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Installation Audacia

Engine type W38B

Engine number 24154 - 24159

This manual is intended for the personal use of engine operators and

should always be at their disposal. The content of this manual shall neither

be copied nor communicated to a third person.

Wrtsil Italia S.p.A.

Bagnoli della Rosandra, 334 34018 San Dorligo della Valle Trieste - ITALY Tel +39 040 319 5000 Fax (Service) +39 040 319 5674 Fax (Spare parts) +39 040 319 5237 Telex 460274/5 GMI

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Copyright by Wrtsil Corporation 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 owner.

THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF PRINTING. HOWEVER, THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN THE AREA, AND THE DESIGN OF THE SUBJECT-PRODUCT IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CAN NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS PUBLICATION OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT HOLDER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.

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Service Department

Wrtsil Italia S.p.A., Business Unit ServiceBagnoli della Rosandra, 33434018 San Dorligo della ValleTrieste ITALY

24h Phone

Nights and weekends, please call mobile phone for service engineer or spare parts

+39 335 784 1217

DIRECT DIAL NUMBERS

SALES SUPPORT TECHNICAL SERVICE

Fax: +39 040 319 5216 Fax: +39 040 319 5767

North, Central and East Europe

Phone: +39 040 319 5071

Wrtsil 64 engines

Phone: +39 040 319 5080

Americas

Phone: +39 040 319 5072

Wrtsil 38B engines

Phone: +39 040 319 5081

Middle East and South Asia

Phone: +39 040 319 5073

Wrtsil 26 engines

Phone: +39 040 319 5082

Southern Europe and Africa

Phone: +39 040 319 5074

Sulzer Z engines

Phone: +39 040 319 5083

Italy

Phone: +39 040 319 5075

GMT engines

Phone: +39 040 319 5084

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The list of Wrtsil Network companies is available atwww.wartsila.com web site.

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Wrtsil Italia S.p.A.

Service

Bagnoli della Rosandra, 334

34018 S. Dorligo della Valle

Trieste, Italy

Telephone: +39 040 319 5000

Telefax: +39 040 319 5647

Telex: 460274/5 GMI

The Wrtsil Engine Documentation

General

The Engine documentation has been split up in five binders:

- Instruction Manual - Spare Parts Catalogue - Service Bulletins - Record Book of engine Parameters- Sub-suppliers Manual

The users of the documentation are assumed to be trained operating and maintenance personnel, with an understanding of the construction and use of the engine.

Contents

The content of the binders is as follows:

Instruction Manual

x General Description of the engine x Description of main engine parts x Main Data x Description of the various gas-, fluid- and control systemsx Operation directives x Maintenance schedule, -tools and -instructionsSpare Parts Catalogue

x Spare Parts Catalogue (of the engine) Service Bulletins

x Division with separate tabs for filing standard forms and all commercial and technical, product related after sales documents which are mailed customer specific.

Record Book of Engine Parameters

x Engine Test protocol x Statement of Compliance EIAPP Technical file x Record forms x General Installation documents Sub-suppliers Manual

x Documentation as received from Sub-suppliers if not incorporated in another way in the engine documentation.

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Wrtsil Italia S.p.A.

Service

Bagnoli della Rosandra, 334

34018 S. Dorligo della Valle

Trieste, Italy

Telephone: +39 040 319 5000

Telefax: +39 040 319 5647

Telex: 460274/5 GMI

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0.0. General 0.0 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0.1. Introduction 0.0 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0.2. Terminology 0.0 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0. Main Data 1.0 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.1. Basic information 1.0 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.2. Output 1.0 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.3. Derating conditions 1.0 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0.3.1. Derating limits for ambient conditions 1.0 5 . . . . . . . . . . . . . . . . . . . . 1.0.3.2. Glycol derating 1.0 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.3.3. Restrictions on the application of the derating calculation 1.0 6 . . . 1.0.3.4. Adjustment of power output for ambient conditions 1.0 6 . . . . . . . .

1.0.4. Correction of heat balances 1.0 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0.5. Operating Data 1.0 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1. Fuel System 1.1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1. General 1.1 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1.1. HFO engines running on distillate fuels* 1.1 2 . . . . . . . . . . . . . . . . . . 1.1.2. Fuel 1.1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2.1. Residual fuel oil quality* 1.1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.2. Crude oil quality* 1.1 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.3. Distillate fuel oil quality 1.1 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.4. Fuel oil quality before engine 1.1 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.5. Fuel conditioning 1.1 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2.6. Avoiding difficulties during operation on HFO* 1.1 16 . . . . . . . . . . . . . 1.1.2.7. Comments on fuel characteristics 1.1 17 . . . . . . . . . . . . . . . . . . . . . . .

1.1.3. Internal fuel system 1.1 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.4. Draining of fuel system 1.1 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2. Lubricating Oil System 1.2 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1. Lubricants 1.2 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1.1. Requirements 1.2 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1.2. Influences on the lubricating oil condition 1.2 5 . . . . . . . . . . . . . . . . . 1.2.1.3. Testing of main lubricating oil 1.2 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1.4. Condemning limits for main lubricating oil 1.2 7 . . . . . . . . . . . . . . . . 1.2.1.5. Comments on lubricating oil characteristics 1.2 8 . . . . . . . . . . . . . . . 1.2.1.6. Recommendations for refreshing lubricating oil 1.2 9 . . . . . . . . . . . .

