INSTRUCTIONS

4-Stroke Engines 3215Q375

Technical Services Issue 2, 9 July 2020

Revised maintenance instructions

For your information
for the charge air shut-off valve
Distribution to operators and owners of installations Engines concerned
concerned 11SGE (11 inch) charge air shut-off valve
installed on WÄRTSILÄ® 32 and
WÄRTSILÄ® 34DF.
Reference
15A Charge air shut-off valve. (Enclosed)
Section
155 Shut-off valve.
Introduction
The charge air shut-off valve is a safety
device and its purpose is to stop the
engine in case of an emergency or engine
overspeed. The shut-off valves must be
tested regularly to ensure proper
functionality.
Issue 1 was published to inform about the
revised maintenance schedule including
(weekly) functional checks and
replacement intervals of the shut-off valve
and its components.
The purpose of this issue is to inform about
the latest revision of the manual pages for
the charge air shut-off valve.
Implement the recommended functional
checks and the replacement intervals.
Validity
Until further notice, replacing issue 1 dated
15 January 2019.
Note
Updated in issue 2:
· WÄRTSILÄ 34DF added
· Chapter 15A “Charge air shut-off
valve” revised.

Before taking any action, always check the available

online systems for the latest revision of this document.
Any locally stored or printed version is considered to
be an uncontrolled document.

Wärtsilä Finland Oy Tel: +358 010 709 0000 www.wartsila.com

P.O. Box 244 (Järvikatu 2-4)
FIN-65101 Vaasa
 INSTRUCTIONS

3215Q375, Issue 2, Page 2 / 3 + 14

Introduction
The charge air shut-off valve is a spring-loaded safety device and its purpose is to stop
the engine by shutting off the charge air, it is activated in case of emergency or engine
overspeed.
The shut-off valve is installed in the charge air duct after each turbocharger, which means
that on a V-engine both banks are equipped with separate devices.
The shut-off valves must be tested regularly in accordance with the maintenance
schedule and the test result recorded in the log book.
The maintenance schedule includes (weekly) functional check and replacement intervals
of the shut-off valve and its components.

Maintenance Schedule and Replacement intervals

Perform the functional test of the shut-off valves weekly.
Follow the testing procedure as described in the revised version of chapter 15A, see the
enclosure.
Following replacement intervals and service kits for the charge air shut-off valve and
components has been introduced, see Table 1 and Figure 1.

Table 1, Replacement intervals

Description Part number 6 000 12 000 18 000 24 000

rhs rhs rhs rhs
Gate support kit 155 704 X X
Spindle kit 155 703 X X
Cover kit 155 705 X
Shut-off valve complete 155 466 X

Figure 1, Overview of the service kits

© 2020 Wärtsilä Finland Oy – All rights reserved – Please read the complete disclaimer at the end of this document.
 INSTRUCTIONS

3215Q375, Issue 2, Page 3 / 3 + 14

Recommendation
· Perform the functional test of the shut-off valves weekly.
· Inspect the function of the engine safety system, i.e. alarm and automatic stop
devices, at the intervals stated in the engine instruction manual.
· Follow the replacement intervals of the shut-off valve and components.
· Distribute this information to all maintenance teams concerned.
· Add the enclosed pages to the engine instructions manual.

Implement the instructions in the local maintenance management system as needed.

Enclosures
Engine manual, updated version of chapter 15A, Charge air shut-off valve, 14 pages.
The enclosed version replaces:
· Section 15.5 “Charge air shutoff valve” in chapter 15 “Turbocharging and Air
Cooling”.
· 3215Q202 Shut-off valve for WÄRTSILÄ ® 32 V-engines.
· 3215Q206 Shut-off valve for WÄRTSILÄ ® 32 in-line engines.

