Terminology00

Instructions,
Contents,

J MainData,
OperatingData,andGeneralDesign 0 |
Water 02
Oil.Cooling
FuelOil.Lubricating
Operation03
Stop,
Start,
D Schedule 04

z
Maintenance
Tools
Maintenance 05
andWearLimits 06
Specifications
Torques
Tightening andInstructions07

=
Troubleshooting 08
andInstallatton09

z
Enoine
Removal
Bearings,
Block,
Engine Liners,
Cylinder OilSump I 0

o
II
Rod,Piston l t
Connecting
Crankshaft,
HeadandValves
Cylinder
Drive
Camshaft
t2
r3
F andValve
Camshaft Train 14
CJ andInlercoolrngl 5
Turbocharging

3 System l 6
Injection
r7
E FuelSystem
Lubricating
0il System 18
F Water
Cooling System r9
o Exhaust
System 20
AirSystem 2 l
Starting
Governing 22
=

I Mechanisrn,
Control
andAutomation2
lnstrumentation 3
00Contents- Instructions- Terminology

00.1 Contents
Thismanualcontainsdataand instructions for operatingand main-
tainingWartsila170engines.lt is assumedthatoperatingandmain_
tenancepersonnelare well awareof the carethat dieselenoines
requireandsobasicsarenotcovered. WARTSTLA FRATCEres6rves
the rightto makechangesand improvements in connectionwith
enginedevelopment withoutrevisingthis manual.Enginesshallbe
fittedoutaccording to thetermslaiddowninthesalesdocuments. No
claimsbasedon thismanualcanbe accepted.particulars of supply
can be tracedvia the numberon the manulactureis plateaffixedto
the engine.Stateclearlythe enginetype,numberand specification
reference in all conespondence or whenorderingspares.Thisma-
nualis supplemented by a SparesCatalogueteaturingcross-sectio-
nalandgeneralviews oI components(partassemblies).

00.2 GeneralRules

L!t Before carrying out any work, Readthe relevantsections

of the manual.
L2 Maintaina log for eachengine.
L3 Keepthe work area perfectly clean and tidy when car-
ryingout maintenance work,
L4 Checkbeforeremovingitemsthat the relevantsystems
havebeendrainedandanypressure released.Coveroil,fueland
air inletsand outletsimmediatelywith maskingtape, suitable
plugs,etc.whendismantling
ll Before any intervention on the feeding gaz circuit, close
the isolationvalve
6 Whenrenewinga worn or damageafeaturinfan iOentiti
cationmarkspecifying thecylinderor bearingnumber,makethe
samemarkson the newpart at the samespot. Noteall renewals
in lhe log and statethe reasonsclearly.
ft After refitting, checkthat all screwfasteningsare tightened
and lockediI necessary.

9808 00-1
 0o Contents- Instructions
- Termino cw170

00.3 Terminology
Themostimportanttermsaredefined asfollows(see
Fig.00-1):
EII A-Bank: Theleft-handsid6of the enginewhenviewedfromthe
flywheel
end (control
devicesareusually located
onthisside).
$l B-Bant<: The oppositesideby definition;thereforethe right-hand
sideof the enginewhenviewedtromthe flywheelend.
Ell plywteetena: Theendto whichthe inertiaflywheelis fitted.
El Freeeno:Theopposite end.
: (To ISO 1204and DIN6265standards.)
Gtl Cylinderdesignation
The designation oI cylindersbeginsat the FlywheelEnd.For a
V engine,left sidecylinders(fromthe tlywheelend)are designa-
ted A1, A2 etc..And thoseon the rightsideare designated 81,
82 etc...(SeeFigureabove)

FleeEnd
COt6Libre

End
F\Wheel
co\e VoloN

Figure00-1

00-2 9808
 cwl70 Contents- Instructions
- Termino 00

00.4 BearingDesignation(seeFig.00-2)
00.4.1MainBearings
Thebearingclosestto theflywheel(aheadof the timinggsarwheel)
isn'0
Thefirstbearingafterthetiminggearwheelis n' 1,the secondn" 2,
etc...

00.4.2Crankshaft
ThrustBearings
Gll ln'tineengine: Thefourhalfthrustbearings
aresupported
byn.
0 mainbearingandarenumbered
00 on theoutsideand0 on the
gearwheelside.
f,ll V-typeengine: Thefourhalfthrustbearings
aresupported
by n"
0 and n"1 mainbearings. The two haltthrustbearingsfittedon
the insidefaceof n'0 mainbearingare numbered 0; thetwo half
thrustbearingsfittedon the outsidefaceof n" 1 mainbearingare
n u m b e r e1d.
0 0 0

Figure00-2

9808 0o-3
 00 Contents- Instructions- T cwl70

00.4.3CamshaftBearings
Thecamshaftbearinglocatedcloseto theflywheelis designated n.
0 . Thefirststandardbearingis n" 1,thesecondn" 2, etc.
Thecamshaftthrust bearings aresupported bythebearingn. O.They
aredesignetedn"oo (extemal, closetotheflwh6el)andn.0 (intemal,
closeto thecamshaftgear).Thecamshaftbushesaredesignated by
theirbearingnumber.

00.5 General
00.5.1Directionof rotation(CCW):
Theenginerotatescounter-clockwise
whenviewedtromtheflwheel
end.

00.5.2Bottomdeadcentr; (BDC):
Positionof the pistonwhenit changesdirectionat the bottomof the
cylinder.

00.5.3Top dead centre(TDC):

Positionof the pistonwhen it changesdirectionat the top of the
cylinder.
TDCoI allcylinders stampedon theflwheel.
Duringa completoworkingcycle in a four-strokeengine,which
corresponds to twotumsof thecrankshaft,
thepistonmovesthrough
TDC twice :
. a firsttimewhenthe inletand exhaustvalvesare open.
. a secondtime at the momentof ignitionwhenlhe valves
are closed.

00-4 9808
 Contents, Terminology00
Instructions,
J MainDala,Operating
Data,
andGeneral
Design 0r
FuelOil,Lubricating
Oil,Cooling
Water 02
Operation 03
Start,Stop,
3
z
MaintenanceSchedule 04
MainlenanceTools 05
andWearLimits 06
Specifications
Tightening andInstructions07
Torques

=
Troubleshocting 08

z Engine
Enqine
Block,
Removal
Bearings,
Cylinder
andInstallation09
Liners,
0il Sump r0
o
I
Crankshaft,
Connecting
Rod,Piston
Cylinder
HeadandValves
ll
r2
F Camshaft
Drive r3
Camshaft
andValve
Train t4
andIntercoolingl 5
()
Turbocharging

f lnjeclion
System l6
t7
E FuelSystem
Lubricating
OilSystem r8
F r9
o
Cooling
Water
System
Exhaust
Syslem 20
AirSystem 2 l
Starting
=

I Control
Mechanism,Governrng22
Inslrumentation
andAutomation
 CW170 MainCharacteristics,Operation,GeneralDescriotion 01

-
01MainCharacteristics,
Operation,General
Description

0 1 . 1 Wdrtsil6170EngineMainData
Bore '170 mm
Stroke 200 mm
Capacity/cylinder: 4 , 5 4|
Pistonspeed 8 m/sat 1200rpm
1 0 m / sa 1 5 0 0rpm
12 m/se 1800rpm
Valves 2 inlet,2 exhaust
V angle 60'
Compressionralio '16/ 1
Direclionof rotation : . . . . . . . ..CCWasstandard

Enginelype
* 6L1?o
8L170 1-2 4-6-8-7-5-3
12Vt70 A1-Rt-A4-82-A2-86,A6,83-A3-
85-A5-81
16V170 A1-87-A7-84-A4-86-A6-88-A8,
82,M-85-45-83-A3-81
18V170 A1-85-A5-89-A9-83-A3-86-A6-
88-A8-82-A2-84-A4-87,47-81

Enginetype I 6L170 8L170 12V170 16V170 18V170

Capacity(litres) ^7^l 5401 6001 6401
Standardsumo
Capacitymin.to
max.dipstickmarks 7ol 1001 1001 1101
(litres)

AeDloxill
Enginetype 6L170 8L170 12V170 16V170 18V170
Enqineonlv 1501 1801 3601 4001
Engineand cooling
svstem

9808 0t-1
 01 MainCharacteristics,
Ooeration.
GeneralDescri cwl70

0'1.2 RecommendedOperalingData
Seetestreoorts:

01.3 Reference
Conditionslor PowerRatings
To ISO3046/1(1986)
A i rp r e s s u r e :....... . . . . 1 0 0 k Plab a r
A m b i e nt et m p e r a t u r.e. .: . . . . . . . . . 2 9 8K ( 2 5 " C )
R e l a t i v e h u m: .i .d. i. t. y. . , . . . . . . . . . . . 9 0 %
E x h a u s t b a c k - p r e s s.u. .r.e : 3kPa(300mmH2O)

01.4 OperatingGonditions
Airpressure :
Relativehumidity :
Ambienltemperature:
Exhaustback-pressure :. . .
lvlaximumintakesuction:
PUIgSANCESITE= a PUISSANCEDE REFEFENCE POWERON SITE = I
CONSOOECARBUFANTSTTE= 0 x CONSOA LA PTI|SSANCE S|TE(chaq6pariiele)
FUEL CON9UMPnON ON S|TE = p t FUEL CON9UMP|. Af qOWER ON SITE (patliat 1@d)

r,000
0,

0,s60
0,940
--- - .t@
0,920

0,900
'@g i si
0,880
: E
0,860
d d
0,840

0,sa)
0,800L
36 37 38 39 40 41 42 13 44 45 6
Tempe.alu@d air d admission 'C

Figure01-1

01-2 9808
 CW170 Main ion. General 01

-
01.5 GeneralEngineDesign- General
TheWartsila170is a high-speed engineavailablein 6 and8 cylin-
der inlineversionsor 12,16and 18cylinderVversions.
It is designed
for200 barsmaximumcombustion pressure.
Itsmaincharacteristicsare itscompactformatand itsoutstanding
maintainability
and reliability.
It hasbeendesigned witha viewto maximumintegration of assem-
bliesandcomDonents.

01.6 EngineBlock
Theengineblock(cylinder blockandcrankcase) is castas a single
pieceof nodularironandis dimensioned to be ruggedand hard-
wearing,capableof absorbing intemalstressandwithstanding im-
Dacls.
Thecrankshatt is underslung andmaintained by the mainbearing
capslvhicharesecuredby two hydraulically tightenedstudsand
two sidescrews.
Themainbearingcapsarenodularironcastingswhichareguided
laterallyby theengineblockand pinnedaxially.
In additionto the mainbearings\,vhich supportthe radialloadsof
thecrankshaft in theconventional locations, an extrabearingnear
theflywheelendsupports the radialloadsof theflywheelandflexi-
blecoupling.
Axialloadsare absorbed by thefoureasivrenewable thrustbea-
ringswhichare alsolocatedat th€llywheelendof the engine.
Thesupercharging air receiveris includedin the engineblock,in
the60" V anglebetweenthetwo banksof cylinders.
Thecoolingwaterpassages betweenlinersandcylinderheadsare
integrated in theengineblock.
Oil is fedalongan oilwayboredin thecentreof the engineblockfor
lubricatingthebearingsandcoolingthe pistons.
A camshatt fittedwithvalvecamsandinjection camscontrolseach
of thetwobanksof cylinders"
Thebearinghousingsarelullyintegrated in theengineblockand lo-
catedon theoutsideof thecylinders.
Therearelargeaccessportsto the crankshaft andcamshafts on
bothsidesot the engineblock.

9808 0 1- 3
 01 MainCharacteristi General cw170

0't.7 Crankshaft
Thecankshaftis forgedas a singlepieceot highmechanical
strengthsteel.V enginecrankshafts
areentirelynitrogencase-har-
denedwhileL enginecrankshafts arehigh-Irequency hardenedfor
optimumstrenglh. Thecrankpinsandjoumalshaverec€ssed
fillets.Thisarangementmakeslor a morecompactand lighteren-
oine.

Note : The crankshattis designedfor the most severeoperatingcon-

ditionsand complieswith ALL BEQUIREMENTS of the Ctassifi-
cation Societiesfor all current and foreseeablefuture power
ratings.

EachcounteMeight is securedby threescrews.Therearetwo

counterweights for eachcanlein (1 percrankweb).Thecamshaft
drivingpinionis heat-shrunk on the crankshaft
at the tlywheelend.
Theflywheelis fastenedto thecrankshaft by a plainflangeon L6,
Lg andV12enginesandby a doubleconesleeveon Vl6 andV18
engines.Thepumpdrivegearwh6elandthetorsionalvibration
damperarescrewfittedat thefreeend.Crankshaft designallows
for a Dowertake-offat thetreeend.

0 1 . 8 ConnectingRods
Eachconnecting rodis forgedas a singlepieceof metal;the big
endis in two parts.The big-endcapis hydraulicallytightenedwith
twostudsandnuts.Theconnecting rodsare mountedsideby side
in V engines.Thesmallendis stepped(widerbearingsurface).
Theconnecting rodis guidedby thesmallendin the piston.An oil-
way is boredin the connectingrodlor lubrication
ot the gudgeon
DinbushandDistonskin.

0 1 . 9 CrankshaftMainBearings
Themainbearingsarefittedwithupperandlowershells.The up-
pershellis positioned
in thelubricatinggrooveby a tongueat each
end.Thelowershellis positioned by a tonguein a grooveof the
mainbearingcap.Axialsupportis providedby fourthrustbearings
mountedback-to-back on n' 0 andn' I mainbearingsfor V engi-
nesandon n" 0 mainbearingfor L engines.

