Hydraulic Tools 32-200643-01 D: Injection pump 1,| Fastening sctewsforheadplece, M16 [105410 _|160#10 2. Fastening screws forhead piece, M12. 12010 3, Frosion plugs 215210 |200#10 | Notel. The erosion plugs must be secured! See section 162.5 e. 4\| Flange fastening screws i913 [9025 5, Locking sctews for injection pump lsoz5 [5085 adjusting screw 6) Fastening nuts for injection pump '400:20 |400:20 Lubricaté threads and contact surfaces with engine ol. 7,| Locking sctew for roller pin e025 [05 Apply Loctite 2701 on threads, see section 07.2. ( 07-6 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 D: Injection pump, Common Rail Lubricats threads and contact surfaces with engine oll Fig 07-7 -anrs.0240 1. Fastening screw for pump elernent M10. 20:8 2,| Fastening screw for head piece M8. [sae3 Fastening screw for head piece M10. [6086 3.) Fastening screw for control valve col i 4|| Fastening screws forcontrolvatve, son 5.| Spring holder fastening screw. oe 6, Locking screw for roller pin. i707 Apply 2701 on threads, see section 07.2. Fastening nut for injection pum J400120 WARTSILA 32 a-7Tightening Torques and Use of Hydraulic Tools 32-200643-01 D: Valve tappet housing Fig 07-8 sooner 1.|_ Valve tappet housing fastening screw. [20010 2.| Guide plate fastening screw 2345 only Lactte B48 on reads, see saction 07 nH i WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 Fuel injection valve Fig 07-9 1,| Injection pipe cap nut to injection pump. 140210 son7079901 2.| Injection pipe cap nuttoconnectionpiece —_|90#10 3.| Connection piece to nozzle holder 16010 4,| Screws for protecting seeve [20:5 5| Injectionnozde capnut__(’Orange) /a50%20 5,| Injectionnozdle capnut Woodward) (67840 1. injection pipe cap nutto injection pump 265410 BI 2.| injection pipe cap nuttoconnectionplece —_|180:10 3.| Connection piece to nozle holder 160210 4| Screws forfiange [e035 5,| Injectionnozde cap nut (Orange) |450:20 5] Injectionnozde cap nut Woodward) [67840 WARTSILA 32 07-907 Tightening Torques and Use of Hydraulic Tools 32-200643-01 E: Fuel injection valve, DWI Fig 07-10 sommn00148 Injection pipe cap nut fo injection pump: 1265410. Injection pipe capnuttoconnectionpiece _|18010. ( 3.| Connection piece to nozzle holder |70+5 |__4.| Screws for flange ro _|e0s5 §,| Injection nozle cap nut 600+20 6.| Screw for high pressure water connection 100+10 Lubricate with Molykote G-Rapid Plus 7.| Screw for leakage water connection 3515, Lubricate with Molykote G-Rapid Plus 8 Screwsforvavebody 7025 9.| Water accumulator fastening screws 7525 Lubricate with Molykote G-Rapid Plus ( 07-10 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 E: Fuel injection valve, Common Rail Fig 07-11 “709601 1,| Injection pipe cap nut fo injection pump [290430 2,| Injection pipe cap nuttoconnection piece [21020 Apply engine oil on threads and seat cones. 3.| Connection piece to nozle holder 160410) 4,| Screws for protecting sleeve 8015) 5,| Injection nozzle cop nut [600120 WARISILA 32 07-1107 Tightening Torques and Use of Hydraulic Tools 32-200643-01 FLOW FUSE #5 E: Water injection flow fuse, DWI FLOW FUSE #7 2 Fig 07-12 soors20048 1.| Fastening screw 7935 2.| Fastening nut 80:5 3,| Limiter screw for shut offstemn 541 4 Fastening screw for plug 71 1. Fastening nut [2542 2.| Nut [3442 07-12 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 E: High pressure pipes, Common Rail Distances X for HP pipe ends (positions A - E) a, PS x aay Fig 07-13 swore 3.) Injection pipe cap nut fo accumulator and pump '29030 Apply engine ollon threads and seat cones. adult d 4 Rail pipe cap nut fo accumulator 140215 Apply engine ollon threads andseat cones. bots 5 Pug 140215 Apply engine oil on threads Distance 00 Pipe end - Power Sleeve (P3). Apply Loctite 2701 on threads. |7,8(+0.5/-0) Distance 00 Pipe end - Power Sleeve (PS). Apply Loctite 2701 on threads. _|6,4(+0.5/-0) Distance (0) Pipe end - Power Sleeve (PS). Apply Loctite 2701 on threads. |7,8(+0.5/-0) Distance 00 Pipe end - Power Sleeve (PS). Apply Loctite 2701 on threads. |10,9(+0.5/-0) Distance (0) Pipe end - Power Sleeve (PS), Apply Loctite 2701 on threads. [7,6(+0.5/-0) m|9|0|p|> Note! The high pressure pipes must be re-tightened according to intervals stated in chapter 04 and as described in chapter 16. WARTSILA 32 07-1307 Tightening Torques and Use of Hydraulic Tools 32-200643-01 Accumulator, Common Rail 4 8 1 9 Fig 07-14 so730240 1,| $8V-vaive connection piece fastening screw 8085 Apply Loctite 243 on threads. 2.| Fastening screws for cir bottie. 