1.2.2. Internal lubricating oil system 1.2 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2.1. Oil flow lower part of the engine 1.2 12 . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2.2. Upper part of the engine oil flow 1.2 19 . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.3. Components of internal system 1.2 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.1. Lubricating oil pump unit 1.2 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.2. Prelubricating oil pump 1.2 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.3. Lubricating oil module 1.2 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.4. Centrifugal filter 1.2 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.5. Lubricating oil sampling valve 1.2 48 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3.6. Crankcase breathing system 1.2 49 . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3. Starting Air System 1.3 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1. General 1.3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1.1. Starting air quality 1.3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.3.1.2. Starting air quantity 1.3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.2. Internal starting air system 1.3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3. Components of starting air system 1.3 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3.1. Main starting valve 1.3 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3.2. Starting air distributor 1.3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3.3. Starting air valve on cylinder head 1.3 11 . . . . . . . . . . . . . . . . . . . . . . . 1.3.3.4. Starting air pipes 1.3 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.3.5. Pneumatic control system 1.3 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4. Cooling Water System 1.4 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.1. General 1.4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2. Cooling water 1.4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.2.1. General 1.4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2.2. Requirements 1.4 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.2.3. Qualities of cooling water additives 1.4 4 . . . . . . . . . . . . . . . . . . . . . . 1.4.2.4. Cooling water control 1.4 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.3. Internal cooling water system 1.4 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.3.1. General 1.4 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.3.2. Cooling water flow HT section 1.4 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.3.3. Cooling water flow LT section 1.4 10 . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.4. Components of internal system 1.4 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.4.1. Cooling water pump 1.4 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.4.2. Flexible pipe connections 1.4 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.5. Maintenance cooling water system 1.4 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.5.1. General 1.4 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.5.2. Cleaning 1.4 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.5.3. Cooling water venting 1.4 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4.5.4. Draining of cooling water 1.4 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5. Charge Air and Exhaust Gas System 1.5 1 . . . . . . . . . . . . . . . . . . . . . . . 1.5.1. General 1.5 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.2. Quality of suction air filtration 1.5 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.3. Charge air system 1.5 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.3.1. General 1.5 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.4. Internal system 1.5 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.4.1. Charge air cooler 1.5 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5. Inlet and Exhaust gas module 1.5 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.5.1. Compensator 1.5 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.2. Insulation box 1.5 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.3. Operation 1.5 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5.4. Maintenance 1.5 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.6. Turbocharger 1.5 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.1. General 1.5 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.2. Maintenance 1.5 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.3. Turbocharger cleaning devices 1.5 16 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.4. Compressor side cleaning 1.5 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.5. Turbine side cleaning 1.5 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.6. Compensator bypass 1.5 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.7. Exhaust waste gate valve control 1.5 25 . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.8. Local indications 1.5 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.9. Remote outputs 1.5 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.6.10. Degraded operating modes 1.5 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1.6. Control System 1.6 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.1. General 1.6 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.2. Speed control system 1.6 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.3. Actuator 1.6 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.3.1. Booster 1.6 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4. Fuel control mechanism 1.6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.4.1. Load indication HP fuel pump 1.6 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.2. HP fuel pump connection 1.6 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.3. Fuel rack adjustment 1.6 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.4. Stop mechanism 1.6 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.5. Checking linkage between actuator

and common fuel control shaft 1.6 11 . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.6. Checking actuator stop position 1.6 11 . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.4.7. Removing / Mounting the actuator 1.6 12 . . . . . . . . . . . . . . . . . . . . . . .

1.6.5. Governing system maintenance and trouble shooting 1.6 13 . . . . . . . . . . . . . . . 1.6.6. Oil mist detector 1.6 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.7. Engine instrumentation 1.6 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.7.1. Switches, transmitters and temperature elements 1.6 17 . . . . . . . . . 1.6.7.2. Speed sensors 1.6 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.7.3. Electro Static Discharge (ESD) 1.6 19 . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.7.4. Welding precautions 1.6 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.7.5. General list of abbreviations 1.6 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.7.6. List of sensor tags and ISO codes 1.6 23 . . . . . . . . . . . . . . . . . . . . . . .

1.6.8. WECS Control System 1.6 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.8.1. System description 1.6 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.8.2. General application info 1.6 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.8.3. Local user interface description 1.6 36 . . . . . . . . . . . . . . . . . . . . . . . . . 1.6.8.4. Instructions for normal operating mode 1.6 44 . . . . . . . . . . . . . . . . . . . 1.6.8.5. Instructions degrading operating mode 1.6 59 . . . . . . . . . . . . . . . . . . . 1.6.8.6. Failure identification facilities 1.6 63 . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3. Start, Operation and Stop 2.3 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1. General 2.3 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2. Start 2.3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.2.1. Preheating 2.3 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.2. Putting the engine into operation 2.3 3 . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.3. Local start 2.3 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.4. Remote or automatic start 2.3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.5. Start after a stop 2.3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2.6. Start after overhaul 2.3 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3. Operation 2.3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.2. Loading performance 2.3 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.3. Wrtsil 38B operating areas 2.3 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.4. Engine log sheet (example) 2.3 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.5. Measurement of cylinder pressure 2.3 17 . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.6. Runningin 2.3 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.7. Operating Troubles 2.3 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3.8. Emergency operation 2.3 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4. Stop 2.3 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4. Maintenance 2.4 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1. Maintenance Schedule 2.4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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2.4.1.1. General 2.4 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1.2. Rules for inspection and maintenance 2.4 2 . . . . . . . . . . . . . . . . . . . 2.4.1.3. Maintenance schedule 2.4 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.2. Maintenance Tools 2.4 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.1. General 2.4 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.2. Tool set 2.4 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.3. Miscellaneous tools 2.4 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.4. Lubricating oil system 2.4 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.5. Cooling water system 2.4 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.6. Charge air and exhaust gas system 2.4 32 . . . . . . . . . . . . . . . . . . . . . 2.4.2.7. Engine block, main bearing, cylinder liner 2.4 34 . . . . . . . . . . . . . . . . 2.4.2.8. Crankshaft, connecting rod, piston 2.4 42 . . . . . . . . . . . . . . . . . . . . . . 2.4.2.9. Cylinder head with valves 2.4 49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.10. Camshaft and valve drive 2.4 59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2.11. Injection system 2.4 68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.3. Background information for hydraulic tools and torque spanners 2.4 74 . . . . . 2.4.3.1. General 2.4 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.2. Pneumatic driven hydraulic pump unit 2.4 75 . . . . . . . . . . . . . . . . . . . 2.4.3.3. Hydraulic tool set 2.4 79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.4. Hydraulic extractor 2.4 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.5. Hydraulic hoses 2.4 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.6. Quickrelease coupling 2.4 83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.7. Hydraulic hand pump 2.4 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3.8. Safety instructions for hydraulic tools 2.4 85 . . . . . . . . . . . . . . . . . . . . 2.4.3.9. Loosening of hydraulically tightened connection 2.4 86 . . . . . . . . . . . 2.4.3.10. Tightening of hydraulically tightened connection 2.4 88 . . . . . . . . . . . 2.4.3.11. Torque spanner 2.4 90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.4. Tightening torque and jack pressure 2.4 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.1. Lubricating oil system components 2.4 92 . . . . . . . . . . . . . . . . . . . . . . 2.4.4.2. Cooling water system components 2.4 93 . . . . . . . . . . . . . . . . . . . . . . 2.4.4.3. Engine block with bearings 2.4 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.4. Crankshaft, connecting rod, piston 2.4 97 . . . . . . . . . . . . . . . . . . . . . . 2.4.4.5. Cylinder head with valves 2.4 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.6. Camshaft and Valve drive 2.4 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.7. Injection system components 2.4 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.8. General table of tightening torques