0 1- 4 9808
01.10CylinderLiner
Thecylinderlineris madeot plateau-honed centri{ugally
castiron.
The lowerpartis sealedbythreeO-rings.
The upperpartis fastenedbythe collarbeingclampedbetween
thecylinderblockandcylinderhead.A circulargrooveis machined
in thecollarforfittingthe pistonlinerexractortool.Thewaterjack-
et is narrowerat the upperpartof the linertoaccelerate
coolingwa-
lerflow.

01.11Piston
Thepistonis composed of a steelcrownandan aluminium
skirt.The
steelcrownis cooledby pressurised
oil in a circularoil-
way,

01.12PistonRings
A pistonringsetcomprises a firering,a sealingringanda spring-
actionoil scraperring.Thethreeringsarefittedin grooveson the
oiston.

01.13CylinderHead
Thecylinderheadis madeof greycastiron.Theareasexposedto
combustion andsubjected to hightemperatures arecooledby the
coolant.An intermediate taperdesigned to absorbmechanical
stressesenhances cooling.
Therobustdesignmeansthecylinderheadcanbe securedwith
fourhydraulicallytightened studs.Thecylinderheadincludestwo
inletvalvesandtwo exhaustvalves.The inletvafuesare of laroer
diameters thantheexhaustvalvesto improvecylinderfillingaid
scavenging of spentgasses.The inletandexhaustportsareall lo-
catedon thesideot thecylinderhead.
The inletandexhaustvalveseatsandguidesareseparateinserts.
Theexhaustvalveseatis cooledby coolantin someapplications.
Theinletandexhaustvalveshavechrome-plated stemsandstel-
lite-coatedbearingsurfaces. Thevalvesarefittedwithrotators(Ro-
tocap)ensuringa perfectairtightsealbetweenthevalveandseat
andimproved distribution
of thermalstresses.

9808 0 1- 5
 01 MainCharacteristi GeneralDescription CW170

01.14 Camshaftand ValveMechanism

Thecamshafts aremadeup of severaleasivhandledsectionsar-
rangedend-to-end.
. two sectionsfor L6 - L8 - Vl2 - V16 engines,
. threesectionsfor V18engines.
Thecamsandbearingsarecase-hardened. Thesectionsareas-
sembledend-to-end withflangesandpins.
Axialsupportis providedbythe bearingat thetlywheelend.The
valvetappetsareof the piston-roller
type.Theyaremountedin the
housingof individual
injectionpumps.

01.15TimingGear
Thetiminggearis incorporatedin a compartment oI the engine
block.Thetiminggearcomponents are identical
lor eachoI thetwo
camshafts on V engines.
Thetiminggearis ot thetwostagetype.The intermediate shafts
havetwogearwheelssecuredby screws(thegearwheels canbe
adjustedrelative
to oneanotherthrough 360.).
Thecamshaftpinionis securedby screws.
Thegeartrainis lubricated
by oiltromspraysdirectedontothe lea-
dingside.

01.16 CouplingCover(flywheelhousing)
Somecoolingwaterandlubrication ductsareintegrated intothe
castingof theflywheelhousing.
Themainlunctionis forflangemounting the altemator,clutch,com-
pressor,etc.depending on theapplication.
lt actsas a supportfor
startermotors,enginecrankinggear,sensorsandflywheelindex-
inodevices.

0 1- 6 9808
 CW170 tvtain on, GeneralDescription

-
01.17 Free-EndCover
Thefre-e-end coverprotectsthevibrationdamperandancillaryitem
onvegearwheels.
Allthepumps.(except forlnjectionpumps)arefittedto thecover.
>ranoaroequtpment consistsof thetwincoolingwaterpump,the di_
rect-drive oil pump.thedjrect-drivefuelpumpa-nO the etectricpr"_
lubrication pump.
Thecoveractsas a supporttorthe oilthermostat caseanddepen-
drngon theversion:
. solt water/ untreatedwatercooter.
. prehealer.
. loadalternator,
. powertake-offs.
It includescoolantpassagesandoilways.

0 1 . 1 8O i l S u m p
Thewet-type oilsumpis madeot weldedsteelsheet.lt incopora_
teslhe oilteedandretumlines.The drainplugis locatedat thef;e
end.lt.isequippedwithan oil levelgaugeandhasbossesfor
mounlngtnermometers andthermostats.

01.19FuelSystem
Thefuelsystemcomprisesone injection
pumppercylinder. The
pumphousingincludesthe injection
tappetandthetwo valvetap_
Dets.

Note: The iniectionline may be sheathedas an option.

Theinjectoris locatedat thecentreof thecylinderhead.The injec_

tor leak-otf.retum
is integratedin thecylinderhead.Theinjection
pumpsandtheirhighandlowpressurelinesarefullvprot;cted
bv
hermeticallysealedcovers.Theengineis fittedwitha direct_driv;
ruelpump."Duplex" full-flow
fuelfilterswhichcanbe chanqedwhile
runnrng,a pre-fiheranda manualor electricprimerpump.-The re_
tum circuit.includes
a regulator valveto ensureuniforminjection
pumpteedpressurc. Thefuelsystemincludesa leak_off;vstem di_
vrdedIntocteanandfoulcircuits.Foulleaksarethosecollectinq in
the "sealedcove/'.A toulfuelleak-offdetection systemcanUeiii_
tedas an option.Cleanleak-offs arethosefromtlreinjectorsafter
lubrication.

9808
0 1- 7
 0l Main Operation,GeneralDescription CW170

01.20 LubricationSystem
Thelubrication systemincludestheoil sump,thelubricating pump,
thecentrifugallilter andtheoil module.
Theoil is draffi alongthefeedlineinsidethe oilsumpto an oilway
in thefree-endcover.Thepumpmodule,whichcomprises the di
rect-drive oil pumpandlhe electricprelubrication pump,is moun-
teddirectlyon thecover.
Theoiltravelsfromthe oil pumpalonganotherintegrated ductto
theoil modulowhichis madeup of thecoolingwater/oilexchanger,
oilfiltersandthermostatic valves.
Forin-lineengines,theoil moduleis locatedon the B sideof th6 en-
gine,nearthefreeend.Forpowergeneration V engines,the oil mo-
duleis locatedon the ffywheelhousing.FormarineV engines,the
oil moduleis locatedon thefreeendcover
Fromthe module,someof the oil lubricates thecamshaftdriveand
camshaftbearings, thetappets,thevalveandthe rockerarm
mechan|sms.
The remainder ol the oiltravelsalongthe maingalleryin thecylin-
der blockto lubricate the mainbearings, big-endbearingshellsand
gudgeonpins.Thisoilwayalsofeedsthe pistoncoolingspraysand
theturbocharge(s).
Thesystempressureregulating valveis located(downline ol the
entiresystem)so as to ensureconstantpressureregardless of va-
riationsin engineloador speed.
Thesystemincludesa centrifugal tilterthatcanbe cleanedwhile
lhe engineis running.
The DuplexfulFflow fiherscanbe cleanedwiththe enginerunning.
Cfhe liherscan be drained by a valvebeforeremoval.)

01.21 StartingSystem
Thestarteris of theairturbinetype.Thesystemincludesa pres-
sureregulating valve,thecontrolvalveanda safetyvalve.Theslar-
ter actsviathe ringgearon the rimof theflywheel.

Note: A secondair turbinestartercan be mountedas an option,

0't -8 9808
 CW170 MainCharacteristics,
Operation,GeneralDescri 01

01.22 CoolingWaterSystem
Thecoolingwatersystemis madeup of twocircuits:
o the hightemperature (HT)circuil,
. the low temperature(LT)circuil.
The LTcircuitcoolsthesupercharging airandthe lubricating oil.
The HT circuitcoolsthecylinders,cylinderheadsandexhaustmul-
tiducts.
A tvvinpumpensurescirculation in thetwocircuits.lt is a centrifugal
pumpfittedwitha mobileshaftwitha two-turbine wheel.
Coolingwatertemperatures arethermostaticallycontrolled.
Thetwothermostatic valvesol eachcircuitareinstailedin the
samecastinglermedthe'boolingwatercontrol unit'.

01.22.1
Coolingwatercircuit
01.22.1.1Powergenerationapplicationequippedtor co-
generation
Formemory: Ell LTCircuit:TheLT circuitcoolantis fedfromthe pumpto the LT
air,/HT
water
exchanger
and Stageof the supercharging air cooler,fromth6reto the oil cooler
air/LT
water
exchanger and then to the controlunit whichregulatesthe flow depending
on IemDeralure.
Thecoldwateris by-passed to thewaterpumpand hotwateris di-
rectedto the LT exchanger. Thefluidretumsto the waterpumpaf-
ter cooling.
El HT Circuit:TheHT circuitcoolantis forcedfrom the waterpump
to the HT stageof the supercharging air exchanger. Fromthere
it is fed to the engineto coolthe cylinders, cylinderheadsand
multiduct.
Fromthemultiduct thecoolantis sentto thecontrolunitwhichregu-
latesthetlowdepending on thetemperature.
Coldwateris by-passed to thewaterpumpandhotwateris direc-
tedto the HT exchanger. Thefluidretumsto the waterpumpwhen
coto
As thecircuitsin thissyslemareindependent, the two stagesof the
waterpumDarefittedwithboostertanks .

9808 0 1- 9
 O'1.22.1.2
Powergenerationapplication without cogene-
ralion
Fo.memory
i EII LT Circuit:Thecoolantis led fromthe LT wateroumoto the LT
single
airlcooling
water
exchanger Stageof the air Coolerand from there to the OilCOOler. Then at
the controtunit, part ot th€ coolantis directedto the HT water
pumpandthe remainder to the thermostaticvalveswhichreou_
latellow dependingon temperature.
Thecoldfluidis by-passed to the LT waterpumpandthe hotfluid
is directedto the heatexchanoer.
El HTCircuit:Coolantlrom is pumped
theLTcircuit bytheHTwater
pumpto the HT stageof the supercharging air cooler.
Fromthereit is directedto the engineandthento the controlunit
whichregulates llowdepending on temperature.The coldfluidis
by-passed to the HTwaterpumpandthe hotlluidis directedto the
heatexchanger.
Thefluidis retumedto the LTwaterpumpaftercooling.Thesys- -
temcomprises two interlinked
circuilsandis equippedwitha boos-
tertank.

01,22.1,3Marine Applications
Thetwocircuitsare interlinked
(LT/tlT).
Thecoolantis cooledby a lreshwater/ seawaterexchanger.
The
engineis fittedwitha seawaterpump.
Ell LT Circuit:Thecoolantis drawnup by thewaterpumpf romthe
series-mounted superchargingairandoilcoolers,Fromtherethe
coolantis pumpedto the controlunitwhichregulatesllow depen-
ding on temperature. The cold fluid is by-passedthe oil and
superchargingair exchangers, whilethe hot fluidis directedto
the freshwater/ sea waterexchangerto bs cooled.
EI t{Tcircuir:
j!l Coolantfrom the LT circuit is pumpedby the HT water
pump to the HT stageof the supercharging air cooling.The
coolantis thendirectedto the engine.As it leavesthe engineat
themultiduct thefluidis directedto thecontrolunil.Thecoldlluid
is by-passed to the HT waterpumpintakewhilethe hotlluid is
directedto the freshwater/ sea waterexchanger.
Q fne luiO is returnedto the enginevia the oil and super
chargingair exchangers aftercooling.

01,22.1.4Options : (for all three apptications)

. Preheatercomprisingresistanceheaters,an electric
pumpandcheckvalves.
. Back-upwaterpump (HT-LT)comprisingan eleclrical
pump,checkvalvesand regulating valves.

0 1- 1 0 9808
 CW170 MainCharacteristics.Operation.GeneralDescriDtion 01

01.23 ExhaustGassesandTurbocharger
System
Theexhaustgassesaresweptfromthecylinderheadsto the ex-
haustmanifold via a muhiduct. Thismulti-tube, multi-pumose com-
ponentis madeof a specialheat-resistant nodularcastiron.lt
transfersairfromtheair manifold, incorporated in the engineblock,
to thecylinderheads.
Furthermore the multiduct transferts
thecoolingwaterfromthe cy-
linderheadto the retumchannel.Additionally the muttiduct sup-
portstheexhaustgaspipesandinsulalion.
TheexhaustpipesaremadeoI specialheat-resistant nodularcast
iron.Thepartsformingtheexhaustpipesareseparated by metal
expansion joints.
All ot the exhaustpipesmaybe contained in an insulating chamber
witha lowextemalsurfacetemDerature. Theheatinsulation is for-
medlromsteelsheetsseparated by variousthicknesses of insula-
tionmaterialdepending on the application.
Twotypesol air supercharger canbe used:a singleturbocharger
systemforimproved performance undertullload,or a multiplesys-
temwithfoursmall,low-inertia turbochargers for enhancedengine
reactionto variations in loadandlor goodperlormance underpar-
tialload.
Bothsystemsare highlye{ficient.
Supercharging is of thesinglestagetypewithcooledair.
o Forpowergenerationapplications the SAC(superchar-
gingair cooler)is a two-stagedevic€.
. Formarineapplications theSACis a single-stage device.
TheSACsare designed to ensurelowtemperature air outputso as
to cutdownexhaustemissions,

9808 0 1- 1 1
01 MainCharacteristics.
Ooeration.
General cwl70

01 -12 9808
 Terminology00
Instructions,
Conlents,
J Main
Data,
OperatingData,andGeneralDesign 0l
FuelOil,Lubricating Water 02
Oil,Cooling
Operation 03
Start,Stop,
D Schedule 04
Maintenance

=
Mainlenance
Tools 05
andWearLimrts 06
Specrfications
Tightening andInstructions07
Torques

=
Troubleshooting 08

z
Enqine andInslallalion 09
Removal
Engine
Block,
Bearings,
Cylinder
Liners,
OilSump r0
o
I
Crankshaft, Rod,Piston
Connecting
HeadandValves
Cylinder
I3
II
t2
F Camshaft
Camshaft
Drive
andValveTrain 1 4
C' andIntercooling l 5
Turbocharging