Contact
For services, spare parts and/or tools, please contact your nearest Wärtsilä
representative or log in to Wärtsilä Online: www.wartsila.com/wartsila-online
If you do not have the contact details at hand, please follow the link:
www.wartsila.com/contact

Technical support
If technical support is needed, please create a TechRequest for further assistance.
When creating the TechRequest, please:
· Specify the service bulletin number 3215Q375 in the subject field.
· Write the comments or questions in the description field.
· Attach photos if possible.
Customers using Wärtsilä Online can create the TechRequest directly in the system.
Customers not connected to Wärtsilä Online, please contact your nearest Wärtsilä
representative.

© 2020 Wärtsilä Finland Oy – All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording,
taping or other information retrieval systems) without the prior written permission of the copyright holder. Wärtsilä Finland Oy makes no
representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for
information contained herein. Information in this publication is subject to change without notice. Wärtsilä does not assume any liability for the
consequences of the owner’s/operator’s actions, inactions, and/or decisions made or based upon the information provided herein.
Unless otherwise expressly set forth, no recommendation contained in this document or any of its appendices is to be construed as provided
due to a defect of the product, but merely as an improvement of the product and/or the maintenance procedures relating thereto. Any actions
by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wärtsilä and such actions will
thus be at the owners/operators own cost and expense.
NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE
© INFORMATION CONTAINED
2020 Wärtsilä Finland Oy – HEREIN.
All rights THIS PUBLICATION
reserved IS CONFIDENTIAL
– Please read AND INTENDED
the complete disclaimer FORofINFORMATION
at the end this document.PURPOSES
ONLY.
 Enclosure to 3215Q375, issue 2

Wärtsilä Engine O&MM 15A. Charge air shut-off valve

15A. Charge air shut-off valve

The charge air shut-off valve (1) is a spring-loaded safety device and its purpose is to stop
the engine by shutting off the charge air to the engine.
The shut-off valve is installed in the charge air duct after each turbocharger, which means
that on a V-engine both banks are equipped with separate devices.
The shut-off valve is not activated in normal operation but only in case of emergency and
engine overspeed.
The shut-off valves are activated at the same time in case of an emergency. The shut-off
valve is released by a solenoid valve which receives the signal from the engine safety
system (overspeed or emergency shutdown buttons). The solenoid valve can be manually
activated by a push button which is located on the side of the solenoid.
The shut-off valve is also equipped with a T-handle so that it can be released manually by
pulling or rotating the handle in case of an emergency. The handle is shut-off-valve-
dependent and in V-engines it does not automatically release the other valve. When the
shut-off valve is released, it must be manually reset “armed”.
The shut-off valves must be tested regularly according to the maintenance schedule and
the test result must be recorded in the log book.

WARNING
Do not place any part of your body or any object into the valve opening when it
is partially or fully open. There is a risk of serious injury if the valve closes.
Use protective eyewear.

1 Charge air shut-off valve

Fig 15A-1 Charge air shut-off valve for L-engine GUID-00B6917F-55CA-4482-9EA5-9EDB85F863EF v1

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

1 Charge air shut-off valves

Fig 15A-2 Charge air shut-off valves for V-engine GUID-614C3836-2FF5-4E3C-B881-AF69EDA60EC3 v1

The figure shows only the principle of the system. The real views can vary depending on the
installation and the equipment used.

15A.1 Releasing and arming the charge air shut-off valve

manually GUID-7DA04C47-A656-4A00-AD51-27DD6DAEDC39 v6

CAUTION
Do not release the shut-off valves manually on a running engine unless it is an
emergency situation.

3 2 2
1 Operating shaft 3 Manual push button
2 Manual T-handle (two alternative 4 Air supply from instrument air
designs) connection 311

Fig 15A-3 Solenoid and manual releasing system (example) GUID-F71B1DED-8F8C-43B0-891D-E33746885862 v2

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Wärtsilä Engine O&MM 15A. Charge air shut-off valve

Procedure

1 To release the shut-off valve, use the manual push button (3) of the solenoid.
In V-engines, this releases both shut-off valves at the same time.

2 Manual T-handle (1) can be used for manual release in two different ways.
● Rotate the T-handle in clockwise direction.
● Pull the T-handle.