for not specified bolt connections 2.4 108 . . . . . . . . . . . . . . . . . . . . . . . . 2.4.5. Adjustments and Tolerances 2.4 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.5.1. Adjustments 2.4 110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.5.2. Tolerances 2.4 111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.6. Dimensions and masses 2.4 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5. Engine Block with Bearings and Cylinder Liner 2.5 1 . . . . . . . . . . . . . 2.5.1. Engine block 2.5 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2. Main bearings 2.5 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.2.1. General 2.5 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2.2. Removal of a main bearing 2.5 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.2.3. Inspection of main bearings and journals 2.5 9 . . . . . . . . . . . . . . . . . 2.5.2.4. Main bearing assembling 2.5 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.3. Crankshaft axial locating bearing 2.5 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3.1. Removal of the 0bearing 2.5 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.3.2. Inspection of axial thrust rings and

thrust collars on the crankshaft. 2.5 18 . . . . . . . . . . . . . . . . . . . . . . . . .

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2.5.3.3. 0bearing assembling 2.5 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.4. Camshaft bearings 2.5 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.4.1. Inspection of the camshaft bearing bush 2.5 19 . . . . . . . . . . . . . . . . . 2.5.4.2. Removal of the camshaft bearing bush 2.5 20 . . . . . . . . . . . . . . . . . . . 2.5.4.3. Mounting the camshaft bearing bush 2.5 21 . . . . . . . . . . . . . . . . . . . .

2.5.5. Cylinder liner 2.5 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.5.1. Inspection of the cylinder liner 2.5 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.5.2. Removal of the cylinder liner 2.5 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.5.3. Mounting the cylinder liner 2.5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5.6. Replacing cylinder head stud 2.5 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7. Crankcase safety valves 2.5 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6. Crankshaft, intermediate (PTO) shaft, connecting rod, piston 2.6 1 2.6.1. Crankshaft 2.6 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1.1. Crankshaft deflections check 2.6 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1.2. Measurement axial clearance crankshaft thrust bearing 2.6 3 . . . .

2.6.2. Intermediate (PTO) shaft* 2.6 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3. Connecting rod and piston 2.6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3.1. General 2.6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3.2. Removal and dismantling of piston and connecting rod 2.6 7 . . . . . 2.6.3.3. Inspection and maintenance of piston rings

and gudgeon pin bearing 2.6 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.3.4. Assembling and mounting of piston and connecting rod 2.6 14 . . . .

2.6.4. Big end bearing 2.6 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.4.1. Removal of big end bearing

after removal of piston and connecting rod 2.6 19 . . . . . . . . . . . . . . . 2.6.4.2. Removal of the big end bearing shells

without removing piston / connecting rod 2.6 23 . . . . . . . . . . . . . . . . . 2.6.4.3. Assembling the big end bearing 2.6 25 . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.5. Vibration damper crankshaft 2.6 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.5.1. General 2.6 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.5.2. Maintenance 2.6 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.5.3. Liquid sampling 2.6 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.6. Turning gear 2.6 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.6.1. General 2.6 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.6.2. Maintenance turning device 2.6 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7. Cylinder Head with Valves 2.7 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1. Cylinder head 2.7 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1.1. Maintenance of the cylinder head 2.7 3 . . . . . . . . . . . . . . . . . . . . . . . 2.7.1.2. Removal of the cylinder head 2.7 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1.3. Mounting of the cylinder head 2.7 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.1.4. Centring the cylinder head. 2.7 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2. Adjusting the valve clearance 2.7 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3. Exhaust and inlet valves 2.7 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.3.1. Removal of the valves 2.7 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3.2. Check and reconditioning of valve disc and valve seat 2.7 19 . . . . . 2.7.3.3. Valve seats 2.7 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3.4. Valve guide 2.7 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3.5. Valves assembling 2.7 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.4. Valve rotators 2.7 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.4.1. General 2.7 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.4.2. Maintenance of the inlet & exhaust valve rotators 2.7 27 . . . . . . . . . .

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2.7.5. Indicator cock and safety valve 2.7 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.6. Starting air valve 2.7 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.7. Fuel injector 2.7 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8. Camshaft and Valve Drive 2.8 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1. Camshaft driving gear 2.8 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.1.1. General 2.8 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1.2. Camshaft gear wheel 2.8 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1.3. Intermediate gear wheel 2.8 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1.4. Crankshaft gear wheel 2.8 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.2. Camshaft 2.8 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2.1. Removal camshaft section / journal 2.8 13 . . . . . . . . . . . . . . . . . . . . . . 2.8.2.2. Mounting camshaft section / journal 2.8 17 . . . . . . . . . . . . . . . . . . . . .

2.8.3. Valve drive mechanism 2.8 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.3.1. Removal of valve drive mechanism 2.8 19 . . . . . . . . . . . . . . . . . . . . . . 2.8.3.2. Inspection of valve drive mechanism 2.8 21 . . . . . . . . . . . . . . . . . . . . . 2.8.3.3. Mounting valve drive mechanism 2.8 22 . . . . . . . . . . . . . . . . . . . . . . . .