3 System I 6
Injection
FuelSystem 1 7
E Lubricaling
0il System l8
F r9
o
Cooling
Water
Syslem
Exhaust
System 20
AirSystem 21
Starting
=

I uovernrn0 22
uonlrotlvtecnantsm,
andAutomation23
Instrumentation
 cw170 LubricatinqOil and Coolinqwater 02

- 02LubricatingOil and Coolingwater

O2.'l Fuel
02.1.1 General
Theengineis designed to operatewithDMXand Dl\ilA-DMB grade
lightfuelas per ISO8217withthefollowingcharacterisiics
:

Note; Thevaluesin thistableareminimumandmaximumvaluesfor

eqg! ppperty. The aetualvaluesfor eachfuel type may vary
within these limits-

Densityat 15'C, kg/m"1) lso 3675 mau. 890.0 900.0

'1.40
Kinemalic al 40'C)
viscosity rso3104 mtn, 1.50
max, 5.50 6.00 11.0
Flashpoint,'C lso2719 mtn, 43 60 60
Meltingpoint,'C 4)
Winterquality -6 o
lso 3016 max.
Summerqualitv max, 0 6
Dewpoint,'C tso 3015 max. -16 5)
% (drm)oo
Cabon€sidue,Flamsbottom tso 4262 max,
107"resadue 0.20 0.20
Cabonresidue, % (nvm)
Ramsbottom max. 0.25
Ashcontento/.(ny'm) tso 6245 max. 0.01 0.01 0.01
qeqIEllly gl!'aCqon,
:/e(I''l.) lso 3735 0.07
tso 3733 max. 0.30
Cetaneindex tso5165 mtn. 45 40
% (rn/m)
Sulphur, max. 1.0 2.O
'C
l1 Densityin kg per litre at 15 mustbe multiplied
by lOOO
beforecomDarisonwiththesevalues.
LZ Therewill be a maximumvalue,in somecountr;es.
lg l cst=1mm2/s
l4 Purchasersmust makesure this pourpointis suitablefor
the equipment,especiallyif the engineis operatingin the
southernandnorthernhemispheres.
oI -15 .C without
5- Fuelis suitablefor use at a temperature
beingpre-heated.

9808 o2-1
v2 Oil and Coolinowater cw170

02.1.2DMXFuel
Thisdieselor domestictypefuelhas,in particular,
a highcotanein-
dex,lowsulphurcontentandlowviscosity.

Note: Theonlyconstraintimposedon useis not to exceeda temp€ra-

tureof 5& C at thefuelinletpump.

02.1.3DMA-DMBFuel
Compared whhDMX,in particular, thesefuelshave:
. a low cetaneindex
. highersulphurcontent
. highviscosity
Thehighcompression ratioon theWARTSILA170shouldmakeit
possibleto obtainsimilarcombustioncharacteristics
whateverthe
cetaneindex.

Note: TheoilTBN must be adapteddependingon the sulphurcontent.

o2-2 9808
 cw170 LubricatinqOil and Coolinowater 02

- o2.2 LubricatingOil
02.2.1Characteristics
lfl Viscosity:Viscosity classSAE40.
f,ll ntratinity:tle requiredatkatinity
of the Iubricating
oitdepends
on theluel usedwiththe enoine.
E Additives: Oils must contain additivestor effectiveorotection
againstcorrosion,highloadingcapacity,and etfectiveresistance
to oxidationand to preventdepositslrom formingon the internal
partsof theengine(especiallyon the pistonringsand bearings).

02.2.2LubeOil Grades

Designation
Commercial
name

Caution! You must consulttheenginemanulacturerbeforcusing lubeoil

not ieaturedin this table.Non approvedoils must be tastedby
the currentWARTSILAFRANCEprocedure.
Nevermix differentbrandsot oil.

02.2.3Inspectionand Maintenance
li For an effective way of predictingoil changeintervalsand
lo gettheenginemanufacturer's opinionon the condition oI your
engine,we recommend thatyou :
o Sendus samplesol oil at regularintervals, indicating the
corresponding numberof hours'operation.
o Takesampleswhentheengineis runningusinga plastic
syringeso theyare representative of the oil in circulation.
. Takesamplesbeforeand not aftertoppingup the oil (to
compensate for oil consumed).
. Rinsethe syringewith oil that is beingsampledbefore
fillingit.

9808 02-3
02 LubricatinqOil and Coolinqwater cwl70

-
2 For a completeevaluationof the oil in service.the fol-
lowinginlormationshouldbe suppliedwiththe sample:
. installation
type,
. enginenumber,
. oil brandname,
. engineoperating hours,
. numberof hoursoil usedfor,
. pointof systemfromwhichsamplewastaken,
. fuel type,
. and any specialremalrks.

Note: Oilsampleslor which no informationis providedotherthanthe

type of installationand enginenumberare virtuallyworthless.

In estimatingthecondition ol the oil used,thefollowingproperties

shouldbe observed. Comparewiththe indicative values(typeana-
lvsis)forfreshoil ol the brandused.
llf Viscosity.lt shouldnot be more than 25o/oabovethe indicated
valueat 100"C.Maximumpermissible viscosity
torSAE40 grade
"C "C.
oilis212cst at40 and19cst at 100 Minimum oermissible
forSAE40gradeoilis 70 cst at40 "C andI cst at 100
viscosity

f,ll Fhsh point, lt shouldnotbemorethan50"Cbelowtheindicated

value.Theminimum permissible(opencup)flashpointis 170'C.
'C
At 150 ther€is a dang€rot the crankcaseexploding.
lll Watercontent.lt shouldnot exceed0.3%.At 0.5% measure-
menlsmusl be taken.The oiJmusl be drainedotf to seekout the
caus€of wateroenetration.
[l feH.fne feU valuemustbe at least50%ofthe nominalvalue
of fresh oil. However,tor oils with nominalTBN valuesof more
than25,the permissible limitIor the oil is 15.
permissible
f,tl Insolublesubstances.The quantitydependson va-
riousfactors.

Note: The oil supplier'srecommendations

must be observed,

It is generally in analysesprovidea betler

trueto saylhatvariations
basisforaDpraisal thanabsolutevalues.

Note; Sudden variationsmay indicateabnormalengine or sysGm

operaflon,

o24 9808
 cwl70 LubricatinqOil and Coolinqwater 02

02.2.3.1
Top up the oil.
Measureandrecordthequantityadded.Attention
to lubeoil con-
sumptionmayprovideimportant
inlormation
aboutenginecondi-
I|on.

Guidelinesfor oil changeintervalsare shown in Chap.04.

Whenchangingthe oil it is recommended to proceedas lollows:

. Drainthe lubricatingsystemwhileit is still hot. l\rakesure
the oil Iilter and coolersare also drained.
. Cleanthe oil spaces,as wellas the filtersand the cam-
shaftcompartment. InsertnewIiltercartridges.
. Fillthesumpwiththe requiredquantityof oil.SeeChap.
01.1.

02.2.4SpeedGovernorLubeOil
Seeth€ govemormanufactureds instruction
booklet.SAE4Ograde
oil is usuallysuitableandis thesameas thatusedin theengine.
SeeChap.04 for oilchangeintervals.

02.3 Coolingwater
02.3.1General
Coolingwatermustbe treatedto preventsaltor scaledeposits, cor-
rosionanderosiondueto cavitation on the metalpartsin contact
withthe coolantin thecoolingsystemsoI dieselengineswithclo-
sedor semi-open circulation.

Caulion! Thequalityof watertreatmentis essentialwherediflerentmetals

are used (steel, aluminium,etc.) so as to prevent galvanic
corrosion.

9808 02-5
02 LubricatinqOil and Coolinowater cw170

Before
treatment
thecooling
watermusthavetheIollowing
mini-
mumchemicalcharacteristics
:
. 7<PH<8
. chloridecontentlessthan 80 mo/litre
. hardness titrelessthan10
. resistivityat 20 "C : 1500ohms/cmand more.

Caution! Distilledwaterwithout additivesabsorbscarbon dioxide from

air and promotescorrosion.

Treatment mustbe caniedoutfromthetimetheengineis first

used.Anyincipient corrosionis difficultto stop.
Seawateris highlycorrosive, andtormsdepositsevenif introdu-
cedin the systemin smallquanlities.
Rainwater hasa highoxygenandcabon dioxidecontent.Accordin-
glyit canbe highlycorrosive
andcannotbe usedas coolant.

Caution! It is mandatoryto treat cooling water . Failureto comply with the

tollowinginstructioninvalidaiesthe equipmentwarranty.

02.3.2Additives
productsonly.
Usethe recommended

Attention: The use of oils in emulsion,phosphatesand borates is not

recommended.

Thetablebelowindicates
theoualitiesof a numberof additives.

Sodium - etficiency 'increasedriskof corosionif

cnromae ' smallactivequantities,0.5% insuflicient
concentrationl - suitableas additivefor objects
byweight localisedcorrosion whereloxicefleclcanbe
- reasonably p ced -harmfulforskin
or - €asylo assessconcentration -loxic:lelhaldosage lolerated
- prohibitedfor usein fresh - carewithusoandsl ngent
(colourcomparison wilhlest
potassium solution) walergenerators forhousehold cnecKs are necessary
chromate
- moreexpansivethantoxio
- nontoxic products
- notdangerous
lo handle - irrcreased
dskofcorrosion,
sensitiveto conectdosaoe

02{ 9808
cw170 LubricatingOil and Coolinqwater 02

02.3.3Treatment
02.3.3,1Genelal
Whenchangingadditiveorwhenintroducing
an additivein a sys-
temwhereuntreated
waterwasused,the entiresvstemmustbe
chemically
cleanedandflushedoutbeforetreatedwateris introdu-
ceo.

Caution! Evaporatedwater must be replacedby treatedwater, lf untreated

wateris usedthe additivecontentmay graduallyr€achunsuita-
ble concentrations.

To makeup for leaksandotherlosses,the coolantlevelmustbe

toppedup withtreatedwater.
Formaintenance operations
thatrequirethecoolingsystemto be
drained,savethetreatedwaterso
s tt
it can
canbe used atn.

Supplier Oeaignatlon Packaging

RD25 Jerrican25 KG
Flohm& Haas DIAI\,,IIGEL Barrel225 KG
DIAGEL Banel225 KG
DIAGEL Jerican25 KG
COOLELF SUPRA Barrel215litres
GLACELF SUPRA Barel215litres
GLACELF SUPRA Barrel25 lilres
WSDS 4 seasons45882196 Barel 215litres

02,3.3.2Preparalion
Diamigel, CoolelfSupraand4 seasonsWSDSare ready-to-use
prooucrs.
However, tor RD25,DiagelandGlacelfSupra,youshouldusede-
mineralised wateror drinkingwaterwiththefollowingcharac-
teristicsfor preparation
ot thetreatmentproduct.
lll Watercharacteristicsbeforetreatment:
Thewatermustbe clear.Suspended particles
separateoutandac-
cumulateat lowpoints.
Waterbeforetreatmentmustexhibittheminimumcharacteristics
definedfortheuseof normaldosesofthe recommended treatment
products.
!l Hardness
:
It mustbe as lowas possibleto preventprecipitation
andencrusta-
tionthatcausescaleto form.
Hardness lessthan12"is desirable.
lll Hydrogenpotentiat(pH):
It mustbe greaterthan7. It necessary,
sodiumbicarbonate
canbe
addedto acidwaterto bringthe pH backto 7.

9808 o2-7
02 LubricatinqOil and Coolinqwater cwl70

OI Chlorideand sulphatecontent:
Concentrationmustbe lessthan50 mg/lof NaCland40 mg/lof
SO4Caequivalent. We adviseyouto consultthe productmanutac-
tureroTWARTSILA FRANCEwhen:
. hardnessis greaterthan 30
. the chloridecontentis greaterthan 300 (althoughsome
instructionsprovidefor treatmentup to 1000).
. the sulphatecont€ntis greaterthan 100

- 4' (1)
Approximalely Filstuse:
9t I afterfirstuse: 48 |
-13' 250|
300 |
-22' 350 |
400 |
100|
200 |
GLACELF - 1 8' 300 |
-25" 400 |
500t
COOLELF
SUPER

Caution! Do not mix RD25with antifreezeand anti-corrosionproducts.

The higherthe mix ratio,the lower the cooling capacityol the
water.

lI youchangethetreatmentproduct,
you mustdrainoffthecooling
systemandcleanthesystemwithcleanwaterbeforerefilling
the
enginewhhthe newtreatment water.

Caution! Neveruse sodiumcarbonateto cleanthe engine.

To obtaina homogeneous mix: if the engineis fittedwitha prehea-

tingwaterpump,circulatethe mixwiththe pumpfor an hour.O-
therwise,
startthe engineandallowit to runfor 10 minutes.

02{ 9808
cw170 LubricatinqOil and Coolinqwater 02

02.3.3.3Checkingtreatmentwaterquality

Seethe maintenancetablein Chap.04.

Testkitscanbe usedto monitorthetreatment

waterqualityyour-
self(pHconcentration
check).Thesekitsareveryeasylo useand
indicatehowthetreatment
variesas wellas whetherthecoolino
wateris contaminated.

Note : N.B.For closermonitoringot your treated.Water,

rlteadviseyou
to send samplesof the treatedwaterto WARTSILAFRANCE.

