瓦锡兰共轨柴油机日常维护.pdf
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瓦锡兰共轨柴油机日常维护.pdf
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WrtsilLand&SealAcademyPage1Chapter8011-Dec-08RT-flexTrainingServiceAspects?
Chapter80WrtsilLand&SeaAcademyPage2Chapter8011-Dec-08RT-flex,Operation&Service?
Goals?
“?
”?
Goalsofchapter“OperationandService”:
?
RT-flex?
TraineeswillknowtooperatetheirRT-flexengineinasafeandeconomicalway?
RT-flex?
TraineeswillbeabletoperformtroubleshootingandbasicmaintenanceworkontheRT-flexengineWrtsilLand&SeaAcademyPage3Chapter8011-Dec-08RT-flex,Operation&Service?
Generalremarks?
Thingstoconsiderduringnormaloperation:
?
flex?
Theflexpartsoftheenginerequiresdifferenttreatmentthanusedonconventionalengines.?
However,forthemechanicalpartsingeneralrefertothemanuals,yourknowledgeasanengineerandtocommonsense.?
Onthefollowingpagessomeimportanthintsandtricksarelistedbutisnotlimitedto.WrtsilLand&SeaAcademyPage4Chapter8011-Dec-08RT-flex,Operation&Service?
Generalremarks?
Pleasenotethatthetips,hintsandremarksmentionedhereafterarejustsomepossibilitiestosolveaproblembasedonexperienceswithrealsituations?
However,themanualsdeliveredwiththeRT-flexengineandon-sitegiveninstructionsfromenginemakerprevailsthesechapters.?
Rememberthatevenatenginestandstill,thereisprobablypressureremainingintherails.?
Depressurisetherailsandpipesbeforestartingtoworkonthem!
WrtsilLand&SeaAcademyPage5Chapter8011-Dec-08RT-flex,Operation&Service?
VisualChecks?
Visualchecksondailyrounds?
Thetopcoversoftherailunitliftupeasily,solookinsidedailyandcheckforleaks,etc.?
Regularlyinspectthefuelpumpregulatingracks.Doesitmovefreelyonallpumps?
Therodcanbepushtoalowerposition,theotherpumpswillautomaticallycompensate.?
Fuel-,Servo-andControloilpumps,valves,distributionblocks,pipeconnections,etc.havetobecheckeddailyforpossibleleaks.WrtsilLand&SeaAcademyPage6Chapter8011-Dec-08RT-flex,Operation&Service?
Safety?
WorkingonPumps,valvesandrailunit?
Beforestartinganyworkonpumps,valvesorrailunitmakesurethatthereisnoresidualpressureWrtsilLand&SeaAcademyPage7Chapter8011-Dec-08RT-flex,Operation&Service?
AfterOverhaul?
Afteroverhaulworksinoraroundtherailunitand/orsupplyunit?
WECS-9520?
flexview?
MakeuseofthesimulationpossibilitiesofWECS-9520andflexView.?
Oncethecontroloilpumporservicepumpisrunning,theexhaustvalvescanbemanuallyopenandclosed.Thisprovesthattheyworkproperlyandleakagescanbedetected.?
“Injectionventing”?
ICU?
30?
TochecktheICU,fuelpipesandinjectorsthefunctionInjectionventingwhichwilltriggerallinjectionrailvalveson-offfor30seconds.Thisprocedurecanbeusedtoventairfromthenewlyassembledparts.Oilwillflowthroughthemandwarmthemup.Possibleleakscanbeseen.WrtsilLand&SeaAcademyPage8Chapter8011-Dec-08RT-flex,Operation&Service?
Donotusewaterwashingdevicesanywherenearanyelectronicunit!
?
2?
Noweldingworkwithin2metersaroundaswitched-onelectronicunits!
?
ElectronicUnitsWrtsilLand&SeaAcademyPage9Chapter8011-Dec-08RT-flex,Operation&Service?
FCM-20FCM-20modules?
E90?
“?
”?
E95?
TheFCM-20installedinE90as“Online-Spare”canbeinstalledinanyE95box.?
MakesurethatALLFCM-20sinthestorehavethesamesoftwareversionloadedthantheonesusedontheengine.WrtsilLand&SeaAcademyPage10Chapter8011-Dec-08RT-flex,Operation&ServiceWECS-9520?
WECS-9520?