1 Manual T-handle

Fig 15A-4 Using the manual T-handle GUID-F45C7F84-895D-4EA0-8C4C-AB256612E0B4 v1

CAUTION
If you release the shut-off valve by rotating the T-handle, you must rotate the
handle back to its home position before you can re-arm the shut-off valve.

NOTE
The T-handle releases only this particular shut-off valve.

3 Arm the shut-off valve manually after releasing.

Before arming, ensure that the T-handle is in the home position. The handle is in the home
position when the roller (3, Fig 15A-5) is fully seated in the groove (4).
Turn the hex head of the operating shaft (1) towards the indicator pointing to the RUN
(open) position using a box-end wrench.
Ensure that the shut-off valve is securely latched in the open position.

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

1
2
3

1 Operating shaft 3 Roller

2 Manual T-handle 4 Groove

Fig 15A-5 Shut-off valve arming GUID-BCD77182-CBA0-4611-BCD0-16D4A5252706 v2

Note that in some charge air shut-off valves RUN and STOP positions are called OPEN and
CLOSED.

15A.2 Charge air shut-off valve operating air GUID-E52DBE8B-D8E7-48A8-AD58-3FD4C95D772F v10

The shut-off valve gets the operating air from the instrument air system. The instrument air/
system must fulfil all the requirements mentioned in the installation instructions. Ensure that
the instrument air pressure is 7-8 bar and the system including the piping, air dryers, drain
points etc. are in good condition. The normal working pressure on the shut-off valve is 5-8
bar.
For a detailed schematic, see the installation-specific documentation.

15A - 4
 Enclosure to 3215Q375, issue 2

Wärtsilä Engine O&MM 15A. Charge air shut-off valve

3 4

1 Air inlet 3 T-handle

2 Solenoid valve 4 Pressure port

Fig 15A-6 Principle of the operating air connection GUID-49262C8C-53BE-486F-A201-D1D495BA4B27 v1

WARNING
Ensure that the air supply to the charge air shut-off valve is always open. The
valve does not work if the air supply is closed.
You can close the air supply only when the engine is stopped for maintenance.
Remember to open it again before starting the engine.

15A.3 Charge air shut-off valve operation in a real situation GUID-2F16ABAB-1101-40A0-835F-C082261BD2C8 v3

When the charge air shut-off valve has been released in a real situation, the test procedure
described in this manual must be carried out.
If any of the tests fails or there is some reason to suspect that the shut-off valve has been
damaged during the shutdown, the whole safety system including the shut-off valve itself
must be inspected. Before the engine can be operated, all damaged or worn parts of the
shut-off valve and the system must be replaced and the system tested once again
according to the test procedure.
It is recommended to inspect the turbocharger bearings if the charge air shut-off valves
have closed during operation above 50% engine load.

15A.4 Testing the charge air shut-off valve GUID-2BDD4F74-195E-493F-8B94-E79A47F2882C v7

The charge air shut-off valve is normally placed in a clean air stream. However, occasionally
dirt, grease, oil or carbon residue can come in contact with the device and impede its
operation.
Since the shut-off valve is intended for emergency use, testing it regularly is important. It is
recommended to carry out the testing procedure every week.

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

NOTE
Test the shut-off valve when the engine is stopped or idling.

WARNING
In dual fuel engines, do not test the shut-off valve while idling on gas mode.
Switch to the diesel operating mode or perform the test when the engine is
stopped.

WARNING
If you perform the test on a running V-engine, ensure that both shut-off valves
are closed simultaneously.
The engine or turbochargers may be damaged, if a shut-off valve closes when
the engine is running at a higher than idle speed.

WARNING
Before maintenance, ensure that the charge air shut-off valve is in the closed
position.