We determine (composition,
thechemicalcharacteristics contami-
nation)of yourtreatedwater.
Thismeansyouknow:
. the time beforethe nexttreatedwaterchange
. the condition of the coolingsyslem
. the causesand originsoI any damage

02.3.4Internalcleaningof the coolingsystem

Thecoolantmaybe accidentally coniaminated (sluny,bacteria,oil
intake,etc.).Thiswillleadto theformation of slurryand"biofouling"
(slurryfrombiochemical activity)
whichmayleadto the conosionin-
hibitoBbeingdeskoyed,UseWSDSdisinfectant # 45890769.
Inthe eventof contamination by oil (e.9.as a resultof piercedoil
cooler),useWSDSde-greaser # 45890770.

02.3.5Checksto be made
leastoncepermonthandaftertoppingup :
. checkthe concentration
of corrosion
inhibitors
o measurethe densitv

Caution! The cooling system must be drainedand tlushed out at least

once every wo years.

9808 02-9
 cwl70 inq. ODerationand 03

-
03Starting,Stopping,OperationandStorage

03.1 Starting
03.1.1Checksbeforestarting
ijl Makesure that lhe cranking gear is disengaged from
the flywheel.
E Checkthe oil level(seeChap.18).
lq Fuelcircuit
. checkthat the valvesare oDen
. the levelot fuel in the tank
4- HT and LT coolingcircuits
. checkthat the coolingwater inlet and outletvalves are
open
. checkthe levelot the radiatorleed(s)
. checkthe pre-heat temperature(see Chap.19)
5 Check the speed governor oil level(tor hydraulic gover-
nors).
id Checkthat the fuel andcoolingcircuitshavebeenproperly
de-aerated.
Z Makesure that the overspeedstop device is operational.
,!_ Checkthat the alarmand controlsyslem is on.
-Si, Check that the start-up air pressure is adequate (mini-
mum7 bars).
jq Check that all the protective covers and plates are in
placebeforestartingthe engine.

03.1.2Manualstarting
_L Turn lhe crankshaft through 2 complete revolutionswith
the manualcrankinggear.
? Disengagethe crankinggear.
jI Check that the automatic alarm and stop systemsare on
(seeChap.23).
4 Startup the prelubricationpump.
I5 Whenthe authorisationto stan is displayedpress the
startbuttonuntilthe enoinefires.

9808 03-1
03 Startin Operationand Stora cw170

Caution! Thestartermustneverbe activatedfor longerthan 10seconds.

Waitat least30 secondsbetweenattemptsto start the engine.
Afler three unsuccessfulattemptsseek out the cause of the
problem.

d After startingcheckthatnormallemperatures andpressu-

res are obtained.Waituntilthe HT watercircuittemperature
(superchargingair exchangerinlet)is at 65' beforeincreasing
power.

03.1.3Automaticand or remotestarting
Atleran extendedstoppage(morethantwoweeks),proceedas in
section03.1.1.
lll Remotestarting
j!l Start the p.elubrication pump. The enginemay be started
whensulficient pressurehasbuiltup (minimum level).
14 In automaticmode,sequentiaFtype prelubrication keeps
theengine (Mak€regular
readyforstarting. checks thatthepump
is in workingorder.).
Pressthe start buttonforaminimum3 to5 seconds to stan
engrne,
The remotetachometeror an indicator
liohtwillshowwhen
enginehasstarted,
tql For some automatic remote control configurations the
prelubrication
pumpstartswhenthe startbuttonis pressed. The
pressure
enginestartsas indicatedbelowaftersutficient hasbuilt
up plusa time-delay set at about10 seconds.
Ell Automaticstarting.
,!] The start order is givenby a controlrelayreceivingan ex-
ternalorder.
,Zl The standard sequenceis as tollows : As soon as the re-
lay receivesthe start signal,the start-upsystemis activatedfor
5 to 10 secondsto startthe enginerunning.

Note: lfthe enginetailstostart,a newattemptis madeafter20seconds.

It the engine fails to start after three attempts, the start failure
alarmis displayed.

Whentheenginehasbuiltup sufficientspeed,theauxiliaryrelay
controlled
by thetachometerrelaycutsoutthestartersystem(cut-
outspeed:200Ipm).At thesameinstant,the prelubrication
pump
andpre-heating systemarestopped.Thenaftera timedelayof 5
to 10secondsthesafetyleaturesandalarmsbecomeoperational
automatically,

03-2 9808
 cw170 Startin Ooerationand 03

- 03.2 Stopping
03.2.1General
Thestopleverlocatedon theengineis usedlor stoppingthe en-
ginemanuallyindependently of the automatic
and remotecontrols
in theev6ntof emergency.
j Enginewith direct-drivecoolingwatercircul.pump.
Runtheengineoffloadfor4 to 5 minutesbeforestoppingso that
the coolingcircuitis at an eventemperature throughout.
e Enginewith separatecoolingwatercircul.pump,
Proceedas shownaboveand leavethe pumprunningtor 2 to 3
minutesafterstoppingthe engine.
iA ClosethecoolingwaterandIuelvalves.

Caution! Aftera suddenstoppageof the engineunderloadbecauseofan

extemalincidenloranilFtimedorderfromthe automaticsystem,
do not attemptto restart without having first trac€d the cause ol
the stoppageand having turned the engine with the manual
crankinggearthroughat leasttwo revolutionsto ensureit runs
freely.

03.2.2Remotestopping
ll Ensureeven heatdistributionas in section03.2.1
E Pressingthe stop button activates the stop relay for a
pre-settime(40to 50 seconds)
allowing
theengineto cometo a
complete stop.

Note: lt is not possibleto startthe engineduringthis time.

lq After the engine has stopped, the alarmsystemis de-acti-

vatedand the prelubrication
and pre-heatingare re-started.

03.2.3Automaticstoppage.
L1 For an automaticstoppagethe engineis stoppedas indi-
catedin section03.2.2.
[2 ln the eventof a suddenstoppage,aftera technicalinci-
dent (e.9.low oil pressure,overspeed,
etc.),the enginestops
instantlv.
3 The controlpanelindicates thecauseol thestoppage (e.g.
lowoil pressureindicator
lighton).

9808 03-3
03.3 Normalsupervision
of operation
1 Record allthe operating parametersperiodically and
comparethe readingswith the correspondingvalues on the
acceptancetest records,

Caution! lf differcncesaris€betweenthe recordedandthe originalvalues,

the causesmust b€ identified.

:a] Check the fuel circuit fouling indicator. As the filters be-
comechokedthe pressure in thecircuitdecreases. A markedfall
in fuel pressurereducesengine performanceand may cause
failuresbecauseoI unevendistribution ot fuel to the cvlinders
(unevenheatdistribution).

Caution! A significant pressuredrop may also detorm the filter cartridges

and causeseizureof the iniectionpumps.

ll Checktheoil filter fouling indicatorand/orthe pressure

ditferencebetweenthe filter inletand outlet.

Caution! Excessivepressureloss becauseoffouled oilflters causesthe

byfass valve to open. This results in reduced filtering and
increasedenginewear.

4] Checkthe sump oil level.Assess the appearanceand

consistency
of the oil.

Note : It is possibleto checkfor watersimplyby droppinga spotot oil

ontoa hot plate(about150"C):if thedropmakesho nbiseit is
not contaminated by water,if it sizzles,the oil containswater.

5l Check that the cooling water circuit venting (at the ex-
pansiontank)is workingproperly.
6l Checkthe amountof tuel leakingIromthe drainljnes.
lZ Check that the inspection ports of the oil coolerand water
coolerare open.
I i Cleanthe day tank of any waterand sediments that might
have built up and drainoff waterfrom lhe intermediatestartinq
air tank.

03-4 98(a
cw170 Operationand 03

g Marineengines(propulsion and auxiliaryengines):For a

stoppedengine, prime lubricationand rotatethe crankshaftto
anotherposition.This reducesthe riskoI vibrationdamageto the
crankshaft and its bearings.
@ To prevent condensation in the cylinder from corroding
the liners,it is essentialto maintainthe intakeair temperature
abovethe dew point,otherwisesome oI the watercontainedin
the intakeair willenterthe cylinderin liquidlorm.Accordingly it
is important to not run the enginelor longperiodsat low loads
(low temperature)and to check that the thermostatvalves are
workingproperly.

60
f r 5 50
! o ,4?
40 -l-/a
d 6
30 v
_2 .lc
. 0o
20
t0
ffi
0
t0
20
30
\\\N
\ l
O Q
R 9 40 <l
,J
8 ! 50
60
\}

i i 10 .01 .02 .03.04.05 .06 .07.08 .09

Wotercontent (kgwoter/ kg d.y ok)
TensJren edr (kg ecu / kg cir secl

Figure 03-1
Exampleilt the ambientair temperaturcis 35"C, with rclativehumidityof 8O%,the
watercontentcan be readofl as 0.029ka waterper ka drv air, lf underthe
sameconditions,theair manifoldpressireis 2.5 ba6 ftivina an absolute
pressureof 3.5 bars),the dewpoint is readfrom thegEph ds 55"C.lf the
air tempen Jrein themanifoldis only45"C,the air can onlycontain0.018
kg of waterper kg of dry air. The aifferenceof 0.011 kd will appearas
condensalon.
i11 Check lhe crankcasepressure,or the crankcase flow-
rate(blew-by),

Caution! One of the most dangerousphenomenator a dieselengine is

the passageof gas (fuel+ air) into the crankcase.

9808 03-5
 03 Startinq,Stoppinq,Operationand cwl70

03.3.1Generalremarks
I No automaticmonitoring,and no testdevicescan substi-
tute for the eyesand ears of an experienceddieselengineer.

Caution! LOOKat and LISTENto the engine!

zl Runningthe engineat a loadof lessthan20%of the rated

powermust be avoid€dat all costs.
Whenthe enginehasbeenrunningin thisway,the loadmustbe in-
creasedgradually
beforethe engineis stopped.

Note: Gradualincreasein powefoveronehourin a seriesof stages.

03.4 Startingafter a long stoppage(morethan 24 hours)

-l!l check:
. the lubricating oil level,
o the coolingwaterlevelin the expansion tank,
. the coolingwaterinletto the heatexchangers,
. the fuel levelin the day tank,
. thatthecontrolsystem pumpracksmove
andtheinjection
freelv.
Z After starting, check that pressuresand temperaturesat-
tainnormalvalues.

03-6 9808
 cwl70 on and 03

- 03.5 Restartingafter servicing

l!, Checkthatthe connectionbetweenihe speed governor

pumpsis correctly
andthe injection set andcannotjam.
I a- Check that the linkages are properlylocked and that the
Iuel racksmovefreely.
!l Check the overspeedstoppagedevice.
[4, Ctrecf the ctearanceof the injectionpump racks:4 mm.

Caution! lf duringthe servicingthe iniectionpumps,the camshaftor its

control gear have been manipulated,the valvetiming must be
checkedagainon at leastone cylinderper camshaftsection.

[5 Checkthe coolingwatercircu:tfor leaks:

. the lowerareaolthocylinderliners(thismustbe checked
with the crankshaftoortsoDen).
. the oil cooler,
. the superchargingair cooler
Lq Checkand adiustvalveclearances. See Chap.06 for the
settings.
7 Eleedany air fromthe fuelcircuitif it hasbeenopened.
!q Startthe prelubricationpump
o Bleedthe air fromthe oil filters.
. Checkthat oil appearsat each lubricationnozzleand at
each bearingas well as at each pistonsprayand at the
rocKergear.
Lq Checkthat all the intemaland externalconnections
ot the
fluidcircuitsare leak-proof.

Note: Rotatethe crankshaftto draw oil to all the connectinorods and

to the valverockergear.

l0 Ragsor lools torgotteninsidethe cylinderblock, badly

tastenednuts or screws,or worn self-lockingnuts are liableto
causetotal failures.Cleanoil containersand oilways(sump,
camshafthousing)ext€ndsthe servicelifeof pumpsandfilters.
L11 See inslrucfionsin Chap.03.1et 03.4for starting.

9808 03-7
 03 I andStoraoe cwl70

03.6 Supervisionof operationafterservicing

1 j When first starting, withthe engineidlinglistencarelullytor
any unusualnoises,

Note: Speedmust be increasedgraduallywhile monitoringall pres-

sure and temperaturereadings.

p After running oft load at the rated speed for 1O minutes

stoptheengineandchecktorgas,coolingwater,tuelor oilleaks.
3 Checkthefu6l circuit caretully(injectionpumps, injec-
tors,fuellines,etc.).Thisis to be donewiththeprotective
covers
removeo.
4] After servicing involving the removalof one or morecon-
nectingrods,and/orone or more main bearings,checktheir
temperatureand clearanceafter removingthe relevantinspec-
tionDorts.

Nole : Checkthe amountof tuel comingfrom the iniectorline leak-ofl

pipes !

Caution! areparticularly
Thefollowinginslructions importantafterservi-
cing

E check :
. the temperatureand pressuregauges,
. the automalic alarmand stoppagedevices,
. thelall in pressureacrossfuelliltersand oil filters
. the sumpoil level,
. de-aeration fromthe coolingwatercircuit,
. the amountoI fuel leak-off,
. crankcasepressureand/orblew-by.

03-8 9808
 cwt70 inq, Stoppinq,Operationand 03

- 03.7 Running-in

iL After overhauling the cylinders and pistons (change of

pistonrings,liners,pistons)followthe programmeshownFig.
o3-2.

Caution! ll the programmecannotbe followed,run the enginetor at least

10 hours at lessthan full load.
Avoid running-inunderlow load at constantspeed.

Theenginemaybe run-inwithstandardlubricating for

oilspecified
the engine.
RODAGE
FUNNING-/N

z
o-
s
=
5
rll

*t

€ E E E E E E E E EE E E E E E E E E E E E € E EE E E E E E E E E E E E E E E E E E E E E E Z

DUREE
DURATION

Figure3-2

98(a G'-9
 03 Starti and cwl70

09.8 Longterm storage

Thistypeof pmtection is necessary
whentheengine:
. is not startedwithin3 monthsafterdelivery.
. is not usedfor morethan2 months.