TheelectronicunitsoftheWECS-9520systemshallalwaysbekepton,thereisnoneedtoswitchitofftheelectronicunitsinport.Butitisrecommendedtoturnoffpowerwhenunpluggingsocketsfrommodulesandduringweldingworksontheengine.?
Powersupplytoasinglecylindercanbecutoffevenwithrunningengine,afterswitchingbackonthecylinderitwillbootandstartworking.?
WECSPowerSupplyWrtsilLand&SeaAcademyPage11Chapter8011-Dec-08RT-flex,Operation&ServiceRV-2?
TheRV-2railvalvesareswitchingveryfasttoachieveapreciseinjectionandexhaustvalvetiming.?
Typicalon-timesare:
?
2.6mspoor?
4.5mslimit!
?
RV-2,On-TimeWrtsilLand&SeaAcademyPage12Chapter8011-Dec-08RT-flex,Operation&Service?
Protectionguards?
E95?
TheE95boxeshavetobeprotectedagainstdamagebyusingtheprotectionguards.?
ProtectionGuardsWrtsilLand&SeaAcademyPage13Chapter8011-Dec-08RT-flex,Operation&Service?
Protection?
Protectionagainstunexpectedalarms?
Toavoidaslow-down/shut-downreleasedbyaccidentallypushedlever,protectitwithacover.WrtsilLand&SeaAcademyPage14Chapter8011-Dec-08RT-flex,Operation&Service?
TraceHeating?
Traceheatingofrailunit,supplyunitandrisingpipes(allfuelparts):
?
4?
:
?
WrtsilLand&SeaAcademyPage15Chapter8011-Dec-08RT-flex,Operation&Service?
OilTreatment?
Oiltreatment?
WrtsilLand&SeaAcademyPage16Chapter8011-Dec-08RT-flex,Operation&Service?
MainStartingValve?
Functiontestofmainstartingvalve?
flexview?
“slowturning”?
“airrun”?
WrtsilLand&SeaAcademyPage17Chapter8011-Dec-08RT-flex,Operation&Service?
Specialmeasuresinemergencycases:
?
ICU?
ICU?
screwplugtool(Nr.94585)?
ICU?
WECS-9520?
ICU?
ICU?
ICU?
!
WrtsilLand&SeaAcademyPage18Chapter8011-Dec-08RT-flex,Operation&Service?
ICUInjectionunit,“quantitypistonstuckinendposition”ICU?
FCM?
“Sticking”doesnotalwaysmeanthatthepistongotphysicallyseized.Itmostlyhappenedduetorailvalvefailed,fuelquantitysensorfailed,FCMfailure,coldcontroloil,etc.?
Veryoftenthepistonstartsworkingagainafterawhilewithwarmoilorafterdepressurizingthefuelrail.?
ICU.NormallyreplacingtheICUisNOTneed.?
ICU?
WrtsilLand&SeaAcademyPage19Chapter8011-Dec-08RT-flex,Operation&Service?
Injection?
Ventingoffueloilrail:
?
Afteramajoroverhaulortofillupanemptyfueloilsystem,ventinghastobedone.?
ICU?
TheventingpluginoneICUperrailmustbeslackened.Runningtheboosterpumpfillstherailwithfuelwhileairandfoamescapesfromtheplug.?
Someenginetypeshavethepossibilitytopressurisethefuelrailviaservooilsystem.?
flexView?
VentingcanalsobedoneviaflexViewunder“User”.WrtsilLand&SeaAcademyPage20Chapter8011-Dec-08RT-flex,Operation&Service?
Detectionofleakages:
ICU?
ICU?
ICU?
slowdownspeed?
ICU?
Screwplugforleakagechecking?
FuelLeakages?
ICU!
OnlyWrtsilapprovedworkshopsareallowedtooverhaulICUs!
WrtsilLand&SeaAcademyPage21Chapter8011-Dec-08RT-flex,Operation&ServiceFuelpress.regulatingvalve?
Emergencyoperation:
?
Agoodvaluewillbebetween?
600-700bar.WrtsilLand&SeaAcademyPage22Chapter8011-Dec-08RT-flex,Operation&Service?
ExhaustValveDrive?
(ToolNr.94586)?
VCUWrtsilLand&SeaAcademyPage23Chapter8011-Dec-08RT-flex,Operation&Service?
Blockingofexhaustvalve:
?
Nr.94259?
