Cc ea SPARE PART WARTSILA NOTICE servers. Varta Fran Oy 7 Engine section Engine type Ret Date tssue DocunentNo. Page 12 Cyinder heads w20 WS: 4-Nov-2008 01 2012P018 12) Valve rotators for WARTSILA® 20 and Auxpac 20 engines Engine type This bulletin concerns WARTSILA® 20 and Auxpac 20 engines. General ‘Two types of valve rotators are in use, see the illustrations below. The two rotators are interchangeable, but not the internal components, To avoid mixing of the components only complete rotators are available as spare parts. Version A Version B K-= Note! The spring plate 121 013 is no longer available as a spare part. Recommendation ‘When a valve rotator is opened for visual inspection the components should ot be mixed with ones from another rotator. Damaged valve rotators should be scrapped and replaced by a complete 4 new rotator. Ordering Contact your closest Wartsila Service Network. When ordering please specify the engine serial number and part number. ‘The part number for the rotators are 121 003 or 121 009, check the engine specific spare part catalogue for the part number to use. Letter distribution _—_Wartsila Service Network and owners/operators of engines concerned, Letter validity Until further notice. ° Warsi Find Oy P.O. B0x252 Torasanie 2) Teecop +358 10700 1847 Tol 358 107000000 Business 07737443 Serv von” Fit vaun: dap 38 9p a, Regiere ce: Vnsa scans ntusecimieese’ panel MMGEEN su dervomeam Servs, Toh FM20811 Tuy, Frias Toecop “e, ia ei iL all isa lial‘Serves, Warsi Fand Oy ‘Spare Parts Notice lssue Document. Page ‘ oF 2orarore 2) (© 2008 Wats Fniand Oy ~ Alright reserved No par of his publication may be reproduced or copied in any form or by ery means (electronic, mechanical graphic. chctocopyng. ‘recog, taping or ther infomation reteval systems) without the prior writen permission ofthe copyright hake. Wartsia Fiend Oy ‘makes no representation, waranty (express or pled) in his publeabon and assumes no responsi forthe coeciess, eros ‘mission for information contained herein. Information in this publication is subject e change without nosce Unioss otherwise exprossy sat fort, no recommendation contained inthis document is to be corstrued as provided due to a ‘etect in the engine, but merely as an improvement of the engine andlor the maintenance procedures relating thereto. Any actions by the ownerfoperator as a result of the recommendations are nol covered under any warrenty provided by WARSI and such actions will thus be atthe owners/operators own cost and expense.Cc Rae SERVICE WARTSILA LETTER Servces, Warts Finland Oy Engine section Engine ype Ret Dole sve Document No. Page 12 0yinder head w20 ws 10-2008 01 20125006 12 Upgrading of “short” centre sleeves in WARTSILA® 20 cylinder heads Engine type This bulletin concerns WARTSILA® 20 engines equipped with cylinder heads with a “short” centre sleeve, see the identification section below. ‘Concemed engines were manufactured before year 2000. General As a result of continuous development of the WARTSILA® 20 engines, the design of the centre sleeve has been modified in several steps. ‘The purpose of this bulletin is to replace the previous bulletins with one regarding upgrading or repairing the cylinder heads, Previous bulletins Following bulletins are replaced: = 20128008 Wartsila 20 cylinder head upgrading (dated 18.1.2000) = 2012X002 Important information for Wartsila 20 cylinder head upgrading (dated 28.9.2000). Original sieeve Repair sieeve Oversize sleeve 120.006 Type 01 Figure 1 Identification ~The first version of centre sleeve used in production engines is identified as “Type 01" in figure 1, (version number 120 006 004). This type was used in cylinder heads with a nozzle holder having a side (horizontal) mounted nozzle opening pressure adjusting screw. = The following version of centre sleeve used in production engines is identified as “Type 02" in figure 1, (version number 120 006 006). This type was used in cylinder heads with a’Kozzle holder having a top. mounted nozzle opening pressure adjusting screw. In unsure cases please contact your local Wartsila Service Office. Waris Fein Oy P.O, Bou 252 (ataajnie 2) Tencop +350 107001847 Te Serene Vaan Frnastot Vaasa Fmand ” Taacop. 25 1708 1380 Regard Oi: Vana waruaa Fuad Oy P.0.8x 80(Stueranats 48) Teeop. +388 107003279 Te. »386 10 7000000, Serene Tum F208 Tuy, Friand Tolecop. 388 19 700.010 ee a jServices, Wartsta Fintan Oy Sendce Leer Tssue —DocumantNo. Page | or zorzsoa 2) Upgrading 1. Cylinder heads equipped with a centre sleeve identified as “Type 01" or “Type 02" in figure 1 can be upgraded with a "Repair sleeve" 2. Cylinder heads equipped with a “Repair sleeve” can be upgraded with an “Oversize sleeve’ KS Note + When replacing a “Type 01 Original sleeve" with a “Repair sleeve, the injection nozzle (167 020) must be replaced with a different type. ‘+ The type of injection nozzle remains the same when replacing a "Type 02 Original sleeve" with a "Repair sleeve" or "Oversize sieeve" Recommendation \Wartsila recommends reconditioning all cylinder heads equipped with an “Original sleeve" at the earliest convenient opportunity, also the cylinder heads in the stock should be reconditioned Installing a repair or oversize sleeve requires machining of the cylinder head centre part with a special