03.8.1Storageprocedure.
Note: lf it is specifiedat the time of orderingthat the new enqineis to
be stored,the operationsare carriedout at the factory:

proceedas lollows:
Otherwise
T Drainthe coolingwaterand oil circuits(of the engine
and accessories)
3 Disconnectthe fuel circuit inlet and return lines and re-
placethe fuel with the protectiveproduct.Fillthe circuitcomple-
telyusinga manualboosterpump.
:q] Crank the engine with the starteror with ths crankinggear
pumpsare properly
so thatthe injection filled.
4] f:ltttre injectorswith the protectiveproductusinga tare
pump.
.51
Beforeretittingthe iniectorsspray storageproductinto
eachcylinderwitha compressed air gun.
d Spray the storage product throughthe inspectionportson
alloftheinternalparts oftheengine(connecting rods,crankshaft,
linerbottoms, etc.).
Z Spraythe productin all the coolingwaterand lub oilcircuit
openrngs,
rrrrrr-:rrrrrl-rrf
Caution! This operationis done with the bleed valves open, and the
circuitsare properlyprotectedwhenthe sprayexits abundanfly
throughthe bleedvalves.

1!] Pourfive litres of productintothe enginesump.The pro-

duct will evaporateto completethe protection.
El Then seal off alt openings so they are perfectlyair tight.
JOI The exhaust outlets must be blocked at the turbocharoer
outlets.The coolingwatercircuitmustbe pluggedat the pu-mp
inletsand at the outletsatterthe thermostats.

03-10 9808
cwl70 Startin and Sto 03

Caution! The enginemust not be turned over (cranked)afterthese ope-

rations.
This procedurewill protectthe enginefor 12 months.
Repeatthe long-te.m protection operations after this period.

03.8.2Restartingafter storage.
i 1 lRemovethe plugs.
tz Beconnectthecoolingwater,oilandfuelcircuits.
3. Check that the turbochargers rotatefreely.
i , 4 Check the injection pump racks movefreely.
Fill and bleedthe coolingwaterandfuel circuits.
'-
b Fill the oil sump.
:_,
Crankthe enginemanually
through2 revolutions.
8 . Connectthe startingsystem.
el Startup as shownin Chap.03.1onstarting.

9808 03-11
 cwl70 MaintenanceSchedule 04

04 Maintenance
Schedule

04.1 General
Themaintenanco necessary
tortheenginedepends
ontheopera-
tingconditions
inthemain..

Note : The periodsstated in this scheduleare guidancevalues only,

bul must not be exceededduringthe guaranteeperoid.

Beforeanystepsaretaken,carelullyreadthecorresponding
hem
in thismanual:
f lt att maintenancework, observethe utmost cleanliness
and order.
l2] aetoredismantling,checkthatall systemsconcerned are
drainedor the pressureis released.AIterdismantling, immedi-
atelycoverholesfor lubricatingoil, fuel oil and air with tape,
plugs,cleanclothor similar.
[- Whenexchanginga worn-outor damagedpart provided
with an identilication
markstatingcylinderor beraingnumb6r.
Everyexchangeshouldbe enteredin the enginelog and the
reasonshouldbe clearlystated.
f4l After reassembling, check that all screws and nuts are
tightenedand locked,it necessary.

Note : The schedulebelowis madefor the normalusing ofthe engine:

- Exhaustgas back pressure: 3 kPa.
- Fioulspecification: DMAet DMB(seeChap,02).
- Oil: only approvedoil
(s€e Chap.02).

9808 0+1
 04 Maintenance
Schedule cwl70

04.2 PowerPlantApplication
04.2.1Continuousgen6ratorset, 1500rpm

Continuouspowerratingis the availableoutputfor the conti-

nuouselectricitysupplyduringan unlimitednumberot hours
peryear,in betweenspecifiedmaintenanceintervalsandunder
specifiedambientconditions,Nooverloadavailable

Fuelspecifications ClassF-DMAand ClassF. D M B

Service coP
Output 'I15 kwcyl

Serviceconditionsaccordingto ISO8528

Caution! Theoil filtersreplacement

mustbe doneevery250hoursuntil
Technology DepaJtment
find a solutionto improvethe fiolters
operating time.

:' APPLICATION
POWERPLANT Using ol the engtne : Unllmlted- !!*)r gqsrh r32000h
:esde.. 10 iint " i2o 240
.;il, '.ii;iii'' .g&,t
500h
:

ibndi2000h
Every Every
't6000h 32000h
Cleantheenqine X X
Findoutleakaaesanddefects X X
Readall molorsDarametels X X
Checkcrankshaft
aliqnment X X X
pushrodsand
Checkcamshafts,
Geals X X X
Checkandadiustvalv€clealances X, X X X
Overheulof cvlinderHeads X X X
CheckTurbochargersbearing X
Engine clearances ixt
ReolaceTulbocharoers beadno X X
CheckCylinders (withanendoscope) .,x x X X
CheckConnectingrods,connecting
rodsbeadnq
Replace
line|s
o .i
X
X
Reolaceoistons .D
Replacepistonsrinos (x) X
Beplaceconnecting
rodbearings X X
Replacecrankshaft
bearings
and
thrustbearinos X
Beplacerubbercoupling
elements X

o+2 9808
 cw170 MaintenanceSchedule 04

APPLICATION
POWERPLANT Uslng ot the englne : t tod - lr.tsr ove.haull.lz OOO
h
Code I 20 60 240::.
Control& llaintenanc€
Operations Every ',Fu"ryEvery Rl6rys l€vely Evqiy
oevi:. 500h 1000h, 800 16000h:noo0l
Replaceringsandthrustb€aringfor
intermediate
shafis X
Replacecrankshaft
oaskels X
Remplace dngsandthrustbearing lor
camshafls X
onlylor ti6 Ikst splcmEd per!)d
Checklub-oillevel X X
Takeoilsampleloranalysis X axl X X X X
Replace lub-oilcadidges,checkleaf
valvecolmation @ X X x X
Replace
Lubri- Inspect
lub-oil
hoses andllexibles
an X X X X
lication X X
Replace hosesandllexibles X X
Replaceoil nozzles X
Replacelub-oilthemostatic
valves X X X
Replacelub-oilthemostalholders X
Cleancentrif
uoalfifter x^ x X X X X X
Checkoil pumpdrive X X X
Replaceoilpump X
Checkinjectionpumps X X
Checkdailytanklevel X X
Fuel Replacepre{iher X) X X X X
Fleplace
tuelcartridge X- X X X X
inlec- Emptvleakaqetanks X
i:on X
Checkinjectors X X
Replaceiniectors X X
Checkfuelpumpanddrive x X X
Replacetuelpump X
'f'Oily
x^ tor-thetirst specffieitietiod
Checkcoolingwaterelevel X X
Checkwaterlreatment X X
Coo- Replacethermostatic
valvesand
coolinqwater X X X
llng
sys" Reolacewalerthermostatholder X
lem Cleanluboilcooler X X X
Checkwaterpumpand drive X X
Beplacewaler pump X
CheckpipesandreDlace flexibles XX X X
Checkcleanness of akfilters X X
Air
Cleanairt ters As soonas colmation
signalappeaFor every1000h
ling Replaceairfilters Dependingonthenumberot cleaninoor every4000h
Cleanchargeaircooler X X X
Star. Checlstadingsyslem X X
ling Checkbatteries X X
device
Checkelectic connections X

9808 04-3
 04 Maintenance
Schedule cw170

APPTICATION
POWERPLANT t of the engine : Unllmlted- Maior oVe{q,rt : 32 O0Oh
de to 20 d a l .120 240
rE{ri:ryEtrlly Evqry Evqlv !very
day *6€k l 600h 20{lti. SHxl 16000h

Speed Checkqovemois oil level b x

con- Checkaovemo/sOear X X X X
trol govemoisgear
Replace
devi- X
Checkcommand linkaoe X X X
Replacegovemois oil X X X
Vibra- Takesampleforanalysis X X
tion
oam- Replace vibration
damperdevice X
per
Con-
trol Checksafetyandconlroldevices X X
device

04-4 9808
 cw170 MaintenanceSchedule 04

04.2.2Continuousgensels, 1800rpm
Fuelspecification ClassF-DMAand ClassF-DMB
Service coP
Output 130kwcyl
04.2.2.1
Descr:ption
:
Continuous powerratingis theavailableoutputtor a continuous
e-
lectricity numberof hoursperyear,in be-
supplyduringan unlimited
tweenspecified maintenance intervals
and underspecifiedambient
conditions.
No overloadavailable

Servic€conditionsaccordingto ISO8528

Caution! Theoil tiltersreplacement

mustbe doneevery250hoursuntil
Technology Depanmentfind a solutionto improvethe fiolters
operating time.

:r-ia:i :,1
.:..; Ciide 3..... @. zd
Group Control & Maint€nance
Operations Every Every Every Every
2000h6000h
,. . .- ..,:.)...,:..:
.. : ,:!J.c-l
..,9"Y:
Cleanthe enqine X X
Findoutleakaoesanddefects X X
Readall motorsparamelers X X
Checkcrankshaftalionment x^ X X X
Checkcamshatts, pushrodsand
Gearc X X X
Checkandadiustvalveclearances X X X X
Overheulof cvlinderHeads X X x
CheckTurbochargers
clearan@s
Engine ReplaceTu6ochargers
bearing

bearing
a X X
x
X
CheckCvlindels (whhanendoscooe) .x) X X X
CheckConnecting rods.connecting X x
rodsbeaino
Reolaceliners X X
Replacepistons X
Replacepistonsrings X X
Replaceconnecling rodbearings X X
Replacecrankshaftbearings
and X
thrustbearings
Bellacerubbercouplingelements X
Fleplace
.ingsandthrustbearing
for X
iniemediateshaits
Replacecrankshaflqaskels X

9808 o+5
 cw170 MaintenanceSchedule 04

rpplrc4ff ).
powERFrtxlitl
€0 6&' 12b 24 .Q.::.
----a
.'evlit
:: Every qdt €".w
Every;
r2000tf
500h '!ls! 2000h.
!e0q
Speed Checkqovemods oillevel X X
con- Checkqovemois qear X X X X
trol Replacegoverno/sqear
devi- X
ces Checkcommand linkaoe X X X
Replacegovernolsoil X X X X
Vibra- Takesampleforanalysis X X
tlon
dam" Replace vibration
damDer device
per X

Con-
trol Checksafetyandconlroldevices X X
device

9808 w7
 04 MaintenanceSchedule cw170

gensets,1500rpm or 1800rpm
04.2.3Emergency
Fuelspecilication ClassF-DMAand ClassF-Dl\,18
Service LTP
Oulput '130 kwcyl (1500tr/mn)
'150 kwcyl (1800tr/mn)
04.2.3.1 Description :
Limitedtimepoweris the maximumoutputavailable for a genset
on a maximumoperation of 500hoursperyear,including 300
hoursmaximumof continuous operation,
in betweenspecified
maintenance inlervalsandunderspecifiedambientconditions.

Serviceconditionsaccordingto ISO8528

Caution! Theoil filtersreplacement

mustbe doneevery250hoursuntil
Technology Department
find a solulionto improvethe tiolters
operatingtime.

6ibi'-iii
t€6as
tugb: 2 :g&, ..{0 120

Jl,rti, 'Every Every Every

q l year 2 16
v"113: .yearc
Cleantheenqine X X
Find out leakaqes and defects X X
ReadallmotorsparameteB X X
Checkcrankshatt
alionment x^ X X
Checkcamshafts,pushrodsand
Geals X X X
Checkandadiustvalveclearances X X X X
Overheulof cylinderHeads X X
CheckTubochargersbearing X X X
clearances
Engine ReplaceTulbocharqerc
beainq X X X
CheckCvlinders(withan endoscog€) X X X X
CheckConnecting rods,connecting
roclsbearinq X
Replacelaners X
Replacepistons X
Replacepistonsrjngs X
Replaceconnecting rodbeafilgs X
Replacecrankshaft beadngsand
thrustbeadnqs X
Replace rubbercouplinqelements X
Replace ringsandthrustbeadng{or
inlermedialeshatts X

04-8 9808
 cwl70 MaintenanceSchedule 04

,
Citde- 10 20'l 40' it r20
lr"rt'
' . 4
E-rt_ery
t6
.yeals t|csrs
Reolacecrankshaftqaskets X
Remplace dngsandthrustbeadngfor X
camshafts
:' ' 'x1" .OnlyTO il* specified perlod
Checklub-oillevel X X
Takeoilsamoleloranalvsis X X X X X X
Replace checkleaf
lub-oilcadridges, X X X X X
valvecolmalion
Replacelub-oil X X X X X
Lubri- Inspecthosesandflexibles X X
lication
Replacehosesandllexibles X X
Beolaceoil nozzles X
Reolacelub-oilthemostatic
vafues X X
Replacelub-oilthemostatholde|s X
Cleancenhituqal filter x^ X X X X X
Checkoilpumpdrive X X
Replaceoilpump
pumps
Checkinjection X X
Checkdailvtanklevel X X
X
Fuel ReDlace ore{ilter X X X X
oal& Replace fuelcartddqe X X X X X
iniec- Empty leakaqetanks X X
iion
Checkiniectors X X X
Replaceinjectors X X X
Checkluelpumpandd ve X X
Replacefuelpump X
tfirr lhe irals.pecif lCtllerlod
Checkcoolinowaterelevel x X
checkwatertrealment X X X X X X
Coo- Replacethermostalic valves and
coolinqwater
X X X
ling
sys- Replace holder
waterthemostat X
rem Cleanluboilcooler X X X
Checkwaterpumpanddive X X
Replace
wateroumo X
Checkpipesand replaceflexibles X X X
Checkcleanness
ot airfilte$ X X
Air
coo- Cleanairfilters As soonas cotmation
sionalaooears
or every1000h
ling Replaceairfifters Depending
ot htenumberofcleaning
orevery4000h X
Cleanchargeaircooler X X X X
Star- Checksiartingsystem Evervmonlh X
lir|g Checkbatleries x X
device
Checkelectricconnections X X X X X X

9808 0+9
 04 MaintenanceSchedule cw170

{rlyo, -
6 Ycrrs
Code :a ,1o..' 't20
Every
yeal., 16
years

Speed Checkoovemois oil level X X

Checkqovemo/sqear X X X
lrol ReDlaceoovemo/s qear X
devi-
ces Checkcommand linkaoe X X X
Replaceoovemo/s oil X X X X
Vibfa- Takesampleforanalysis X X
lion
dam- Reolacevibration damoer device X
pef
Con-
trol Checksaletyandcontroldevices X X X X X
device

04{0 9808
 cwl70 MaintenanceSchedule 04

.-
04.3 MarineApplication
04.3.1 duty & Continuouson-board
Sontinnous
04,3,1.1Propulsionengines,1600,1650or 1500rpm
Fuelspecification:. . . . . . . ClassF-DMAandClassF-DMB
Service
Load 100 "k
Running hours 100 "/"
Torque 75 "/"to 1OO"/" nominalsDeed
Output 122,5kWlcyl
Max.speed 1650rpm
I S OP M E 20,26bars

Auxilliaryengines,1500rpm
04.3.1.2
F u e ls p e c i f i c a t i o n : . . . . . . C l a s sF - D M Aa n dC l a s sF - D M B
Service :,..,..... Continuouson-boardgense
Load :,....... ............90%
R u n n i hn og u r s : . . . . . . . . ...........100%

Load : 100% for load impact recovery

Loadimpactrequirement
: . . . max 10 % speeddropfor 50 %

Output
Max.speed

Caution! Theoil filtersreplacementmustbe doneevery250hoursuntil

Technology Depariment
find a solutionto improvethe fiolters
operating time.

