Diesel WARTSILA F 240 Manuel utilisateur

Manual

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Date of issue November 2004

ENGINE TYPE F 240 --engine

Author SERVICE

Approved

AUTHORIZATION Management WNL

DOCUMENT

13128

Distribution

Status

Number

Manual

F 240 COMMUNICATION

Ver. 01 xx -- 3

In order to maintain the operational safety of your engine, a simple, and a fast contact

between you and Stork--Wärtsilä Diesel B.V can be of essential importance.

Stork--Wärtsilä Diesel B.V.

Postbus 10608

8000 GB ZWOLLE

Telefoon 038--4253253

Telex 42116

FAX 038-- 4223564

From Monday to Friday Stork--Wärtsilä Diesel B.V can be contacted on telephone

number 038--4253 253 during working hours from 08.00 -- 16.30 hours; ask for

departments:

-- SERVICE-- PARTS:

For information about inquiries, information about service, ordering spare parts

or tools

-- SERVICE --INSPECTION:

For all technical support.

During non--working hours one of our staff members will always be available on the

above number. He will have one of our experts to call you back as soon as possible.

Furthermore youcan contact one ofour Service Departments inThe Netherlands dur-

ing working hours as mentioned below:

SCHIEDAM (ROTTERDAM)

DEN HELDER

STELLENDAM

URK (only on Saturday)

IJMUIDEN

For information on Service Departments throughout the world, please contact Stork--

Wärtsilä Diesel B.V. headquaters, Zwolle.

-- o -- o -- o -- o -- o --

Introduction

Headquarters

in The

Netherlands

Service

departments in

the Netherlands

Service depart-

ments through-

out the world

Hanzelaan 95

8017 JE ZWOLLE

Tel.: 010 -- 4 277 100

Adres: Havenstraat 24

Fax: 010 -- 4 264 571

Tel.: 0223 -- 33 59 88

Adres:Het NieuweWerk102

Fax: 0223 -- 333890

Tel: 0187 -- 491956

Adres: Deltahaven 7

Fax: 0187 -- 493428

Tel: 0527 -- 682053

Adres: Industrierondweg 6D

Tel.: 0255 -- 511678

Adres: Trawlerkade 46

Fax: 0255 -- 536724

Manual

F 240 COMMUNICATION

Ver. 01 xx -- 4

Manual

F 240 CONTENTS

xx -- 5

Ver. 01

CHAPTER 0: GENERAL

0A PURPOSE 0--1..............................................................

0B DOCUMENTATION OVERVIEW 0--2...........................................

0C MANUAL SETUP/PAGE SETUP 0--3..........................................

1. Manual setup 0--3........................................................

2. Page setup 0--3..........................................................

0D DESCRIPTION OF THE ENGINE 0--5.........................................

1. Crankshaft and bedplate 0--5.........................................

2. Cylinder block 0--5...................................................

3. Cylinder liner 0--5....................................................

4. Piston with connecting rod 0--5.......................................

5. Cylinder head 0--5...................................................

6. Camshaft and valve mechanism 0--5..................................

7. Injection equipment 0--6..............................................

8. Exhaust manifold 0--6................................................

9. Turbocharging and charge air cooling 0--6.............................

10.Definitions 0--6......................................................

CHAPTER 1: OPERATION

1A GENERAL 1--1.............................................................

1. Commissioning 1--1....................................................

2. General 1--1...........................................................

3. Starting and stopping of the engine 1--1.................................

4. Operation 1--1.........................................................

5. Running--in 1--1........................................................

6. During operation 1--1...................................................

7. After stopping 1--2.....................................................

8. Long shut--downs 1--2..................................................

CHAPTER 2: BACKGROUND INFORMATION

2A SAFETY ASPECTS 2--1.....................................................

1. Safety aspects 2--1.....................................................

Risk of crankcase explosion 2--1..........................................

2. Maintenance instructions 2--1...........................................

General 2--1............................................................

Removal 2--2...........................................................

Fuel injector 2--2........................................................

Mounting 2--2...........................................................

Last check 2--2.........................................................

2B CRANK DEGREES NINE CYLINDER ENGINE 2--3.................................

1. General 2--3...........................................................

2. Reading crank position 2--3.............................................

2C ENGINE TOOLS 2--4............................................................

1. General 2--4...........................................................

2. Tool 9612 F 927 2--4....................................................

2D INDEX OF SYMBOLS 2--5.......................................................