025 3,| Fastening screws for SSV-valve. 110410 4,| Fastening screws for head piece. 1520820 5. Reducing plug Apply Loctite 542on threads 1201 6.| Airbottie top piece. 350120 7 Airbottie. x 350120 8.| Fastening screws for leak detecting ring, 20:5 9.| Airbottle bottom plug. [27010 07-14 WARISILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 iston Piston with 4 screws Piston of type 1 Fig 07-15 Piston with 2 screws Piston of type 2 00708200142 1. Piston crown connection screws. 1. Lubricate threads and contact surfaces with engine oil 2.Tighten the screws crosswise. 3, Loosen the screws. 4. Pretighten the screws crosswise. 5. Tighten the screws crosswise further with an angle of 6 Testor the right tightness. Sctew should not move when lightening by125 Nm torque. Note! When changing piston top renew the Screwsif over langnt excaecs 169.5 mm 165Nm, |40Nm 805° Piston crown connection screws. 1. Lubricate threads and contact surfaces with engine ol, 2. Tighten the screws. 3. Loosen the screws. 4. Tighten the screws. 8. Tighten the screws further with an, angle of 7.Testfor the right tightness, Screw should not move when lightening by 250 Nm torque. Note! When changing piston fop renew screwsif overalllenght exceeds 131.4 mm 250Nm_ 80m 90°10 WARTSILA 32 07-1507 Tightening Torques and Use of Hydraulic Tools 32-200643-01 View A Piston with 4 screws Piston of type 3 Fig 07-16 400790200142 3,] Piston crown connection screws. 1. Lubrleate threads and contact surfaces with engine oll 2. Tighten all screws, 3. Tighten all screws further with an angle of, 4, Loosen screws | and 3, 5: Tighten screws 1 and3. 6.Tighten screws 1. and further with an, ‘angle of, 7. Loosen screws 2 and 4, 8 Tighten screws 2 and 4. 9UTighten screws 2.and 4 further with an angle of 10. Test for the right tightness. Screw should not move when tightening by 165 Nm torque. Note! When changing piston crown renew alll screws 07-16 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 G: Turbocharger fastening screws (2 Ke Fig 07-17 soors2e01 1 Tutbocharger fastening screw =TPL61,1PL65,M20 1560420 —NA295,NA297, M20 560430 —NA355,M24 650430 | = TPL69.M24 —=NA357,M24 92040 | 2,| Fostening screws for turbo chergerbracket 132, M16 195410 =V32, M24 (650130 WARTSILA 32 07-1707 Tightening Torques and Use of Hydraulic Tools 32-200643-01 H, |: Engine driven pumps Fig 07-18 Driving gear of engine driven pumps: Tighten screws crosswise —FuelfeedpumpC) 3212 — Lubricating ol pump 132 (*) 75:5 —lubtcating of pune Voz) 1505 —Water pump 132°) 3242 —Water pump V32.) 50:2 Tighten the screws crosswise (0-20- 40-50 Nm) (The screws aie treated with locking compound ‘and canbe used only once. Replace the screws with new, treated ones. Only Drloc 201 or Drloc: 211 should be used. 2.| Impeller screw for HT and LT water pump Pump type WD-90/ -91/-120: ja5e5 Pump type WD- 121; 11085 Apply Loctite 2701 on threads, see section 07.2. 3] Screws for bearing retainer 1083 Apply Loctite 242 on threads, see section 07.2. To avoid damaging the threads (Pos. 2 and 3), heat up the screws before loosening. 07-18 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools H, | Engine driven control oil pump, Common Rail 1. Screw 007243 Fig 07-19 Fastening sorews for ctving gecr Tighten the screws cr osswise The screws are rected withiocking compound {nd can be usec only once, Replace the screws 1¢ 201 oF with new, treated ones. Only Dri Drloc be used. : 211 should WARTSILA 32 07-19| 07 Tightening Torques and Use of Hydraulic Tools 32-200643-01 Screws: olpame, ‘driving gear at free end of 1800£25 cranksh Lubricate threads with engine lubricating oil, We recommend the use of torque measuring tools also when tightening other screws and nuts. The following torques apply to screws of the strength class 8.8; when oiled with lubricating oil or treated with Loctite. Ma: 13 6. (7s 2s Mio Tz 8 las (46 M12 19 10 80, 8.1 Mi6 za 14 190__|193 M20 130 het 1370 37.5. M24 36 a 19 }640 165.0 07.2 Use of locking fluid When using locking fluid (Loctite), clean parts carefully in de- greasing fluid and let then dry completely before applying locking fluid. 07 - 20 WARISILA 32 (32-200643-01 __ Tightening Torques and Use of Hydraulic Tools 07 Cc K: Sensors for HT-water Fig 07-21 soon 1.| Temperature sensor pocket 4045 2.