9808 o4-11
 04 MaintenanceSchedule cw170

Checkandadiuslvalveclearances
Ovefieulof cvlinder
Heads

Turbochargelsbearing
Engirre CheckCylinders
(wilhanendoscope)
CheckConneclingrods,connecting

Replace
rubbercoupling
olements

Bemplaceings andthrust
bearingfor
camshafts

Fleplacelub-oilcarlridges,
checkleaf
valvecolmation

Lubd-,
ficall6t

Replace
lub-oillhermostaticvalves
Replace
lub-oilihermostat
holders

Checkoilpumpdrive

0+12 9808
 cw170 Maintenance
Schedule 04

Uslnga tqqiqe : Unlimited - Maigt ovelhaul : 32 0OOh

Code i.:. 10 20 60a.ti 120 240.
coniit l Eve.y
&.6ry 6{.'v Every Eyery,Fvery 16000h
,:500h 1000h20001 a0ouh
!aY
ReDlaceinieclors x X X
Checkfuelpumpanddrive (D X X
Replaceluelpump X
xr :.,.i.4t, dnly tor lhe flrst sBq{iiliedperiod
Checkcoolinqwalerelevel X X
Checkwaterlreatment (x X
Coo- Replacethermostaticvalvesand X X X
ling coolingwater
sys- Replacewaterthermostatholder X
lem Cleanluboilcooler
.x) X X
Checkwaleroumo andddve X X X
Replacewaterpump X
CheckoiDesandreolace flexibles X X X X
Checkcleanness of airfilters X X
Ai.
coo- Cleanairfilters As soonas colmationsiqnalappearsor everv1000 h X
Iing Replace airfilters Dependinoonthenumberofcleanino or every4000h X
Cleanchargeaircooler r,lf X X
Star. Checkstadinqsystem X X
ti.|g Checkbatteries X X
device
Checkelectric connections X
Speed Checkoovemols oillevel X X
con- Checkoovemolsqear X X X X
trol Replacegoveanols gear
devi-
ces Checkcommandlinkaqe x X X
Reolaceqovemods oil X X X X
Vibra- Take6ampleforanalysis X X
tion
dam- Replace damperdevice
vibration X
pe.
Coa-
trol Checksaletyandcontroldevices X X
device
pumo
Speci- Checkseawater X X X
flc seawaterpump
ReDlace X
ma- Checkanode X X
rine
pars ReDlaceanode X X X X
Cloan waterexchanger
sea X X

9808 0+13
 04 Maintenance
Schedule cw170

04.3.t.3Propulsionengines,1800rpm
F u e sl p e c i f i c a t i o n: . . . . . . . C l a s sF - D M Aa n dC l a s sF - D M B
Service :........ . . . C o n t i n u od u st y
Load 100"/"
Running hours 1 0 0%
Torque 75 % to 100% nominalspeed
Output
lvlax.speed

04.3.1.4Auxilliaryengines,1800rpm
Fuelspecification : ClassF-DMAandClassF-DMB
Service on-boardgensets
Continuous
Load 90 "/"
Runninghours 1 0 0%

Load: 100% for load impactrecovery

Loadimpactrequirement: . . . max 10 % speeddropfor 50 %

suddenimpact
Output :. .. . . .. . . . . . . . . 1 3 0k w c y l
Max.speed

Caution! Theoil tiltersreplacement

mustbe doneevery250hoursuntil
Technology Department
find a solutionto improvethe fiolters
operating time,

.:,' Iue.trPPt.{CAfloN Uslnq.df:r Ilmited - Majoioverhaul | 24 000 h

10 20 . 120 .:2{O

Cleanlheenqine X
€i6ry Every. qvery
week 50oh:l 1000h wi Every
24000h

X
Findoutleakaqesanddefects X X
Read all motors parameteF X X
Checkcrankshaftaliqnment x^ X X X
Checkcamshafts,push rodsand
Gears x X X
Moteur Checkand adiustvalveclearances
X X X
Overheulof cvlinder
Heads X X X
CheckTr.rbochargers bearing
cEarances X X
ReplaceTurbochargels bearing X X X
(with
CheckCylinders anendoscope) X X X X
CheckConnecling rods,connecting
roosoeanno X X

0/'l4 9808
 cwl70 MaintenanceSchedule 04

MARINEAPPLICATION Udidlt the engine: Unli! f" fttajorqillihaur I i4 | n

cori6' t o ' 29. 120 240
Groyp
Fvery Every E!!€na:!veiy Elefv
weeK 500h trylr2000h 6tsth
Replaceliners X X
Replacepistons X
Reolaceoistonsdnos x X
Beplace rodbearinqs
conneclinq X X
Replacecrankshafi bearingsand
thruslbearinqs X
Replacerubbercouplangelements X
Replacedngsandthrusibea ngfor
interm€diate
shafts X
Reolacecrankshattoaskets X
Remplace dngsandthrustbearinglor
cam6hatts X
xx onlia*tlltre flrstspociti€d
i i
Checklub-oillevel X
Takeoilsample
foranalvsis X X X X X X
Replacelub-oilcadridges,checkleaf
valvecolmation x X X X X
Replace
lub-oil X X X X X
L!bil-
llcation lnsDecthosesandflexibles X X
Repiace hosesandllexibles X X X
Replace oilnozzles X
Reolace lub-oil valves
thermostatic X X X
ReDlace lub-oilthermostat
holdels X
Cleancenhifuqal{iher x^ X X X X X x
Checkoilpumpdrive X X X
ReDlaceoilDumD X
pumps
Checkiniection X X
CheckdaiMtank {evel X X
ReplacepreJilter X X X X X
Fuel
oil & Replacefuelcartridqe X X X X X
iniec- Emptyleakage tanks X X
tion
Checkinieclors X X
ReDlaceiniectors X X X
Checkfuelpump
andddve X X X
Replacefuelpump X
Only lor.the.lirat speclllediFieiiod
Check cooling watere level X x
checkwatertreatment X
Coo- Replace valvesand
thermostalic
coolinowater X X X
ling
sys_ Replacewalerthemostalholder X
tem Cleanluboi:cooler X X X
Checkwaterpump andddve X X X
Replacewaterpump X
Checkpipesandreplace flexibles X X X X

9808 04-15
 (M MaintenanceSchedule cw170

MARINE
A!f!l6fhoN mlted. Maiora :24O0Oh
.@de rl1 0. 20 '240
,20
'Ev€fy Everyi ...&!r't EveO& fo"rv Every
day ,weer 500h 2000nl 12000h
ry*n
Checkcleanness of airfilters X X
Air
coo- Cleanairfilters As soonas colmation
siqnalappearsor every1000h
ling Replaceairfihers Dependinqonthenumb€rot cleanirq or everv4000
Cleancharueakcooler X X X
Star- Check starling system X X
ling Checkbattedes X X
device
Checkelectdc
connections X
speed Checkoovemo/soillevel X X
con- Checkgovemo/sgear X X X X
t.ol Replaceqovemols qear
devi- X
ces Checkcommand linkaoe X X X
Replacegovemois oil X X X X
Vib.a- TakesamDlefor analvsis x X
tion
dam- Reolacevibrationdamoerdevice X
per
Con-
lrol Checksafetyandcontroldevices X X
device
Speci- Checksea waterpump X X X
lic Replaceseawaterpump X
ma- Checkanode
nn6 X X
pan6 Replace anode X X X X
Cleanseawaterexchanoer X X X

(X-16 9808
 cw170 MaintenanceSchedule 04

04.3.2Emergency
Gensets
04.3.2.1AuxiliaryEngines,1500rpm, 1800rpm
Fuel specification . ClassF-DMAandClassF-DMB
Service Emergency gensets
- Load 100%
Runninghours 10./.
- Load 8 0 % , 5 0 % o 0u '/.
Runninghours 30"/"

Charge: 110% for loadimpactrecovery

: . . . max l0 % speeddropfor 50 %
Loadimpactrequirement
suddenimpact
Output '130kwcyl (1500rpm)
150kwcyl (1800rpm)

Caution! The oil filters replacementmust b€ done every250 hours until

TechnologyDepartmenttind a solutionto improvethe fiolters
operatingtime.

usingot the englne: Unlimlted-

Maloroverhaul: every12years
't6le :', 2O 0.0: 120 24v'
' Conliol& Malntenance
Operations Evgrv Every
4 12
years years
Cleanthe enqine x X
Findoutleakaoes anddefecls X X
Readallmotorsparameterc X X
Checkcrankshaft aliqnmerf x^ X X
Checkcamshafis, pushrodsand X X X
Gearc
Checkandadiustvalveclearances X X X X X
Englne Ovelheul of cvlinderHeads X X
CheckTurbochargeN bearing X X X
clearances
Fleplace
Tubochargers bearing X X X
CheckCvlinders (wilhanendoscope) X X X X X
CheckConnecting rods,connecting X
rodsbearina
Replace liners X
Replacepistons X
Replacepistonsrings X
ReDlaceconnectinorod bearinos X

9808 o+17
 04 MainlenanceSchedule cw170

MARINE
APPLICATION 12
Code
a
'Every
.
Every ver Evglt
dav lrbek tt,
vei&:
Replacecrankshattbeadngsand
thrustbeadngs X
Beplace rubb€rcouplinqelements x
Replace ringsandthruslb€aringlor
intermedialeshafts X
Reolacecrankshattoaskets X
Remplace dngsandthrustbeadngfor
camshafts X
x Onlytor
Checklub-oillovel X X
Takeoilsamplefor analysis X X X X X X
Replacelub-oilcaiddges, checkleaf
valve colmation X X X X X
Replacelub-oil X X X X X
Lubri- lnsDecthoses andflexibles
fieatlon X X
R€olacehosesandllexibles X X
Replaceoil nozzles x
Replacelub-oilthernostatic
valves X X
Replacelub-oilthermostat
holders X
Cleanc€ntdluoal lilter x^ X X X X X
Checkoil oumDdfive X x
Replacedlpump X
pumps
Checkinjeclion X X
Checkdailvtanklevel X X
Fuel Reolace oreJilter X X X X x
oil & ReolaceJuelcarhidqe X X X X X
injec- Emptvleakaqetanks X X
tion
Checkinieclors X X X
Beplacein:ectors X X
Checktuelpumpanddrive X X
Replacetuelpump x
Ontyibi'the llrsr specifiedperiod
Checkcoolinqwaterelevel X
Checkwatertreatment x X X X X x
Coo- Replacethermostaticvalvesand x X X
ling coolinqwater
sys- Replacewaterlhemostalholder X
rem Cleanluboilcooler X X X
Checkwaterpumpanddrive X X
waterpump
Fleplace X
Checkpipesandreplace
flexibles X X X
Air
coo- Checkcleannesso( air liltels X X
ling
Cleanairlilters As soonas colmationsiqnalaDDears
or evev l0O0h

04-18 9808
 MARINE
APPLICATION

r':f: Code 5 . 10 x0 0 q . 1S 240

Grouit Ev..9ry. ..E'u:,'Y E!*. Eyery
.rst 4
,rl aay
{9nrh€ yd6ls v:i9
Replaceairfilters Depending
of lhe numberot cleaninO
or every,4000
h X
Cleancharqeaircooler X X X X
Star- Checkstadingsystem Everymonth X
ting Checkbatteries X X
device
Checkelectricconnoctions X X X X X X
speed Checkaovemolsoillevel X X
con- Checkgovemols gear X X X
trol Replaceqoverno/s qear
dev:- X
ces Checkcommand linkaoe X X X
Replaceqovernols oil X X X X
Vlbra- Takesampletor analvsis X X
tion
oam- Replace
vibralion
damgerdevice X
pel
Con-
trol Checksaletvandcontroldevic€s X X X X
device
Speci CheckseawaleroumD X X X
fic Replaceseawateroumo X
ma- Checkanode X
atne X X
pa.ts Replaceanode X X X
Cleanseawalerexchanoer X X X

9808 04-19
 I cw170 Maintenance
Tools

-
05Maintenance
Tools

05.1 General
Maintenance of a dieselenginerequiressomespecialtoolsdevelo-
pedin thecourseol enginedesign.Someof thesetoolsaresupplied
withtheengine,andothersareavaihbbthroughourservicestations
orlor directpurchaseby thecustomel
Tool requirements for a particularinstallation
may varygreatly,de-
pendingontheuseandservicearea.Standard toolsetsaretherefore
selectedto meetbasicreouirements.
Thislistpresentsa comprehensive selectionof toolsforthe CWl70
engrne.
Toolsetsaregroupedinordertofacilitate selection forspecitic
service
operations.Thismakesthejob of the end-usermucheasier.