2.9. Injection System 2.9 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1. General 2.9 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2. HP fuel pump 2.9 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.2.1. General 2.9 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.2. HP fuel pump maintenance 2.9 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.3. Removing HP fuel pump 2.9 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.4. HP fuel pump disassembling 2.9 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.5. Assembling of the HP fuel pump 2.9 7 . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.6. HP fuel pump adjustment 2.9 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.7. HP fuel pump mounting 2.9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.3. Fuel pump drive 2.9 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.3.1. Disassembling the fuel pump drive 2.9 12 . . . . . . . . . . . . . . . . . . . . . . 2.9.3.2. Mounting the fuel pump drive 2.9 13 . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.4. Fuel injector 2.9 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4.1. Removing the fuel injector 2.9 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4.2. Fuel injector maintenance 2.9 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4.3. Testing of fuel injectors 2.9 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4.4. Mounting the fuel injector 2.9 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.5. HP fuel line 2.9 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.5.1. Connection HP fuel line 2.9 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1. Instruction Drawings 3.1 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.1. Internal Systems & Pipes Connections 3.1 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2. Wiring Diagrams & Configuration Lists 3.1 5 . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Fig. 0.0 1 Engine definitions 0.0 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 0.0 2 Example of reading the flywheel 0.0 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 0.0 3 Designation of main & camshaft bearings 0.0 6 . . . . . . . . . . . . . . . . . . . . . . . . Fig. 0.0 4 Designation of valves 0.0 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 1 Viscosity conversion diagram 1.1 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 2 Viscosity temperature diagram 1.1 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 3 Nomogram for deriving CCAI 1.1 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 4 Low pressure fuel pipes 1.1 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.1 5 Drain plugs engine fuel system 1.1 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 1 Runningin filter main bearing 1.2 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 2 Oil flow main bearing 1.2 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 3 Oil flow connecting rod 1.2 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 4 Oil flow piston 1.2 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 5 Pump drive oil flow 1.2 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 6 Oil flow gear drive 1.2 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 7 Axial camshaft bearing oil flow 1.2 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 8 Runningin filter 1.2 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 9 Oil flow for drive HP fuel pump/valves and camshaft 1.2 20 . . . . . . . . . . . . . . . Fig. 1.2 10 Oil flow cylinder head 1.2 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 11 Lubricating oil pump unit 1.2 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 12 Gearwheel pump 1.2 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 13 Pressure control and safety valve unit 1.2 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 14 Prelubricating oil pump 1.2 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 15 Lubricating oil module 1.2 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 16 Lubricating oil flow through the cooler 1.2 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 17 LT cooling water flow through the cooler 1.2 29 . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 18 Cooling water flows not through the cooler 1.2 30 . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 19 Lubricating oil cooler 1.2 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 20 Thermostatic valve 1.2 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 21 Automatic backflushing filter 1.2 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 22 Automatic backflushing filter (Filtration phase) 1.2 37 . . . . . . . . . . . . . . . . . . . Fig. 1.2 23 Automatic backflushing filter (Back flushing phase) 1.2 38 . . . . . . . . . . . . . . . Fig. 1.2 24 Automatic backflushing filter (Overflow valves) 1.2 39 . . . . . . . . . . . . . . . . . . Fig. 1.2 25 Automatic backflushing filter (Maintenance) 1.2 40 . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 26 Centrifugal filter on engine 1.2 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 27 Centrifugal filter 1.2 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.2 28 The Location of the lubricating oil sampling valve 1.2 48 . . . . . . . . . . . . . . . . . Fig. 1.2 29 Crankcase breather and vent pipe 1.2 50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 1 Starting and slow turn sequence 1.3 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 2 Starting air distributor with drive 1.3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 3 Starting air distributor 1.3 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 4 Setting of air distributor disc 1.3 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 5 Pilot air lines 1.3 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 6 Starting air valve 1.3 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.3 7 Starting air pipe arrangement 1.3 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 1 Cooling water flow to the cylinder head 1.4 7 . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 2 Location of cooling water thermostatic valves 1.4 8 . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 3 Cooling water pump 1.4 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 4 Cooling water pump assembly 1.4 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.4 5 Draining points of the HT and LT cooling water system 1.4 18 . . . . . . . . . . . . Fig. 1.5 1 Charge air cooler 1.5 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 2 Cooler stack 1.5 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Fig. 1.5 3 Front view charge air cooler 1.5 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 4 Loosening the cooler stack 1.5 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 5 Removal of cooler stack 1.5 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 6 Exhaust gas system 1.5 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 7 Fixation of exhaust section 1.5 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 8 Gas flow in Compensator 1.5 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 9 Compressor cleaning device 1.5 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 10 Turbine washing system layout 1.5 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 11 Position of valves before and after cleaning procedure on L engines 1.5 21 .Fig. 1.5 12 Position of valves during cleaning procedure on L engines 1.5 21 . . . . . . . . . Fig. 1.5 13 Gas flow in compensator 1.5 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 14 Bypass pipe compensator 1.5 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 15 Block Diagram Exhaust WasteGate Valve Control 1.5 25 . . . . . . . . . . . . . . . . . Fig. 1.5 16 Position of wastegate valve 1.5 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.5 17 Wastegate valve assembly 1.5 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 1 Actuator / drive / booster 1.6 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 2 Fuel control mechanism 1.6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 3 Load indication 1.6 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 4 HP fuel pump connection 1.6 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 5 Preclearance levers to HP fuel pump 1.6 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 6 Local start and stop unit 1.6 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 7 Emergency stop device 1.6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 8 Oil mist detector 1.6 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 9 Speed sensor at the turning gear wheel 1.6 17 . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 10 Speed sensors at camshaft 1.6 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 11 Structure of WECS 1.6 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 12 Principle diagram speed control system 1.6 33 . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 13 Signal block diagram of WECS 7000 in overall system 1.6 35 . . . . . . . . . . . . . Fig. 1.6 14 Frontend cabinet overview 1.6 37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 15 Local display unit 1.6 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 16 Example view of main page 1.6 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 17 Example view of history page 1.6 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 18 Example view of Start Blocks & Pressures page 1.6 41 . . . . . . . . . . . . . . . . . . Fig. 1.6 19 Example view of Menu page 1.6 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 20 View of control switches for local engine operation 1.6 42 . . . . . . . . . . . . . . . . Fig. 1.6 21 View of panel meters for digital indications 1.6 43 . . . . . . . . . . . . . . . . . . . . . . . Fig. 1.6 22 System layout 1.6 63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 1 Local control panel 2.3 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 2 Local control stand 2.3 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 3 DE (Marine), gradual load increase 2.3 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 4 Maximum sudden power increase 2.3 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 5 Runningin diagram (n = constant 600 rpm) 2.3 18 . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 6 Local stop 2.3 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.3 7 Manual stop 2.3 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 1 Diagram of pneumatically driven hydraulic pump unit 2.4 76 . . . . . . . . . . . . . . Fig. 2.4 2 Pneumatic driven hydraulic pump and jacks 2.4 78 . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 3 Single hydrauli jack cross section 2.4 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 4 Twin hydraulic jack cross section 2.4 80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 5 Hydraulic jack 2.4 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 6 H.P. quickrelease coupling (example) 2.4 83 . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 7 Dust caps H.P. quickrelease coupling (example) 2.4 83 . . . . . . . . . . . . . . . . . Fig. 2.4 8 Hydraulic hand pump 2.4 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Fig. 2.4 9 Torque spanner extension 2.4 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 10 Lubricating oil pump assembly 2.4 92 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 11 Cooling water pump gear wheel assembly 2.4 93 . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 12 Main bearing 2.4 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 13 Cylinder liner clamp 2.4 95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 14 Explosion cover 2.4 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 15 Crankshaft 2.4 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 16 Big end bearing and counter weight 2.4 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 17 Exhaust connection cylinder head 2.4 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 18 Cylinder head 2.4 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 19 Starting valve 2.4 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 20 Cylinder head upper side 2.4 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 21 Camshaft 2.4 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 22 Actuator drive shaft 2.4 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 23 Starting air distrubutor drive on camshaft 2.4 104 . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 24 High pressure fuel injector 2.4 105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 25 Injector, HP fuel pipe 2.4 106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 26 HP fuel pump 2.4 107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 27 Gear wheel train 2.4 112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 28 Measuring the cylinder liner bore 2.4 113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 29 Measuring the big end bore 2.4 117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 30 Valve stem and valve disc burning in wear 2.4 119 . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 31 Inlet valve and valve seat in cylinder head 2.4 120 . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 32 Exhaust valve and valve seat in cylinder head 2.4 120 . . . . . . . . . . . . . . . . . . . . Fig. 2.4 33 Driving gear 2.4 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 34 Governor drive 2.4 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 35 Valve drive mechanism 2.4 124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 36 Fuel pump bracket 2.4 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 37 Nozzle 2.4 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 38 HP fuel pump adjustment 2.4 126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 39 Engine components 2.4 127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 40 Turbochargers 2.4 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.4 41 Charge air cooler inserts 2.4 128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 1 Engine block (view freeend side) 2.5 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 2 Position bearing temperature sensor 2.5 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 3 Positioning jack on side stud 2.5 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 4 Positioning the main bearing jacks 2.5 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 5 Bearing shell driver 2.5 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 6 Inserting main bearing shell 2.5 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 7 Pushing the upper main bearing shell into position 2.5 10 . . . . . . . . . . . . . . . . Fig. 2.5 8 Crankshaft axial locating bearing 2.5 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 9 Camshaft and axial bearing assembly 2.5 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 10 Connect the hoses to the pump 2.5 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 11 0bearing bush in engine block 2.5 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 12 Liner in engine block 2.5 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 13 Liner lifting device 2.5 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 14 Lifting the cylinder liner 2.5 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 15 Centre of gravity 2.5 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 16 Measuring the cylinder liner bore 2.5 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 17 Marks on cylinder liner 2.5 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 18 Replacing cylinder head stud 2.5 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.5 19 Crankcase safety valve 2.5 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Fig. 2.6 1 Taking crankshaft deflection readings 2.6 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 2 PTO shaft arrangement at free end. 2.6 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 3 Connecting rod and piston assembling 2.6 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 4 Removal of antibore polishing ring 2.6 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 5 Hydraulic tool connecting rod studs 2.6 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 6 Connection of the hydraulic tools 2.6 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 7 Hoisting tool 2.6 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 8 Fitting the protecting device 2.6 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 9 Hoisting the piston 2.6 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 10 Piston with fixating tool 2.6 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 11 Removal of the retainer spring 2.6 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 12 Removal of gudgeon pin 2.6 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 13 Marks on piston and connecting rod 2.6 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 14 Moving the connecting rod into the piston 2.6 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 15 Piston on connecting rod 2.6 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 16 Lowering the piston and connecting rod into the cylinder liner 2.6 17 . . . . . . . . . . Fig. 2.6 17 Hydraulic tool big end bearing studs 2.6 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 18 Connection HP hoses big end bearing 2.6 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 19 Frame and support big end bearing caps 2.6 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 20 Carriers of the big end bearing caps 2.6 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 21 Mount piston support 2.6 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 22 Fit hydraulic tightening tool 2.6 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 23 Positioning device 2.6 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 24 The big end 2.6 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 25 Liquid sampling 2.6 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.6 26 Electrically driven turning device 2.6 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 1 Cross section cylinder head 2.7 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 2 Tilting frame cylinder head 2.7 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 3 Removal of the hotbox panels 2.7 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 4 Removal of cylinder head 2.7 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 5 Loosening the cylinder head nuts 2.7 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 6 Lifting the cylinder head 2.7 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 7 Cylinder head on liner 2.7 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 8 Protecting ring for cylinder head 2.7 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 9 Centring tool usage 2.7 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 10 Valve clearance adjustment 2.7 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 11 Valves 2.7 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 12 Removal of valves 2.7 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 13 Blueing test 2.7 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 14 Removing the exhaust valve seats 2.7 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 15 Removing inlet valve seats 2.7 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 16 Mounting valve seats 2.7 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 17 Extracting the valve guide 2.7 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 18 Valve guide detail 2.7 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 19 Valves rotators 2.7 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.7 20 Indicator cock / safety valve 2.7 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 1 Gearwheel drive camshaft 2.8 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 2 Camshaft section 2.8 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 3 Axial bearing camshaft 2.8 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 4 Removal of camshaft end journal 2.8 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 5 Position of jack bolt 2.8 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 6 Position of pillar bolt 2.8 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Fig. 2.8 7 Removal of the camshaft gear wheel 2.8 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 8 Tool for intermediate gear wheel 2.8 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 9 Intermediate gear wheel section 2.8 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 10 Removal of intermediate gear wheel shaft 2.8 10 . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 11 Mount shaft intermediate gear 2.8 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 12 Crankshaft gear wheel assembly 2.8 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 13 Securing fuel tappet 2.8 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 14 Tappet securing plate 2.8 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 15 Position of pillar bolt 2.8 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 16 Removal of camshaft section 2.8 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 17 Removal of camshaft journal 2.8 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 18 Tightening camshaft section / journal 2.8 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 19 Valve drive mechanism 2.8 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 20 Valve lifting gear 2.8 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 21 Push rod assembly 2.8 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.8 22 Tappet guide block assembly 2.8 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 1 HP fuel pump and drive 2.9 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 2 Removing the HP fuel pump 2.9 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 3 Tool dis/assembling HP Fuel pump 2.9 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 4 HP Fuel pump 2.9 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 5 Injection timing deviation graph 2.9 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 6 HP fuel pump drive adjustment 2.9 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 7 Fuel pump drive 2.9 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 8 Cylinder head with injector 2.9 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 9 Fuel injector assembly 2.9 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 10 Extracting the fuel injector 2.9 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 11 Fuel injector cross section 2.9 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 12 Protecting the nozzle tip 2.9 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 13 Testing fuel injectors 2.9 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fig. 2.9 14 HP fuel pipe connection 2.9 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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0.0. General