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F 240 CONTENTS

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Ver. 01

CHAPTER 3: TECHNICAL DATA

3A MAIN DATA 3--1............................................................

1. Engine specifications 3--1..............................................

2. Weights in kg. 3--1.....................................................

3. Oil contents in liters 3--1................................................

4. Cooling water in liters 3--1.............................................

5. Cylinder numbers 3--2..................................................

6. Combustion sequence 3--2.............................................

7. Standard valve timing 3--2..............................................

8. Valve clearance 3--2....................................................

9. Pressures 3--3.........................................................

10. Temperatures 3--3......................................................

11. Pump data 3--3.........................................................

3B TIGHTENING TORQUES 3--4.................................................

1. Cylinder head 3--4......................................................

2. Cylinder block 3--4.....................................................

3. Fuel 3--4...............................................................

4. Camshaft 3--5..........................................................

5. Connecting rod 3--5....................................................

6. Main bearings 3--5.....................................................

7. Crankshaft 3--5........................................................

8. Engine/generator on foundation 3--5....................................

9. Assembly tie rods 3--6..................................................

3C NO GO CRITERIA 3--8......................................................

1. Piston (2--parts conf.) 3--8..............................................

2. Connecting rod 3--8....................................................

3. Main bearing (with mounted cylinder block) 3--8.........................

4. Axial bearing 3--8......................................................

5. Camshaft 3--9..........................................................

6. Camshaft drive 3--9....................................................

7. Valves (inlet and exhaust) 3--9..........................................

8. Lubricating oil pump 3--9...............................................

CHAPTER 4: INJECTION AND MAINTENANCE

4A GENERAL 4--1..............................................................

1. General 4--1...........................................................

2. Daily check 4--1........................................................

3. Weekly check 4--2......................................................

4. Observation list 4--3....................................................

4B INSPECTION AND MAINTENANCE PROCEDURES 4--4........................

1. Maintenance interval/effective life 4--4...................................

2. Inspection 4--4.........................................................

3. Daily maintenance 4--5.................................................

4. Weekly maintenance 4--6...............................................

5. 750--hours overhaul 4--7................................................

6. 1500--hours overhaul 4--8...............................................

7. 3000--hours overhaul 4--9...............................................

8. 6000--hours overhaul 4--10...............................................

9. 12000--hours overhaul 4--12..............................................

10. 24000--hours overhaul 4--14..............................................

11. 36000--hours overhaul 4--16..............................................

4C TEST RUNNING 4--18........................................................

1. Test running 4--18.......................................................

2. Running--in 4--18........................................................

3. Functional test 4--20.....................................................

Manual

F 240 CONTENTS

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Ver. 01

CHAPTER 5: FUEL SYSTEM

5A INTRODUCTION 5--1........................................................

1. General 5--1...........................................................

2. Description of engine parts 5--1.........................................

Fuel feed pump (1.1) 5--1................................................

Fine fuel filter (1.2) 5--1..................................................

High pressure fuel pumps (1.3) 5--1........................................

Fuel injector (1.5) 5--2...................................................

Pressure regulating valve (1.6) 5--2........................................

Leak--off fuel (2.1, 2.2 and 2.3) 5--2........................................

5B FUEL REQUIREMENTS 5--3.................................................

Bunker requirements 5--3................................................

Engine fuel requirements 5--3.............................................

5C FUEL FILTER ELEMENT 5--4.................................................

1. General 5--4...........................................................

2. Removal 5--4...........................................................

3. Fitting 5--5.............................................................

5D INSPECTIONS, MOMENT OF INJECTION 5--6.................................

1. Training tools 5--6......................................................

2. Fuel control system 5--7................................................

3. Verification of moment of injection 5--8..................................

4. Checking pre--lifting 5--9................................................

5E CONSTANT PRESSURE VALVE 5--10..........................................

1. Tool 5--10...............................................................

Tool A 5--10.............................................................

Tool B 5--10.............................................................

2. Testing 5--10............................................................

5F GENERAL DIAGRAM 5--11....................................................

CHAPTER 6: LUBRICATING OIL SYSTEM

6A INTRODUCTION 6--1........................................................

1. General 6--1...........................................................

2. Description of engine parts 6--1.........................................

Lubricating oil pump (1.0) 6--1............................................

Thermostatic three--way valve (1.2) 6--1....................................