Ifacylindercoolingwaterleakageintocombustionspaceoccurs,theengineshallbeoperatedwithanopenexhaustvalve.Thereforethevalveismovedopenmanuallybyuserparameter(willclosebyitselfafterashorttime!
),andpinsNr.94259canbeinserted.?
Ofcoursetheinjectionhastobecutoffaswell!
?
ExhaustValveWrtsilLand&SeaAcademyPage24Chapter8011-Dec-08RT-flex,Operation&Service?
ExhaustValve?
Non-closingofExhaustValves?
WrtsilLand&SeaAcademyPage25Chapter8011-Dec-08RT-flex,Operation&Service?
Liftingafuelpump:
?
ExocentricshaftToolNr:
94430?
Roller?
ExocentricshaftToolNr:
94430Rollerguide?
LiftingofFuelPumpWrtsilLand&SeaAcademyPage26Chapter8011-Dec-08RT-flex,Operation&Service?
LiftingofFuelPump?
:
?
:
?
blankflange“8”(tool94569)?
blankflange“15”(tool94569a)?
intermediatefuelaccumulator?
WrtsilLand&SeaAcademyPage27Chapter8011-Dec-08RT-flex,Operation&Service?
FuelPumpSpacerRegulatingrack?
Wheninternalactuatorfaultsoccur,thepositioniskeptonactualposition.?
regulatingrack?
spacers?
WrtsilLand&SeaAcademyPage28Chapter8011-Dec-08RT-flex,Operation&Service?
CA?
WECS-9520?
Thecrankanglesignalisabsolutelyindispensableforengineoperation.Atleastoneofthesensorsmustbeworking.Ifonefails,WECS-9520candetectthefailureandwillkeepworkingwiththehealthysignal(plausibilitycheck).Incasebothsensorsfail,theenginewillstopwithoutdelay.?
ThereisnoemergencyoperationpossiblewithoutatleastoneCAsensor!
WrtsilLand&SeaAcademyPage29Chapter8011-Dec-08RT-flex,Operation&Service?
CA?
Crankanglesensorsanddrive?
Thecrankanglesensordrivehastobecheckedforproperlubrication.Checkdailyifthelubeoilpipefeelswarm.Ifnot,thefineorificeattheinlettothehousingmaybeclogged.?
Openthecovereveryfewmonthsandlookinside.?
ArethebeltsOKandwithcorrecttension?
Isthereanydirtoroil?
Dosensorwheelshaveplay?
WrtsilLand&SeaAcademyPage30Chapter8011-Dec-08RT-flex,Operation&Service?
CA?
0.0?
3.5kg?
4.5kg?
2?
Sensorswithbeltsandscrews,1?
completedriveunitassembled.?
35?
Thebeltshavetobeexchangedafterawhile(estimatedlifetime35years).?
Thebeltsmustbefreeofoil!
WrtsilLand&SeaAcademyPage31Chapter8011-Dec-08RT-flex,Operation&Service?
Correctassemblyofthecrankanglesensorsand-driveisindispensablefortheoperationalsafety.DroppedgearwheelGearwheelWornfaceSensorpulley,droppedoffsidering:
Consequenceofovertightenedbelt.?
CAWrtsilLand&SeaAcademyPage32Chapter8011-Dec-08RT-flex,Operation&Service?
CAApplyMolykotetoslidingsurface!
?
Molykote?
Fittingofshaftencoder1.?
2.?
3.?
4.?
WrtsilLand&SeaAcademyPage33Chapter8011-Dec-08RT-flex,Operation&Service?
CA?
Fittingoftoothedbelt1.?
2.?
3.?
4.?
3.5kg4.5kg?
CylinderNo1mustbeatitsactual,physicalTDCduringthewholeinstallationprocess!
(ThisisNOTnecessarilycorrespondingwiththeTDCsignaltooth.!
)WrtsilLand&SeaAcademyPage34Chapter8011-Dec-08RT-flex,Operation&Service?
Itisimportanttore-checktensionafterseveralenginerevs.Itwillmostlybecomeabitslackasconsequenceofalignmentonthewheels.?
Visualcheckforbelttensionseesketch:
BeltteethinTDCandBDCofwheelmustrestinground.?
CA5.?
6.?
7.?
8.?
WrtsilLand&SeaAcademyPage35Chapter8011-Dec-08RT-flex,Operation&ServiceCA-Sensor,completewithholderandcable.?
CA?
(0.360)?
0.1?
BUScables?
WECS-9520?
Thetwored
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