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0.0.1. Introduction

The purpose of this manual is to give the user a guide for operation andmaintenance on the engine. Basic general knowledge hasnt beenentered. The manual is part of the documentation supplied with theengine.Before starting or while performing any job could happen you havequestions which the manual gives no answers to, in this case do not takeany unnecessary risks and contact the Service department of WrtsilCorporation or your local Wrtsil Service network.

Wrtsil Corporation reserves the right to minor alterations andimprovements due to engine development without being obliged toenter the corresponding changes in this manual.

The diesel engine will be supplied as agreed upon in the salesdocuments. No claim can be made on the basis of this instructionmanual as there are some components described herein that are notincluded in every delivery.

The operation and/or maintenance work described in this manual mustonly be carried out by trained technicians specialised in diesel engines.

Be sure everyone who works with the engine has this manual availableand understands the contents.

Ensure all equipment and tools for maintenance purposes are in goodorder.

Use only genuine parts to ensure the best efficiency, reliability and lifetime of the engine and its components.

Modifications as to the settings may only be made after written approvalfrom Wrtsil Corporation. Settings altering may effect the warranty.

During the warranty period of the engine the owner is obliged to followstrictly the instructions for operation and maintenance outlined in thismanual.

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0.0.2. Terminology

General about terminologyThe most important term used in this instruction manual are definedas follows:

Manoeuvring (Operating) sideThe longitudinal side of the engine where the operating devices arelocated (start and stop, instrument panels, speed governor, ...).

Rear (Nonoperating) sideThe longitudinal side opposite to the manouvering side.

Driving endThe end of the engine where the flywheel is located.

Free endThe end opposite the driving end.

Designation of cylindersAccording to ISO recommendation 932 and DIN 6256 the designationof cylinders begins at the driving end. In a Vengine the cylinders inthe left bank, seen from the driving end, are termed A1, A2, etc., and inthe right bank B1, B2, etc. (See fig. 0.0 1 ).

Designation of engine sides and endsManoeuvring side and ends

Details located on the manoeuvring side may be marked with M" andcorrespondly B" for the back one of the engine (Bbank on aVengine) (see also fig. 0.0 1 ).

Clockwise rotating engineAn engine which has a clockwise rotating crankshaft when looking fromthe driving end.

CounterClockwise rotating engineAn engine which has a counterclockwise rotating crankshaft whenlooking from the driving end.

Bottom dead center (BDC)It is the bottom turning point of the piston in the cylinder, where thepiston speed is zero.

Top dead center (TDC)It is the top turning point of the piston in the cylinder, where the pistonspeed is zero. During a complete working cycle, consisting of twocrankshaft revolutions in a fourstroke engine, the piston reaches theTDC twice.

1

2

3

4

1

2

3

4

5

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1. Top dead center at scavengingFor the first time, the piston reaches the TDC when the exhaust strokeof the previous working cycle ends and the suction stroke of thefollowing one begins. Exhaust valves as well as inlet valves aresomewhat open and then the scavenging phase takes place. If thecrankshaft is turned back and forth from this TDC both exhaust andinlet valves will move, a fact which indicates that the cranckshaft is nearthe position which is called TDC at scavenging.

2. Top dead center at firingFor the second time, the piston reaches the TDC when, within the samecycle, the compression stroke comes to the end and the working one isgoing to begin. Slightly before this TDC the fuel injection take place (onan engine in operation) and therefore this TDC can be defined as TDCat firing. In this case all the valves are closed and do not move if thecrankshaft is turned back and forth from this TDC. When watching thecamshaft and the injection pump it is possible to note that the tappetroller is on the lifting side of the fuel cam.

A6A5

A4A3

A2A1

B6B5

B4B3

B2B1

1245

63

Manoeuvring side

Driving end

Free end

Fig. 0.0 1 Engine definitions

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Marks on the flywheelMarkings on the circumference of the flywheel indicate the TDC foreach cylinder. From 15 before till 15 after each TDC the circumferenceof the flywheel is divided into sections of 5.Where two TDCs are indicated at the same mark, one cylinder is in TDCat firing and the other in TDC at scavenging. The indicator (1) is provided with a scale per degree, starting at 5before TDC till 5 after TDC.For the firing order see chapter 1.0.

1

CW CCW

Fig. 0.0 2 Example of reading the flywheel

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Designation of bearings

Main bearingsThe flywheel bearing is No. 0, the first standard main bearing is No. 1,the second No. 2 etc.

Thrust bearingsThe thrust bearing rails are located at the flywheel side. the outer railsclose to the flywheel are marked with 00 and the inner rails with 0.

Camshaft bearingCamshaft bearings are designated in the same sequence as the mainbearings and the thrust bearing bushings are designated, the outer one00 and the inner one 0.

Intermediate shaft (Power Take Off) bearingThe PTO bearing, for the additional power take off shaft on the engine,is located on the pump cover at free end.

Intermediate (camshaft) gear wheel bearingsThe bearings located directly behind the flywheel are designated as 00and the inner bearings as 0.

2 134n1nn+1 0

n = number of cylinders on each bank

Fig. 0.0 3 Designation of main & camshaft bearings

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Designation of valves

AIR IN EXHAUST OUT

A D

CB

A & B INLET VALVES

C & D EXHAUST VALVES

Fig. 0.0 4 Designation of valves

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1.0. Main Data

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1.0.1. Basic informationIn the Configuration Structure for Wrtsil 38B engines thefollowing applications are identified:

1. Marine: Main engine, Fixed Pitch Propeller

2. Marine: Main engine, Continuous Pitch Propeller.

3. Marine: Main engine, Diesel Electric Propulsion

4. Power Plant: Power Plant Base Load

Engine types:

6L38B 12V38B

8L38B 16V38B

9L38B 18V38B

Cylinder bore 380mm

Stroke 475mm

Number of cylinders 6/8/9/12/16/18

Direction of rotation Clockwise Counter Clockwise

Firing order 6L38B 142635 153624

Firing order 8L38B 13258674 14768523

Firing order 9L38B 174286395 159368247

Firing order 12V38B50 consecutive

A1B1A3B3A5B5A6B6A4B4A2B2

A1B2A2B4A4B6A6B5A5B3A3B1

Firing order 16V38B50 consecutive

A1B1A3B3A2B2A5B5A8B8A6B6A7B7A4B4

A1B4A4B7A7B6A6B8A8B5A5B2A2B3A3B1

Firing order 18V38B410 alternate

A1B8A7B6A4B3A2B9A8B5A6B1A3B7A9B4A5B2

A1B2A5B4A9B7A3B1A6B5A8B9A2B3A4B6A7B8

The Wrtsil 38B diesel engine is a 4stroke, medium speed,turbocharged and intercooled engine with direct fuel injection.