Safety overflow valve (1.3) 6--1...........................................

Pressure regulating valve (1.6) 6--1........................................

Main lubricating oil manifold (1.7) 6--2......................................

Pre--lubricating pump (4.0) 6--2...........................................

Needle valve (5.6) 6--2...................................................

Crankcase venting (A) 6--2...............................................

6B LUBRICATING OIL REQUIREMENTS 6--3.....................................

1. General 6--3...........................................................

2. Engine lubricating oil 6--3..............................................

3. Sub--suppliers manuals 6--3............................................

4. Testing engine lubricating oil 6--4.......................................

5. No go criteria for engine lubricating oil 6--4..............................

6C LUBRICATING OIL FILTER 6--5..............................................

1. General 6--5...........................................................

2. Removing 6--6.........................................................

3. Assembly 6--6.........................................................

6D CENTRIFUGAL FILTER 6--7..................................................

1. General 6--7...........................................................

2. Disassembly 6--7.......................................................

3. Replacement 6--7......................................................

6E LUBRICATION OF INLET VALVE SEATS 6--9..................................

1. General 6--9...........................................................

2. Checking 6--9..........................................................

Manual

F 240 CONTENTS

xx -- 8

Ver. 01

6F BARRIER OIL SYSTEM HIGH PRESSURE FUEL PUMPS 6--10...................

1. General 6--10...........................................................

2. Checking the barrier oil system HP fuel pumps 6--10......................

6G INSPECTIONS 6--11..........................................................

1. Lubricating oil overflow valves 6--11......................................

6H LUBRICATING OIL THERMOSTATS 6--12......................................

1. General 6--12...........................................................

2. Inspection of the thermostatic wax elements 6--12........................

6J GENERAL DIAGRAM 6--13....................................................

CHAPTER 7: COOLING WATER SYSTEM

7A INTRODUCTION 7--1........................................................

1. General 7--1...........................................................

2. Description of engine parts HT--circuit 7--1...............................

Cooling water pump (1.0) 7--1.............................................

De--aeration points (1.3) 7--1..............................................

Thermostatic 3--way valve (1.4) 7--1.......................................

Water cooler (1.5) 7--1...................................................

Cooling water expansion tank (1.7) 7--1....................................

Emergency cooling (E) 7--1...............................................

3. Description engine parts LT--circuit 7--2.................................

Cooling water pump (2.0) 7--2.............................................

Charge air cooler (2.3) 7--2...............................................

Lube oil cooler (2.4) and water cooler (1.5) 7--2.............................

Emergency cooling LT--circuit 7--2.........................................

7B REQUIREMENTS 7--3.......................................................

1. Cooling water specifications 7--3........................................

2. Cooling water treatments 7--4...........................................

3. Checking of cooling water quality 7--5...................................

7C COOLING WATER DE--AERATION 7--6........................................

General 7--6............................................................

Checking and inspection 7--6.............................................

7D COOLERS 7--7.............................................................

1. Heat exchangers 7--7...................................................

2. Air cooler 7--7..........................................................

Insufficient cooling 7--7...................................................

7E COOLING WATER THERMOSTATS 7--8.......................................

7F COOLING WATER PUMP 7--9................................................

1. Disassembly 7--9.......................................................

2. Assembly 7--10.........................................................

7G INSPECTION COOLING WATER SPACE 7--11..................................

7H GENERAL DIAGRAM 7--12....................................................

CHAPTER 8: AIR INLET AND EXHAUST SYSTEM

8A INTRODUCTION 8--1........................................................

1. General 8--1...........................................................

2. Description of engine parts 8--1.........................................

Inlet air filter (1.1) 8--1...................................................

Turbocharger (1.2) 8--1..................................................

Air cooler (1.4) 8--2......................................................

Exhaust manifold (2.1) 8--2...............................................

8B COMBUSTION AIR REQUIREMENTS 8--3.....................................

1. Specification 8--3......................................................

Reference conditions 8--3................................................

2. Receiver pressure and exhaust gas temnperature 8--3....................

8C CHARGE AIR CONDENSATION 8--4..........................................

1. Checking discharge opening 8--4.......................................

2. Inspection discharge 8--4...............................................

Manual

F 240 CONTENTS

xx -- 9

Ver. 01

8D TURBOCHARGER 8--5......................................................