| Temperature sensor pocket 12 ¢ C WARISILA 32 07-2107 Tightening Torques and Use of Hydraulic Tools 32-200643-01 07.3 Hydraulically tightened connections 07.3.1 Tightening pressures Fig 07-22 1,] Cylinder head screws M56 in two steps: 2V86B224 Fist step 520 Secondstep 520 540 2.) Main bearing screws M56 in two steps: [3868218 First stop 250 Secondstep_ (515 saa 625) | 3,) Lateral screws of main bear. M42 in two steps: |SV86B78 Fiststep 1250 Secondstep 615: 1635 ‘4| Connecting rod screws: [2v86B478 —Upper- and lower con. M27 in two steps: Firststep 1400 Secondstep 1800 \e20 5,| Counterweight screws Ma2in two steps: 3v86878 vo2 First step 300 Secondstep 700 720 132 (Screw stamped:940) Fiststep 300 3V86878 Secondstep 700 720 132 (Screw stamped:1569)_Fiststep |4c0 3ve6878 ____ Second step 800 820 6 Engine fastening screws By 7,| Intermediate gears M80 in two steps: |2V86B341 8|| Camshaft driving gear M80 in two steps: First step 760 Secondstep 760 780 07 - 22 WARISILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 Exception! Caution! Piston in cylindrical hydraulic tools (see Fig 07-24) x) Pos. 6 see installation instructions. The stud bolts are tightened to the casting at the following torques: M6 Cylinder head M56 Main Bearing ‘AIIMQ7 studs on connectingrod _|100=10 é i Mé2and 48x [20010 Ma0 Intermediate gear |200+10 Screws ace, to pos. 3 and 6. Pos. 3 see chapter 10, section 10.3.3. The screws will be overloaded if the maximum hydraulic pressure is exceeded. Itis recommended to change the screws if maximum hydrau- lic pressure is exceeded for some reason. 07.3.2 Hydraulic Tool Safety Instructions Since the hydraulic tools operate under high pressure and pro- duce great force, proper safety precautions must be taken to reduce the risk of injury to persons and damage to material during work on the engine and in the workshop. 7.000 Screwsin “twin cylinder’ hydraulic tool (see Fig 07-23) 1.000 Hydraulic hoses and couplings 10.000 There are two types of hydraulic tools for the connecting rod shank screws, see Fig 07-23. The screws and nuts in the tool of new design (introduced in year 2001) should be replaced before reaching 1000 loading cycles, i.e raising the pressure to nominal value 1000 times) The screws and nuts of previous design, see Fig 07-23, should be replaced before reaching 250 loading cycles. Ifthe hydraulically tensioned nuts not easily can be turned when the maximum hydraulic pressure is reached: check for corrosion in threads; check tool condition and manometer error. WARTSILA 32 07 - 2307 Tightening Torques and Use of Hydraulic Tools __-32-200643-01 Hydraulic tightening tool for connecting rod shank screw 1. Hydraulic tightening tool Previous design New design 2.Nut 2 3. screw , 40 Qe {13 soratz00027 Cylindrical hydraulic tool 1. Cylinder 2, Piston 3. Sleeve 1 2 Fig 07-24 sono 07.3.3 Filling, venting and control of the high pres- sure hydraulic tool set ‘The hydraulic tool set consists of a high pressure hand pump with an integrated oil container, hoses fitted with quick-coupling’s and non-return valves, cylinders and a pressure gauge mounted on the hand pump but not connected to the pressure side of the pump. ‘The components are coupled in series with the pressure gauge being the last component thus securing that every cylinder is fed with the correct pressure. 07 - 24 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 ‘Caution! ‘The non-return valves in the hoses are integrated with the quick-coupling’s and are opened by the pins located in the centre of the male and female parts. If these pins get worn the coupling must be replaced because of the risk of blocking. © In the high pressure hydraulic tool set it is recommended to use a special hydraulic oil or in any case an oil with a viscosity of about 12cSt at 20°C. During the filling of the container of the high pressure pump it is recommendable to couple the set according to scheme B, Fig 07-25. Before filling, open the release valve (2) and empty the cylinders (4) by pressing the piston and cylinder together. After that, drain the oil and re-fill through the filling plug Q). After filling, vent the system by pressing in, with a finger, the centre pin of the female part of the last quick-coupling, the coupling being disconnected from the pressure gauge. Keep on pumping until air free oil emerges from the coupling. Check the pressure gauge of the hydraulic tool set regularly. For this purpose a comparison pressure gauge is delivered. ‘This pressure gauge can be connected to the plug hole (7), the outlet hose of the pump being connected direct to the pressure gauges. 