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1.0.2. Output

Engine output according to engine rating plateFywheel Output 100% kW/Cyl.Marine:DE, CPP. 725FPP 675Power Plant:BL 675Rated Engine speed rpm [600]Charge air coolant temperature oC 38Suction air temperature oC 45

Engine output according to ISO 30461 : 1995(E)Fywheel Output 100% kW/ Same as tableFywheel Output 100% kW/

Cyl.Same as table

aboveCyl. aboveRated Engine speed rpm [600]

ISO 3046 substitute reference conditionsMarine engines

Ambient air pressure kPa 100Site altitude above sea level m 0Suction air temperature oC 45Charge air coolant temperature oC 38Total exhaust gas back pressure kPa 3Total suction air pressure loss kPa 1

Continuous Power and Prime Power enginesAmbient air pressure kPa 100Suction air temperature oC 35Charge air coolant temperature oC 45Sum of suction air losses and exhaust gasback pressures

kPa 5

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The full output of the engine is available at the ISO substitutereference conditions. No compensation (uprating) is allowed foroperating conditions better than the ISO substitute referenceconditions. For derating data see section 1.0.3.

Fuel limiter settingsMarine:DE 110 % for governing purposes onlyCPP, FPP 100 %Power Plant:BL 100 % no overload is allowed

Continuous power base load

Continuous power is defined in ISO 85281 as the power that agenerating set is capable to deliver continuously for an unlimitednumber of hours per year, between stated maintenance intervals andunder the stated ambient conditions, if the maintenance has beencarried out as prescribed by the manufacturer.

Torsional vibration barred operational conditionsBarred speed/load range during normal oper-ation

rpm none

Speed range to be restricted during misfiring forcontinuous running

rpm none

Barred speed and load ranges:The zone where the load caused by torsional vibrations exeed thepermissible values for continuous operation.Misfiring: see section 2.3.3.8.3

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1.0.3. Derating conditions

1.0.3.1. Derating limits for ambient conditions

The derating is according to ISO 30461:1995(E) applying: m

The rated output of the engine is available at the rated substitutereference conditions. No compensation (upgrading) is allowed forambient conditions better than substitute.

1.0.3.2. Glycol derating

Maximum allowable glycol% in water is 50 %. In case glycol is appliedin cooling system the capacity of the lubricating oil cooler on the engineand all external heat exchangers has to be designed for the specifiedglycol%.

If glycol is applied in winter season only, there is no derating forglycol; anyway the settings of the thermostatic valves have to bechanged during winter time. while changing from the cold season to thewarm one the clycol cooling water has to be replaced by fresh water.

HT water system

Control temperature for the HT water after the engine:t HT water with glycol: 2C/10% glycol (85C at 50% glycol insteadof 93C at 0%).

LT water system

Control temperature for the LT water:t LT water with glycol: 1C/10% glycol.

As soon as there is no risk of below 0C temperatures the glycolcooling water must be replaced by fresh water immediately.

If the glycol is used also during summer time, then derating will beapplicable. For certain applications where glycolwater is used ascooling media in the HT &/or LT cooling system derating is 0,5%/10%.

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1.0.3.3. Restrictions on the application of thederating calculation

Modifications to the engine may be required when the calculated poweradjustment factor "" trepasses the value of 0,95. In such a case thederated output of the engine is subjected to the confirmation of theTechnology Department of Wrtsil Italia S.p.A. by means of thePerformance Request Sheet".

1.0.3.4. Adjustment of power output forambient conditions

The adjusted output for site conditions is calculated by means of thefollowing formula:

Px Pra

Px" is the adjusted power output under site conditions;

Pra" is the power output under substitute reference conditions;

" is the power adjustment factor.

" must be calculated by means of the following formula andparameters:

Ktot 0, 7 (1 Ktot) 10, 9 1

Ktot K1 K2 K3 K4

Derating due to the suction air temperature tx" (C)

Marine:

tx 15 K1 1 0, 004 (tx 15)

15 tx 45 K1 1

45 tx K1 (273 45)(273 tx)1,2

Continuous power and Prime Power engines:

tx 15 K1 1 0, 004 (tx 15)

15 tx 35 K1 1

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35 tx K1 (273 35)(273 tx)1,2

Emergency Genset (LTP):

tx 15 K1 1 0, 004 (tx 15)

15 tx 25 K1 1

25 tx K1 (273 25)(273 tx)1,2

For suction air temperature below 5 C heating of suction air and/orspecial requirements may be required.

Derating due to the charge air coolant temperature tcx" (C)

Marine:

tcx 38 K2 1

38 tcx K2 (273 38)(273 tcx)

Continuous power and Prime Power engines:

tcx 45 K2 1

45 tcx K2 (273 45)(273 tcx)

Emergency Genset (LTP):

tcx 35 K2 1

35 tcx K2 (273 35)(273 tcx)

The dew point shall be calculated for the specific site conditions.The minimum charge air temperature shall be above the dew pointin order to avoid condensation occurs in charge air cooler.

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Derating due to ambient air pressure pair" (kPa)

Marine:

Under the assumption that the ambient air pressure for marineapplications is equal to the barometric pressure, K3"

K3 1

Continuous power and Prime Power engines & Emergency Genset(LTP):

pair 100 K3 pair1000,7

pair 100 K3 1

Derating due to the total exhaust gas back pressure pex"(kPa)

Marine:

pex 3 K4 1

pex 3 K4 103(100 pex)1,5

For total exhaust gas back pressure a factor is added to ISO30461:1995(E). The factor shall be added if the design target of 3kPa is exceeded.

Continuous power and Prime Power engines:

pex 5 K4 1

pex 5 K4 105(100 pex)1,5

Emergency Genset (LTP):

pex 3 K4 1

pex 3 K4 103(100 pex)1,5

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Data mentioned in Operating Data (section 1.0.5.) must stay at thenominal values

Reduce engine load if operating temperatures of lubricating oil orcooling water exceed the nominal values or exhaust gas tends to exceedthe maximum values, see section 1.0.5.

High operating temperatures can be caused among other by:

contamination of coolers

reduction of charge air pressure by:

contamination of turbocharger compressor and/or turbine

too much wear of the turbine

contamination of air in take filter

contamination of charge air cooler

deviation of setting of (individual) high pressure fuel pumps

bad functioning of fuel injectors

bad functioning of HP fuel pumps

high fuel CCAI value (> 870)

high ambient temperature

Never change fuel rack settings to equalize the exhaust gastemperature.

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34567

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1.0.4. Correction of heat balances

The following table supplyes a complete overview for heat balanceguidance values according to different ambient conditions in relation tothe substitute reference conditions as stated above.