1. General 8--5...........................................................

2. Cleaning compressor side 8--5..........................................

3. Cleaning of the air filter 8--6............................................

8E EXHAUST COMPENSATORS 8--7............................................

1. Necessary tools 8--7....................................................

2. Fitting of the compensator 8--7..........................................

8F GENERAL DIAGRAM 8--8....................................................

CHAPTER 9: STARTING AND STOPPING SYSTEM

9A INTRODUCTION 9--1........................................................

1. General 9--1...........................................................

2. Description of engine parts 9--1.........................................

Starting device (1.--) 9--1.................................................

Stopping device (2.--) 9--1................................................

9B STARTING PROCEDURE 9--2................................................

1. Prior to starting 9--2....................................................

Fuel system 9--2........................................................

Cooling water system 9--2................................................

Start and stop system 9--2................................................

Alarm system 9--2.......................................................

Lubricating oil system 9--2................................................

2. Starting 9--2...........................................................

3. Stopping 9--2..........................................................

9C STARTING AIR DISTRIBUTOR 9--3...........................................

1. Replacing the driver 9--3................................................

2. Checking the setting 9--3...............................................

3. Setting the distributor disc 9--4.........................................

9D GENERAL DIAGRAM 9--5....................................................

CHAPTER 10: ALARM AND SAFETY SYSTEM

10A DESCRIPTION 10--1..........................................................

1. General 10--1...........................................................

2. Speed measuring system 10--1...........................................

3. Alarm and protection switches 10--3......................................

4. Alarm and protection unit 10--4..........................................

5. Co--signaling board 10--5................................................

10B TESTING THE SETTINGS 10--6...............................................

1. General 10--6...........................................................

2. Test, checks and calibrations 10--6.......................................

10C DIAGRAM RPM MEASURING SYSTEM 10--8...................................

10D DIAGRAM ALARM AND SAFETY 10--10.........................................

CHAPTER 11: MAIN BEARINGS

11A NECESSARY TOOLS 11--1....................................................

Tool A 11--1.............................................................

Tool B 11--2.............................................................

Tool C 11--3.............................................................

11B REMOVAL 11--4..............................................................

11C REPLACEMENT 11--5........................................................

CHAPTER 13: CYLINDER BLOCK

13A INTERNAL INSPECTION 13--1................................................

1. Crankshaft space 13--1..................................................

2. Cooling water spaces 13--1..............................................

Manual

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xx -- 10

Ver. 01

CHAPTER 14: EXPLOSION VALVE

14A CHECKING 14--1.............................................................

CHAPTER 15: CYLINDER LINER

15A NECESSARY TOOLS 15--1....................................................

Tool A 15--1.............................................................

15B INSPECTION 15--2...........................................................

1. Endoscope inspection 15--2.............................................

2. Inspection points 15--2..................................................

15C REMOVAL 15--3..............................................................

Tool A 15--3.............................................................

15D FITTING 15--4................................................................

CHAPTER 16: PISTON AND CONNECTING ROD

16A GENERAL DESCRIPTION 16--1...............................................

1. Piston 16--1.............................................................

2. Connecting rod 16--1....................................................

16B NECESSARY TOOLS 16--2....................................................

Tool A 16--2.............................................................

Item 1 16--2.............................................................

Item 2 16--3.............................................................

Item 3 16--3.............................................................

Item 4 16--3.............................................................

Item 5 16--3.............................................................

Item 6 16--4.............................................................

Item 7 16--4.............................................................

Item 8 16--4.............................................................

Tool B 16--5.............................................................

Tool C 16--6.............................................................

16C REMOVAL BIG END BEARING 16--7...........................................

Tool A 16--7.............................................................

Tool A+B 16--7...........................................................

16D FITTING BIG END BEARING 16--9.............................................

Tool A 16--9.............................................................

Tool B 16--9.............................................................

16E REMOVING 16--11............................................................

Tool A 16--11.............................................................

16F REMOVAL OF GUDGEON PIN 16--12...........................................

16G FITTING OF GUDGEON PIN 16--13.............................................

16H REMOVAL OF PISTON RINGS 16--14...........................................

Tool C 16--14.............................................................

16J FITTING OF PISTON RINGS 16--15.............................................

Tool C 16--15.............................................................

16K FITTING PISTON AND CONNECTING ROD 16--16................................

Tool A 16--16.............................................................

Tool A 16--17.............................................................

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