05.1.1 Howto usethis list

.1 Readthe correspondingitem in this Manualbeforeany
maintenance
workis started.
e Checkwith tist belowthat all the maintenance tools are
available.
3 ] Check that necessarysparepartsandconsumablepartsare
available.

05.1.2 Orderingot maintenance

tools
1 Findlhe part(s)thatinterests you in the followingpages.
2 ] Selectthe tools or pads required.Notethat all the tools
arenotpanofthestandard Youcanusethepartnumber
delivery.
belowthe figurewhenordering.
3 Makea note ol the specificationsand other information
on yourorder.
4 Sendthe orderto yourlocalservicestation.Stateinslalla-
tionnameand enginenumber(s) whenordering.

9841 05-1
05.2 Hydraulictighteningtool (Chap.07)
Partll9_,- Description Ouantity

8 3 6 11 2 Cylinderheadhydraulic
tightening
tool. 1
t$,-;-l Fchd€l
rsmailbasIincluding:
I IIRRR
I Handpump. .............1
I I]HHH
I rc*i"*r q 2 v c y l i n d e r s t y p e M 3 .o. .. .. .. .. .. . . . . . 4
, a V B r a c e t y p e M 3 0 . . . . . . . . . . . . 4. . . . . . .
-&_=- F l e x i b l e p1i m
p ee t e r . . . . . . . . . . . . . . 3.
HtE_ F l e x i b l e p i p e 5 m e t e r . . . . . . . .1. . . . . . .
-=M3o Smallbag .... ........... 1
E= sx
t_l &ti*,
Box..... .... ........... 1

836 105 BracetypeM . .3. 0

. . . . . . . . . . . . . . . .2
M30 tor crankshaft
bearingcap

o5-2 9841
 L Ctv170 Maintenance
Tools 05 l

' os.s Cylinderliner(Chap.10)

PartNo Descriotion , Quantity

8 3 61 0 0 E x t r a c t i n g a n d i n s e r t i o n d e v i c e .I. . . . . .

o
,/

9841 05-3
1 0 5 Maintenance
Tools cwlzQl

05.4 Piston(Chap.11)
PartNo Descriotion QuantiW

843002 Clamp
d e v i c e f o r p i s troi nng s . . . . . . . . . 1

6L

843 004 r gp l i e r s
R e t a i nrei n ........1

oV-

843 003 P i s l o rni n gp l i e r s. .. . ...... t (-

oL

054 9841
 i cw170 Maintenance
Tools

\!
05.5 rod (Chap.11)
Connecting
PartNo Description QuantiW

8 3 611 8 Tightening
conrodscrewset
including:
Ratchetwrench
Torquewrench.
Longsocket

0s.6 Cylinderhead(Chap.12)
PartNo Description Quantitv

832 004 L i f t i n g t o o l f o r c y l i n d e r h e a d . . .1. . . . . . .

o(

9841 05-5
| 05 Maintenance
Tools cw170 !

P44N9 Description Quantity -

8 4 60 1 0 D i s m a n t l idnegv i c e f o r v a l v.e. .s. . . . . 1

ov
v

848 003 V a l v e c l e a r a n c e f e e l e r g.a. .u. g. .e. . 1

OK

056 984t
 -
I ew7o Maintenance
Tools 05"1

-' 05.7 Injectionequipment(Chap.16)

Eqrt No Description Quantity

86401 I T a d p u m p f o r i n j e c t o r s . . . . . . . .1. . . . . .
including:

8 6 40 1 2 Pressuregauge
8 6 40 1 0 pipefortadpump
Injection

806009 K e yf o rt i g t h ei n gn u t . . . . . .
with nolch

9841 05-7
 Maintenance
Tools cw170

quq'tlity

862 003 pumprackpositionning

Injeclion rod

05.8 Miscellaneous
tools
PartNo Description Ouantity

800 002 Specialhandtoolset . . . . . . . . . . . . . . . 1

803 011 M30studdriver. ..........1
820 003 180-900NmTorquewrench,,.......'
820 008 2 0 - 1 0N0 mT o r q uwe r e n c .h. . . . . . . . . 1
820 014 4 0 - 2 0N0 m T o r q u e w r e n. .c. h. . . . . . . 1
837001 N o z z l e h o l d e r r e m o v .a. l.t.o. .o. l. . . 1

(Chap.15)
05.9 Turbocharger
PartN" Descriotion
865 001 T u r b o c h atrogoelr. ...,.... 1
includingr
R e m o v saol c k e t ..........1
Screwdriversockel . . . . . . . . . . . . . . . . 1
M a l e l i f t i n g r i n g . . . . . . . . . . . . . . .1. . . . .

05{ 9841
06Adjustment,clearances
and wearlimits
06.1 Adiustment
06.1.1
Valvetiming

gtatic{ming,l"

Overlap

Fig. 06-1

9841 06-1
06 clearancesand wearlimits cwl70
06.1.2Otherset values
Valvecle.ga.Dle(cold engine)iMarquevaleurs
c_.0.4lnlet'
. u.6txnaust
MI Openingpressureof fuEliniectionvalve:
. 570
E Liftvalueof the iniectioncam.
. Valvetiming

Sl rio .,rtll@
'.'wb tvc
timinq balbie TDC afterTDC afbl€CD
'Ade
Av.statioue AOAav.PMH RFEap.Pl\4H. RFA,d!. PMB av.pt,tg utotsemenl
-12.5 22.5 35.5 36.5 60,5 58
24 34 62 58
-16 26 32 64 58

. Statictimingsetting:
- on cgln'1 (L6engine)
- oncgln'1 (LBengine)

ljii€c1ion
"'n?iit,.cam
1500 lom Genset 14' belore TDC 4 mm (+/-0,11)
1600/1650rpm Propulsion
'l 800 rDmGenset 16' BeforeTDC 4 mm (+/-0,11)

. Statictimingchecking:
- on cgl n"6 (L6engine)
- oncgln"8(L8engine)

Statictim:ng lnjeclioncam
liftt:du6.
1500 rDmGensel 14' before TOC 4 mm (+l- 0,271
1600/1650rpm Propulsion
1800rpmGenset 16' BeforeTDC 4 nm (+l- 0,271

06-2 9841
 CW170 Adiustment,clearanc€sand wear limits 06

and wearlimits(at 20"C)

06.2 Clearances

'
D€wingdimensiori
{mm)
Max. Min*
Ivainbearing
clearance (alsotlywheel
bearing) 0.159/0.258
Diameter 175.000 174.975
JOUmal Outofchculanty 0.030
Taper 0.020
N4ainbeaingshellthickness 5.690
Boreof mainbeadnghousing 186.546 186.500
Assembled beaingbore 175.233 175.159
Thrustbearing,
axialclearance 0.210/0.340
Thrustwasherthickness 10.880 10.860
10 Beadnobushclearance 0.142/O-234
Assembledcamshatt bearino
bushdiameter 154.203 154.142
Beadngbush,thickness 4.940 4.925
Camshafl Bearinghousing,bore 164.040 164.000
Thrustbearinghousing,bore 164.040 164.000
Assembledthrustbearingdiameter 144.140 144,206
Thrustbea.ingclearance 0.'t40t0.2s7
Thrustbearing,
aj)(ial
clerance 0.350/0.700
IOP
Diameter 170.040 17.000
Cylinder botlom
lrner OuI of cylindricityat TDC 0.020
Antipolishing ring,wallthickness 6.49 6.31
Bigendbearingclearance 0.186 0.106
Crankpin,diameter 146.000 145.975
Housingdiameler(bigend) 154,025 '154"000
Crankpin,parallelism 0.03/100
Bigend beanngshellthickness 3.940
Bigendboreovality 0.015
Asembledbearingbore (bigend) 1 4 6 . 1 6 1 146.106
pinbearingbushclearance
' 1 1 Gudgeon {smallend) 0.113 0.053
Gudgeonpin diameter 75.000 74.992
Smallendbore 84.984 84.962
Assembled bearingbore(smallend) 75.105 75.053
Connectrng (srnall
rodaxialclearance end) 0.200/0.s00
Smallendbearingbush,thickness 4.970 4.955
Clearancegudgeonpin- piston 0.028 0.008
Borediameterin piston 75.O20 75.008
Bigendbore 154.025 154.000
Axialclearance
of theclankshaft
oearwheel 0.480 0.160
Axialclearnace
of the camshafloearwheel 0.700 0.350

9841 06-3
06 Adiustment.clearancesand wear limits cwl70
.Drawingdimension
Palt, measuringpoint (mm) Wearlimil
(mml
Max. Min.
Pistonfing Compressionrinq1 4.990 4.965
height Compressionring2 4.990 4.965
clea€nce
It Oilscraperring 4.990
Pistoning GrooveI 5.170 5.150
grcove Groovell 5.080 5.060
heaght
Groovelll 5.060 5.040
Guidediameler assembled 11.992 12,O43
Stemdiameter exhausl 11.945 11.925
Stemdiameter iniake 1 1 . 9 6 0 11.940
Seatdevialion guide(max.value)
relative 0.'100
Exhauslval,
/e sealboreincylinder
head 56.019 56.000
lntake Outerbore 62.019 62.000
borern
cylinder tnneroore 54.800 54.200
neao
lnlet
'140.8' 140.3'
angle Exhausl 120.8' 120.3'
Inletvalve 140.5' 140.0'
Seaifor
Exhauslvalve 120.5" 120.0"
lntermedi clearance 0.188/0.100
e gearot
camshaft Axialclearaace 0.35/0.70
dnve
Bearinq diameterassembled 110.166 110.100
Beadng joumaldiameter 't10.000 109.988
Crankshaftgearwheeland large 0.340 o.220
Backlash qearwheel
intermediate
behveen: gearwheelandcamshaft
Smallintemedaile 0.340 0.220
gearwheel,
Crankshail assembled
:
6teelh 101.099 101.043

Base gearwheel
Largeintemediate :
6leelh 101.174 101.118
rangenr
lenghl: gearwheel
Smallintermediate
4leelh
Camshaftgearwheel
: 120-443 120.427
7 teeth

064 9841
cwl70 ustment.clearancesand wear limits 06
Drawing
dimension Normiii
(mml clearani:d Wearlimit
(mml
Max. Min. (mm)
Valvelappel,diameier
Guidediameter 40.039 40.000
Diameterclearance
Tappelrollerborediameler 20.o4'l 20-o20
14
Tappeipindiameler 20.000 19.979
Clearancerollerpin 0.041
Rockerarm botediameter 40.064 40.025
Shattleverrockerbracketiournaldiameter 40.000 39.984
Yokepindiameier 14.950 14.939
Yokeborediameter 15.018 15.000
Diamelerclearance 0.068/0.061
Nozzleneedlelitt 0.430 0.380 +0.03
o'4o.oz
oilpumpdiameterol
Lubricaling shaft 35.000 34.970
1 8 Axialclearance
Baselangentlengthover I teelh 69.486
Backlashbetlveenwaterpumpandcrankshaftgearwf'eel
19
Baselangentlenghtover7 teeth 60.500 60.453
21 Backlorslarlingmotordnve 1-2 1.0 1.14

9841 06-5
 cwl70 ninqtorqueand procedure 07

torqueand procedure
0TTightening
Nota : All externbalfastenerswill be lubricatedwith clean enoineoil
(SAE30/40) on threadsand underfaslenerhead.
All externalexhaust svstem fastenersincludinqturbocharqer -
turbinecasingfasteneisto be lubricatedwith Rd'colJl66.
All internalfastenerswill be installedwith loctite243on threads
and cleanengineoil underhead.
All studs will be installedwith loctite243.

07.1 Standardtorquevalue
07.1.1Standardtorquevaluesfor 8.8.10.9and 12.9
gradefastencirsin steel or casi iron

NiJtdndud Screw Nutonboft

Ihpaqi . Stud
,:.r,
ins€ti 8.8.9€q€.: !o.e 12.9 10.9 aJ9.s :.1o.s 12.9
'..tllade orad6 orade qrade 8.8grade ) orade oradeI
M5 I I I I 8
M6 3 I 13 16 I 13 16 9 13 16
M8 I 32 38 32 38 22 32 38
M10 11 44 75 44 44 64 75
M12 22 76 111 130 111 130 76 1't1 130
M14 44 121 178 209 121 178 209 't21 174 209
M16 64 189 278 325 189 278 325 189 278
M18 261 384 449 261 384 449 261 384 449
M20 121 370 544 370 5{4 370 544 637
M24 189 637 936 1095 637 936 1095 1095

Nota: Torquevaluesfor screwsand nutsarebasedon 75oloyieldstress

of the scr€wstud or bolt,
Stud installationtorquesare basedon 25 to 35%torque value
of an 8.8gradefustener.