3 2 2
1 Operating shaft 3 Manual push button
2 Manual T-handle (two alternative 4 Air supply from instrument air
designs) connection 311

Fig 15A-7 Solenoid and manual releasing system (example) GUID-F71B1DED-8F8C-43B0-891D-E33746885862 v2

Procedure

1 Ensure that the air supply to the shut-off valves is open and the air pressure is
correct.

2 Ensure that the shut-off valves are armed.

3 Simulate overspeed trip.

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Wärtsilä Engine O&MM 15A. Charge air shut-off valve

4 Check that the shut-off valves close (closed valve position).

In this position the sensors should give the alarm signal and block engine start. If the engine
is running, it should stop.

5 Arm the shut-off valves.

6 Activate the emergency stop.

7 Check that the shut-off valves close (closed valve position).

In this position the sensors should give the alarm signal and block engine start. If the engine
is running, it should stop.

8 Arm the shut-off valve(s).

NOTE
At each test, confirm that both shut-off valves of a V-engine are activated
simultaneously.

If the charge air shut-off valve fails to close or stop a running engine during the test, the
reason for the failure must be found and rectified before the engine can be taken into
operation.

15A.5 Transportation, storage and installation of the shut-

off valve GUID-62F13AFC-D3D3-43E3-8486-C4ED264214FC v3

The shut-off valve must be in the closed position (released) during transportation, storage
and installation.

15A.6 Replacing the gate support assembly GUID-69276443-0E9E-4C00-AE2D-747484D39CE1 v1

Prerequisites
Stop the engine.

Procedure

1 Release the shut-off valve manually with the T-handle (1, Fig 15A-4).
Check that the indicator on the operating shaft points to the closed position.

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

2 Remove the old gate support assembly.

1 2 3 4 5 6

1 Gate support bearing 5 Cap

2 O-ring 6 Cap screw
3 Gate support 7 Clocking feature
4 Spring

Fig 15A-8 Removing the gate support GUID-B1C6B0FF-B154-4653-A9F7-692D7FED2FD3 v1

WARNING
Wear safety glasses, and keep the cap still by pressing against it as it is under
slight spring pressure.

a While pressing the gate support cap (5), remove the two cap screws (6).

b Slowly remove the cap.

c Remove the spring (4), gate support (3), and sealing ring (2).

3 Inspect and clean the surfaces.

a Inspect the cover mating surface and the inside surface of the gate support
bearing (1).
If either surface is damaged, replace the cover assembly.

b Use a soft cloth to remove any debris from the sealing ring groove and the inside
surface of the gate support bearing.

4 Apply a light layer of DuPont Krytox GPL296 grease to the O-ring (2) and mount the O-
ring into its groove.

5 Install the new gate support into the bearing.

Position the gate support so that the clocking feature (7) is orientated away from the T-
handle.

6 Place the new spring into the gate support.

7 Mount the new cap.

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Wärtsilä Engine O&MM 15A. Charge air shut-off valve

a Prepare two new cap screws with one lock washer and one flat washer for each
screw.
Apply a small amount of high temperature thread locker on each screw.

b Align the clocking feature on the new cap to the clocking feature on the gate
support.

c Press the cap against the spring until the mating surface of the cap is entirely flush
with the mating surface of the cover.

d While still holding the cap in place, mount the two cap screws by hand.

e Tighten the screws to a torque of 50 Nm.

8 Arm the shut-off valve.

See section 15A.1.

9 Test the shut-off valve.

See section 15A.4 and section 15A.1.

15A.7 Replacing the spindle assembly GUID-0F52A459-E1F7-494A-A105-E12FB9080168 v1

Prerequisites
Stop the engine.

Procedure

1 Release the shut-off valve manually with the T-handle (1, Fig 15A-4).
Check that the indicator on the operating shaft points to the closed position.

2 Isolate and bleed down the actuation air pressure.

WARNING
Wear safety glasses, and ensure that the pressure is properly turned off and
bled down.

3 Remove the old spindle assembly.

a Remove the retaining ring (1) that holds the spindle assembly to the valve.
Use snap ring pliers.

WARNING
Wear safety glasses, as the retaining ring is under significant compressive force
from the snap ring pliers.