07.3.3.1 Instructions for high pressure hydraulic tools Pay special attention to cleanliness and carefulness when using and maintaining the hydraulic high pressure tools. © When the hoses are pressurised, any maintenance, adjust- ments nor repairing are allowed, not even tightening of the connections. © Before rising the pressure in the high pressure tool, all hydraulic parts (pump, pipes, hoses, regulating units) has to be vented. © The weakest parts maximum allowed pressure must not be exceeded. © Keep a logbook or similar of the hydraulic tools. WARTSILA 32 07-25Warning! Filing plug Release valve Hose Hydraulic cylinder Hose Pressure gauge Plug hole 07 Tightening Torques and Use of Hydraulic Tools 32-200643-01 | 07.3.4 Dismantling hydraulically tightened screw connections Do not stand absolute next to a pressurized hydraulic tool. 1] Attach distance sleeves and hydraulic cylinders according to Fig 07-25 A. Screw on cylinders by hand 2| Connect the hoses to the pump and cylinders according to scheme Fig 07-25 B. Open the release valve (2) and screw cylinders in clockwise direction to expel possible oil. 3] Screw the cylinders in counter-clockwise direction about alf a revolution (180°), otherwise the nut is locked by the cylinder and impossible to loosen. | 4| Close the release valve and pump pressure to the stated value. 5] Screw the nut in counter-clockwise direction about half a revolution with the pin. 6) Open the release valve and remove the hydraulic tool set. 7) Screw off the nuts by hand. Hydraulic cylinder Fig 07-25 sores 07 - 26 WARTSILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 Note! 07.3.5 Reassembling hydraulically tightened screw connections Check that the threads and contact surfaces are clean and free from particles. 1] Screw on nuts and attach distance sleeves. Screw on. cylinders by hand. 2] Connect the hoses to the pump and cylinders. Check that the release valve is open and screw the cylinders in clockwise direction to expel possible oil. 3] Close the release valve and pump pressure to the stated value. 4] Screw the nuts in a clockwise direction until in close con- tact with the face. Use the pin intended for this purpose and tighten the nut as much as possible without breaking the pin. Keep the pressure constant at the stated value. |5| Open the release valve and remove the hydraulic tool set. ‘To ensure that the nut will be properly tightened, the pressure can be raised in two steps. Pump the pressure according to section 07.3.1 and screw the nut in a clockwise direction until in close contact with the face. Increase the pressure further to the stated pressure, and screw the nut until in close contact with the face again. This time the nut should move just a limited angle but approximately the same angle for all nuts of the same kind. Before the engine is started, ensure that all screw connections that have been opened are properly tightened and locked. WARTSILA 32 07 - 2707 Tightening Torques and Use of Hydraulic Tools 32-200643-01 07.4 Use of hydraulic extractor cylinder For some power demanding operations a hydraulic extractor cylinder (800063) is used. In connection with this cylinder, the hydraulic high pressure hand pump is utilized, coupling scheme ace. to Fig 07-26. Hydraulic extractor cylinder Fig 07-26 sasa05 According to the design of the cylinder, the outer cylinder (1) must not be loaded, but the force is created between the surfaces A and B. ‘The piston is prevented from running out of the cylinder by an expansion ring (2). The strength of this ring is limited, and it is recommended to be careful when operating at the end of the stroke. ‘The effective area of the piston is 82,2 em” which gives the following relation between pressure and force (using tool 2V83E0186), see Fig 07-27, (1) Inthe previous tool (marked with 3830061) the effective area ofthe piston is 14,42cm”, The relation between pressure and force is shown in Fig 07-27, (). 07 - 28 WARISILA 3232-200643-01 Tightening Torques and Use of Hydraulic Tools 07 Relation between pressure and force ea Max pressure 200 + oo" acco” 6600” 8000 " 10000 12000 G00 ' 14000 18000" 20000 22000 24000 26000K> oco 4c000 " 60000” go000 "160000" 120000" 14¢000 140000° 180000' 200000' 220000' 240000° NN Fig 07-27 sooraraaos2 07.5 Low pressure pump for lifting purposes in the crankcase A special low pressure pump (150 bar) 800 059 is delivered for lifting tools used in the crankcase. Normal engine oil, which is used in the engine lubricating system (sump) must be used in this pump because the drain oil from the tools is led to the sump of the engine. WARTSILA 32 07-2907 Tightening Torques and Use of Hydraulic Tools ___32-200643-01 07-30 WARTSILA 32