9841 07- 1
 07 hteninqtorqueand Droc€dure cw170

07.1.2Standardtorquevaluestor 8.8.10.9and 12.9

gradefasten€irsin aluminium<!rbrass

t '*'[.0 "i." Nuton stud Itut anboh

8.8 qrade td9 qraae '12.9orade
M5 1 4 8
M6 2 7 I 13 't6
M8 4 18 18 22 32 38
Ml0 8 35 44 64
Ml2 61 61 76 1tl 130
t 14 22 97 121 178 209
MI6 44 151 151 189 278 325
u18 61 209 209 26'l 384 il49
!r20 54 296 296 370 544 637
M24 121 510 510 637 936 1095

Nota: Torquesvaluesfor screwsand nuts on studsare basedon 60%

yield stress of an 8.8 grade lastener.
Torquevaluesfor nuts and bolts are basedon 757"yield sttess
for the respectivegrade fastener.
Studinstallationtorquesarebasedon 15to 25%torquevalueof
an 8.8 grade fastener,

07- 2 9841
07.2 Engineblock

Fig.07n
07.2.1Cylinder head studs
Il ApplyRocolJ166to prevent
corrosion.
p figntenthe studsn"1 100Nm

07.2.2Main bearing studs

[1- Apply RocolJ166to prevenlcorrosion.

? Tightenthe studs n"2 100Nm.

9841 07- 3
07 hteninqtoroueand Drocedure cwl70

07.2.3Main bearingcap
07.2,3.1Assembly
a Cleanthe main bearingscrewsand theirholesin the en-
gineblock.
2 Cleanthe bearingsite, main bearingcap, bearing shells
and the crankshaftjournalvery carefully.
3 Removethe protectionfor the oil drillingsand lubricate
the crankshaftjournalwith cleanoil.
4 The bearinghalveshaveto be markedwiththe site num-
ber usingan electricpencilon theflywheelside.
5 Assemblethe upperbearingshellsin the engineblock.
6 Lubricatethe bearingface of the shellwithcleanlubrica-
tinooil.
Assemblethe crankshaftandthrustbearino.
q I Assemblethe lowerbearingshell into the main bearing
cap and lubricate
the bearingface.
9 ] Assemblethe caps into the engineblock,usingthe loca-
tingpinsto ensurecorrectorientation.
l0 Lubricatethe threads and the surface belowthe headfor
the sidescrewsn"3.Assemblethe screwsand assemblethem
by hand.
11] Lubricatethe nuts n'2 and assemblethem by hand.Un-
tiqhtenthema halfrevolulion.
l? Pre-tightenthe B side screwn'3 to 100Nm.
S ngnten the two nuts accordingto the hydrautictighte-
ningIor studsprocedure.
-141Tightenagainthe B side screwsto 350Nm.
151Tightenthe A side screwto 350Nm.
07.2.3.2Removal of one main bearing cap
1l Removethe two inspectionporl doors aroundthe maln
bearingto be removed.
2j Releasethe side screwsn"3 of the relevantmainbearing
andthoseof thetwo neighbouring
mainbearings.
3 Usethe hydraulictool to releasethe mainbearingnuts.
4] Removethe nuts.
5l Removethe main bearingcap and lowerhalfshell.

07-4 9841
 07.2.3,3Assembling of a single main bearing
l Cleanlhe half shells,main bearingcap and crankshaft
journalcarefully.
'2
Removethe protectorsfrom the crankshafloil hole and
thejournalwithcleanlubricating
lubricate oil.
jl Lubricatethe bearingtace of theuppershellwithcleanoil.
4l Fit the upperhalt shell into the engine.Fit the lowerhalf
shellintothe mainbearingcap.
q Fit the main bearingcap. Tightenthesidescrewsuntilfirm
contactis achievedand tightenthe mainbearingnutsby hand
untilth€ cap andthe engineblockare in contact.
IO_.fighten the B side screws(theoneofthedismantled main
bearingandthoseof the neighbouring mainbearing)to 100Nm.
I fignten ttre main bearingnuts accordingto the hydraulic
tighteningfor studsprocedure.
E Tightenthe B side screws(theoneof thedismantled main
bearingandthoseof theneighbouringmainbearing) to 350 Nm.
E Tighten the A side screws (theone of the dismantledmain
bearingandthoseof theneighbouringmainbearing) to 350 Nm.

9841 07- 5
07 ninq torqueand cw170

07.3 Damper

Fig. 07-2
07.3.1Assemblyol the sleeve
r1l Use oil SAE30/40on threadsand underbolthead.
ia Tightenthe nutsn"l on screwsn"2in twosteps:
.0to76Nm.
o 76 to 261 Nm.

07.3.2Assemblyof the damperon the sleeve

-!l Use oil SAE30/40on threadsand underbolthead.
2l Tightenthe screwsn"3 in two steps i
.0to76Nm
. 76 to 544 Nm.

07.3.3Assemblyot the gear

ILJ Use oil SAE30/40underbolt headand LOCTTTE
243 on
threads.
-l Tighten the screws n"4 in two steps :
.0to76Nm
. 76 to 278 Nm.

07-6 9841
 cwl70 hteninqtorqueand procedure 07

07.4 Flywheel

Fig. 07-3
07.4.1Assemblyof the sleeveon the crankshaft
Ll Blockthe crankshaftfrom turning.
E Clean the bore of the sleeve N'1 carefully. Lubricate it
withcleanluboil.Avoidtheuseol lubricant
madeof molybdenum
disulphideas l\,4OLYCOTE.
[t Cleanlhe both conicalsleevesN'2 caretully.Use MO-
LYCOTEBR2on thethreadsand underthe headof the screws
n'3. Fitthe conicalpartsontothe sleeve,Fitthe screwsn'3 into
the sleeven"1 andtightenthemby hand.
l4 Do not tightenthe screwsn"3 beforethe locationof the
assemblyontothe crankshaft.
[5 Shrinkthe locatingdowel pinn"4and screw the thrust
Dlaten"5 on the sleeve.
l6 Cleanihe nose of lhe crankshaftcarefullyandshrinkthe
locatingdowelpin n'6 intothe crankshaft.
[7 Fit the sleeveonto the crankshaft.Turnit in rightposition
and pushit stillfirmcontactis achieved.
E ldentity the starting screw. Tighten the screws n"3
clockwise
to 40 Nm.

9841 07-7
07 hteningtorqueand procedure cwt70

9l Tightenthe screwsn"3 clockwiseto 90 Nm. Beginthis

operationwiththe screwwhichis locatedat the oppositefromthe
startingscrew.
10] Tightenthe screwsn"3 clockwiseto 140Nm. Beginthis
operationwith the startingscrew.
d Tightenthe screwsn"3 clockwiseto 190Nm. Beginthis
operationwiththe screwwhichis locatedat the oppositefromthe
startingscrew.
121 Tighten tne screws n'3 clockwise to 240 Nm. Beginthis
operationwith the staningscrew.
:!!] Check the axial warping of the sleeve.The maximumac-
ceptablevalueis 0.15mm on a 420 mm diameter.

07.4.2Assemblyot the flywheelon the sleeve

j!l Useoil SAE40underscrew headand LOCTITE243 on
threads.
]4 T:ght the screws n'7 in two stages :
.0to76Nm
. 76 to 544 Nm.

07.4.3Dismantleof the sleeve

't Untighten
l the screws n'3 clockwise in severalstepsin or-
derto avoidthe jammingol the conicalsleeves.
2l Do not exit the screws from their threads in order to
avoidthe fallol a sleeve.
3j Hangthe sleeveby slings and extractit from the crank-
shaft.
4l Extractthe conicalsleevesfromthe mainsleeve.
5] Betorelo be fitted againthe sleevesmustbe controlled.
3 Lubricatethe conicalareaofthe sleeveswith grease
madeof molybdenum disulphideas MOLYKOTE G Rapid.
7l lf the conicalareaare nol damaged,they must be lubri-
catewithMOLYKOTE BR2only.

07-8 9841
 cwl70 Tighteninqtorqueand procedure 07

'
gear
07.5 Camshaftand intermediale

Fig.07-4
07.5.1Camshaltand liming gears
1 Use LOCTITE270 on the thread.
2 Tightenthe studs n'l to 60 Nm.
-3
Use oil SAE30/40on the thread.
4' Tigbtenthe nut n'2 in 2 slages:
.0to22Nm
. 22 to 130Nm.

07.5.2Camgearscrews
f-! Use oit SAE3O/40
on the threadand under the screw
head.
[Z Tightenthe screwn"3 in 2 stages:
.0to76Nm
. 76 to 650 Nm.

9841 07- 9
07 Tiqhteninqtorqueand procedure cwl70

gears
07.5.3Intermediate
'!j Use oil
SAE30/40
on the threadand under the screw
head.
2l Tightenthe screwn'4 in 2 stages:
.0to76Nm
. 76 to 650 Nm.

07-10 9841
 cwl70 hteninqtorqueand Drocedure 07

07.6 Rockerlever

Fig. 07-5
07.6.1Rockerleversupport
l!, Use oil SAE30/40on threadand underscrewhead.
E Tightenthe screwn"1to 120Nm.

07.6.2Crosshead
adiustingscrew
I Use oil SAE30/40on thread.
lZ Tightenthe nut n"2 to 40 Nm.

07.6.3Valveclearanceadiustingscrew
11 Use oil SAE30/40on thread.
2l Tightenthe nut n'3 to 60 Nm.

9841 07-11
 07 Tiohteninotoroueand orocedure cw170

07.7 Exhaust6ystem

Fig.07-6
07.7.1Exhaustmanifold
1i use ROCOLJ178on thread.
ti Tightenthe screwsn'1 to 50 Nm.

07.7.2Exhaustmanifoldsupport
_11Use oil SAE30/40on thread.
Z Tightenthe screwsn'2 to 130Nm.
ql Use ROCOLJ178on thread.
4l Tightenthe studs n'3 and lhe nutsn'4 to 1'11Nm.

07.7.3Exhaustoutlethousingsupport
jll Use FOCOI J178on thread.
Z T i g h t e nt h e s t u d sn ' 5 a n d t h en u t sn ' 6 t o 1 1 1N m .

07- 12 9841
 07 Tiqhteninqtoroueand orocedure cw170

07.8 Waterpumpgear

l!l Use oil SAE30/40on threads,underboltheadandon ring-

federassy.
2] tigtrten lightlyand alignhub.
E Tightenthe screwsin threestagesin diametrically
oppo-
sitesequence to 25 Nm.
?l Cheektight in samesequenceat 25 Nm untilall aretight.

07.9 Lub oil pumpgear

1 Use oil SAE30I40 on threads,underboltheadandon ring-

federassy.
'21
righten lightlyand alignhub.
3 Tighten the screws in three stages in diametricallyoppo-
silesequenceto 17 Nm.
4 Checktight in samesequenceat 17Nm untilall are tight.

07.10 Con rod

-!l Cleanthe bearingsite,cap andcon-rodverycarelully.

2] Use oil SAE3OW on threadand oil SAE 140 EP underthe
neao.
f Tight the screwsto 50 Nm tollowing
theligureabove.
'
41 Tightthe screwsto 120 Nm following
the figureabove.
s I ligtrt tne screws to 220 Nm followingthe figureabove.
.ql Checkthe right at 220 Nm.

o @
e @

Fig. 07-8

07-14 9841
 cw170 Ti ue and ute 07

07.11 Hydraulictighteningfor studs procedure

07.11.1
Tightening

ll Ensurethat the tooling is compressedto its normalwor-

kingheight(seevaluein thetable).
p Assembleeach nut onto its stud and put it manuallyin
contactwith the partto be tightened.
I C- tigtrten by hand (clockwise rotalion) the tool assem-
bly ontoeachstudof the component to be tightened
. 2 for mainbearingcap,
. 4 for cylinderhead.
l4 Connecttne nosesaccordingto the diagram.In case of
problem thetoolslightly(bylessthana turn).
of access,untighten
Ch.Fa! d€ p.lld M./D b€.rtng [ 5- Increasethe pressureto the 90 % value specified in the
table and tightenthe nuts with the pin until firm contactis
achievedagain.
L6 Releasethe pressureslowlyto zero.
l- Increasethe pressureto the 100 "/ovalue specified in
thetableandtightenall nutsagainwiththe pin untilfirmcontact
is achieved.

Caulion! lfany nutshavenotturned,thenthetighteningprocedureshould

be abandonedandthe partsdismantledto investigatethecause
and rectily before restarting at step l.

llqt Releasethe pressure slowly to zero.

9- Disconnectthe hoses,
.LOrUntighten the tools manually (counter clockwise rota-
tion).
11 With tooling apartfrom enginecomponents,reconnect
the hosesmakingsurethatthe hydraulicpressureis released,
compress toolingto its normalworkingheight.

9841 07-15
07 Tiohteninotoroueand Drocedure cw170

07.11.2
Untightening
T Ensurethat the tooling is comprcssedto its normalwor-
kingheight(seevaluein thetableabove).
2j tignten by handthe tools unlil contacton each stud ot
the componentto be untightened.
3 Loosenthe toofs by Y2loY4ol alurn.
_41Connectthe hosesaccord:ngto the diagram.
Nota: In case of problemof accessto the connector,untightenthe
tools slightly.(By less than a tum).

E Increasethe pressureto the valuespecifiedin the table.

jl Untightenthe nuts by approximatelyone revolution
(360') by rotatingcounterclockwisewith the pin.
7 Releasethe pressure slowly.
3 Disconnect hoses.
9l Untightenthe tools manually.
E With tooling apartfrom enginecomponents,reconnect
the hosesmakingsurethal the hydraulicpressureis released,
compress toolingto its normalworkingheight.

07.11.3Tableof value
Normat
I 'wofting
Studsize a
w% 1000/" height(mm)
Cylinder M30 16-00-278 785 870 119
head Rev G
Main bea- M30 16.00.280 875 970 107
rlng cap REvC

07-16 9841