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

1 Retaining ring

Fig 15A-9 Removing the retaining ring GUID-174DDB4B-2963-4F37-820A-D63AE76C7F0D v1

b Use the T-handle to carefully pull the spindle assembly straight away from the
valve cover.

NOTE
Take care not to damage the actuator bore.

4 Inspect and clean the surfaces.

a Inspect the internal surfaces of the actuator bore.

If the inside of the bore is damaged, replace the cover assembly.

b Use a soft cloth to clean the internal surfaces of the actuator bore.

5 Install the new spindle assembly into the valve cover.

1
2
3
1

1 Clocking feature
2 Sealing ring
3 Sealing ring

Fig 15A-10 Installing the spindle assembly GUID-EE5C7EAB-8468-4BCC-B6E6-D775EAAE9940 v1

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 Enclosure to 3215Q375, issue 2

Wärtsilä Engine O&MM 15A. Charge air shut-off valve

a Apply DuPont Krytox GPL296 grease into the spindle bore and sealing rings (2) and
(3).

b Align the clocking feature (1) on the spindle assembly to the clocking feature on
the valve cover.

c Carefully push the spindle assembly through the actuator bore until the clocking
features have interlocked.

d Install the retaining ring (1, Fig 15A-9) in the circular groove between the spindle
assembly and the valve cover.
Use snap ring pliers.

6 Arm the shut-off valve.

See section 15A.1.

7 Test the shut-off valve.

See section 15A.4 and section 15A.1.

15A.8 Replacing the cover assembly GUID-23C72CBB-5276-4610-9D9E-766BCF959035 v1

Prerequisites
Stop the engine.

Procedure

1 Release the shut-off valve manually with the T-handle (1, Fig 15A-4).
Check that the indicator on the operating shaft points to the closed position.

2 Isolate and bleed down the actuation air pressure.

WARNING
Wear safety glasses, and ensure that the pressure is properly turned off and
bled down.

3 Disconnect the air supply line from the valve.

Ensure that no dirt or other particles can enter the air supply line.

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

4 Remove the old cover assembly.

1 2 3

4 5

1 Body 4 Cap screw with washer

2 Gate latch mechanism 5 Cover
3 O-ring

Fig 15A-11 Removing the cover GUID-587C64DD-9860-4B25-9FB7-05DA2418DEE0 v1

a Remove the eight cap screws with washers (4) that attach the cover (5) to the body
(1).
Keep the cover still in its place while removing the screws.

b Carefully remove the cover.

c Remove the O-ring (3).

NOTE
Take great care not to damage the mating surface of the body.

5 Inspect and clean the surfaces.

a Inspect the gate latch mechanism (2) for serious wear, such as breaks or cracks.
If the gate latch mechanism is damaged, replace the body assembly.

b Use a soft cloth to remove all remnants from the body mating surface.

6 Install the new cover assembly (5) and O-ring (3).

a Apply a small amount of DuPont Krytox GPL296 grease to the new O-ring.
Ensure that the O-ring is thoroughly greased.

b Mount the O-ring to the cover.

Ensure that the O-ring is fully seated in its groove.

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 Enclosure to 3215Q375, issue 2

Wärtsilä Engine O&MM 15A. Charge air shut-off valve

c Secure the new cover to the body by mounting eight new cap screws with washers
(4) by hand.
For each cap screw, mount one lock washer and one flat washer. Apply a small amount
of high temperature thread locker on each screw.

d Tighten the cap screws to a torque of 29 Nm in the order shown by the figure
below.

7 1 4 6

5 3 2 8

Fig 15A-12 Tightening order for the cap screws GUID-3D4C1BD5-9666-4C68-B2E8-0A4379DA071B v1

e Remove the protective plug from the air inlet port of the new cover.
Check that the port is clean of debris.

f Connect the air supply line to the new cover using the appropriate pipe sealant.

7 Arm the shut-off valve.

See section 15A.1.

8 Test the shut-off valve.

See section 15A.4 and section 15A.1.

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15A. Charge air shut-off valve Wärtsilä Engine O&MM

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