Turbocharger air inlet temperatureExhaust waste gate No Yes ReferenceAir and exhaust mass flow kg/s 2.6 % +0.0 % per 10 C higer suction air temp.Exhaust gas temperature C +10.3 C +0.3 C per 10 C higer suction air temp.Charge air heat, total kW +5.1 % +10.1 % per 10 C higer suction air temp.HT kW +8.4 % +14.1 % per 10 C higer suction air temp.LT kW +0.1 % +3.2 % per 10 C higer suction air temp.Jacket water heat kW +2.7 % +0.8 % per 10 C higer suction air temp.Lubricating oil heat kW +1.3 % +0.0 % per 10 C higer suction air temp.Air temp. after compressor C +11.5 C +16.1 C per 10 C higer suction air temp.LTcoolant temperature before air coolerExhaust waste gate No Yes ReferenceAir and exhaust mass flow kg/s +0.0 % +0.0 per 10 C higer LTcool. temp.Exhaust gas temperature C +6.1 C +6.6 C per 10 C higer LTcool. temp.Charge air heat, total kW 5.3 % 5.2 % per 10 C higer LTcool. temp.HT kW +0.0 % +0.0 % per 10 C higer LTcool. temp.LT kW 13.3 % 14.0 % per 10 C higer LTcool. temp.Jacket water heat kW +2.1 % +2.2 % per 10 C higer LTcool. temp.Lubricating oil heat kW +0.7 % +0.8 % per 10 C higer LTcool. temp.Air temp. after compressor C +1.0 C +1.0 C per 10 C higer LTcool. temp.Altitude

/ / ReferenceAir and exhaust mass flow kg/s 4.1 % per 1000 Above Sea LevelExhaust gas temperature C +16.0 C per 1000 Above Sea LevelCharge air heat, total kW +2.2 % per 1000 Above Sea LevelHT kW +4.8 % per 1000 Above Sea LevelLT kW 1.7 % per 1000 Above Sea LevelJacket water heat kW +3.8 % per 1000 Above Sea LevelLubricating oil heat kW +2.1 % per 1000 Above Sea LevelAir temp. after compressor C +9.6 C per 1000 Above Sea Level

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1.0.5. Operating Data

Operating Data ConditionsMax. Nom. Min.

Fuel condition before injection pumps: Pressure bar 10 Viscosity (HFO) cSt 24 20 16 Viscosity (LFO) 1) cSt 24 2 Temperature (HFO) oC 140 Temperature (LFO) oC 45 Lube oil condition: Temperature before engine oC 63 Pressure before engine bar 4.5 HT cooling water condition: Temperature before engine oC 73 Temperature after engine oC 93 Pressure before engine bar 4.6 3.8 2) LT cooling water condition: Temperature before engine oC 38 Temperature after engine oC 44 Pressure before engine bar 4.6 3.4 2) HT and LT cooling water static pressure: At inlet cooling water pump bar 0.8 0.5Charge air temperature in air receiver oC 50 Starting air pressure (min. pres. at 20 oC) bar 33 30 12Firing pressure bar 210

1) The temperature of the fuel shall be adjusted such that the minimumviscosity before the engine is well above 2 cSt.

2)static pressure to be added.

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1.1. Fuel System

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1.1.1. General

Selection of the most economical fuel for diesel engines depends onseveral variables such as engine requirements, operating conditions,fuel quality, availability, and costs. Engines vary widely in the grade offuel required for satisfactory operations. In general high speed enginesrequire a more refined fuel than low speed types.

High cetane number light distillate fuels are more expensive than lowcetane heaviertype fuels. For any class of fuel, careful control ofuniformity generally carries a price premium because of the operatinglimitations imposed on the refiner.

Engine operation on any fuel resulting in excessive maintenance isobviously uneconomical regardless of fuel cost. The enginemanufacturers recommendation is the logical starting point forselecting the fuel of an engine. These recommendations maysubsequently be tempered to obtain additional economies in view ofexperience and the local fuel situation. Such steps, however, should betaken carefully.

1.1.1.1. HFO engines running on distillatefuels*

(*) This section must be taken into account for HFO engines only.

The engine is designed for continuous operation on heavy fuel. For limitedperiods it is possible to operate the engine on distillate fuel withoutmodification. Engines designed for continuous or prolonged operation ondistillate fuels corresponding to ISO 8217 : 2005(E), FDMA & DMB areadapted to such fuels and consequentely require no modification.For continuous operation on distillate fuel corresponding to ISO 8217 :2005(E), FDMC, no specific modifications are needed on the engine. Seealso section 1.1.2.3.

Engines can be started and stopped on heavy fuel oil by providing the engineand fuel system are preheated to operating temperature.It is only recommended to change over from HFO to distillate fueloperation when it is necessary to fill or flush the fuel oil system.

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1.1.2. Fuel

1.1.2.1. Residual fuel oil quality*(*) This section must be taken into account for HFO engines only.

The fuel specification HFO 2" is based on the ISO 8217 : 2005(E)standard and covers the fuel categories ISOFRMA30 & RMK55.Additionally the engine manufacturer has specified an alternative fuelHFO 1" with a tighter specification. By using a fuel meeting thisspecification longer overhaul intervals of the specific enginecomponents are reached.

The residual fuels are further in this manual indicated as Heavy FuelOil (HFO).

Bunker qualityThe residual fuel oil quality as bunkered must be within the followingspecification:

Property Unit LimitHFO 1

LimitHFO 2

Test methodreference

Viscosity at: 100C cSt max. 55 55 ISO 3104Viscosity at: 50C cSt max. 700 700 ISO 3104Viscosity at: 100F Redwood No.1 sec max. 7200 7200 ISO 3104Density at: 15C 1) kg/m3 max. 991.0 991.0 ISO 3675 or

ISO 12185kg/m3 max. 1010.0 1010.0 ISO 12185CCAI 2) 4) max. 850 870 ISO 8217,

Annex BWater % volume max. 0.5 0.5 ISO 3733Water before engine 4) % volume max. 0.3 0.3 ISO 3733Sulphur % mass max. 2.0 5.0 ISO 8754 or

ISO 14596Ash % mass max. 0.05 0.20 ISO 6245Vanadium 3) mg/kg max. 100 600 ISO 14597 or

IP 501 or 470Sodium 3) 4) mg/kg max. 50 50 ISO 10478Sodium before engine 4) mg/kg max. 30 30 ISO 10478Aluminium + Silicon mg/kg max. 30 80 ISO 10478 or

IP 501 or 470Conradson Carbon residue % mass max. 15 22 ISO 10730Asphaltenes 4) % ma