tool in a machining unit to ensure good surface quality. All upgradings are to be reported to the Product Company to ensure correct information in the spare part system. Ordering Contact your nearest Wartsila Service Office for offers and to coordinate the upgrading of the cylinder heads. When ordering please specify the engine serial number, type of cylinder head and quantity. Ask also for availabilty of replacement heads. Ref.type | Part number_| Version _ Description wa0 - Cylinder head without valves weo 120028 Cylinder head with valves w20 120001 Cylinder heed complete weo 167 020 066 _ Injection nozzle Reference Service Letter 20168005 Injection valve tightening procedure (dated 15.06.1999) Letter distribution _Wartsila Service Network and owners /operators of concemed engines. Letter validity Until further notice. (© 2008 Wrist Fniand Oy — Al rights reserved "No par of his pubicabon may be reprocuced or coped in any form or by any means (lecroni, mechanical. graphic. photocopying, recorang, tng or ob information retneval ystems) wahout the pie writen parmsson of te copyright older. Wartsla Fland Oy | ‘makes no represertaton, waranty (express or pled) n is publeaion and assumes ro responsibly the corectness, errs ‘mission fo inlermation contained here. Iriratin inthis publeaton is subject o change without notice | Unless othorwise expressly set fort, no recommendation contained inthis document i to be constued as provided due toa ‘merely az an improvement ofthe engine andor the maintenance procedures relating threto. Any actions Tesult ofthe recommendations are no! covered under any warranty provided by WANs ‘owners/operators own cost and expense.EET 12. Cylinder Head with Valves 12.1 Data and dimensions Material: cast grey ron tensile strength:250-300 N/mm? Weight: kg Combustion space design pres.: 200 bar - test pressure: 225 bor Water space = test pressure: 10 bor Operation temperature: ) -waterretum: 95°C 1. Bearing bracket 2. Rocker arm 3. Yoke for valves 4, Yoke for injection valve 5. Cylinder head 6. Rotocap 7. Screws for connection piece 8, Exhaust valve seat 9. Exhaust valve 10. Inlet valve 11. Inlet valve seat 12. Indicator valve rea General description The cylinder heads are cast of special quality grey iron. Each head includes two inlet valves, two exhaust valves, a centrally located injection valve and an indicator valve. The cylinder heads are individually tightened to the cylinder liner with four studs and hydraulically tightened nuts. A metallicgasket is sealing between the cylinder liner and the cylinder head. The combustion air and the exhaust gas channels are connected to a common multi-duet, which is connected to the cylinder head by six screws. The four screw and box-cone design is a traditional and wel proven design for cylinder heads. The benefits of four screws not only the ease of maintenance but it also allows the design of large and correctly designed channels for combustion air ani exhaust gases. In a heavy fuel engine the correct material peratures are a crucial factor to ensure long lifetime 1 components being in contact with combustion gases. Efficie cooling and a rigid design is best achieved with the “double d design in which the flame plate is relatively thin and the med cal load is transferred to the strong intermediate deck. The channels optimized to distribute the water flow evenly arouii valves and the centrally located fuel injector. The injection vaive is described in chapter 16. Cylinder head assemblyroan 12.1.1 Functions The flame plate of the cylinder head is a part of the combustion chamber. During the combustion, the flame plate is exposed to high pressures and high temperatures. Combustion air is led from the air receiver through the multiduct and the cylinder head inlet channel into the cylinder. The air flow is governed by two inlet valves in the flameplate. In a similar way, the exhaust gas is led from the cylinder through the cylinder head exhaust channel and the multiduct to the exhaust manifold. The gas flow is governed by two exhaust valves. ‘The multi-orifice injection valve, as well as injection valve — sleeve, is centrally mounted in the cylinder head. The injection valve sleeve holds the injection valve in position and separates the injection valve from the cooling water. Each cylinder head is individually cooled by a water flow enter- _——~ ing the cylinder head from the cylinder jacket through one single bore. There are drilled cooling passages to the exhaust valve seats. ‘The cooling water is collected to a single flow after passing the flame plate and the seat rings. The cooling water flows out from % the cylinder head direct to the multiduct. Any possible air or gas in the cooling water is vented from the top of the multiduct. The valve mechanism is lubricated from the lube oil system. The oil is led through a pipe from the valve tappet guide in the multihousing to the rocker arm bracket. All other flows in the cylinder head are through drillings. ‘The controlled leaks of the injection valve is returned through the protection pipe. ‘The fuel pipe is also provided with protection against hazardous leaks from the highypressure connection stud. Removing and mounting of the cylinder head > 12.2.1 Removing of the cylinder head EB Drain the cooling water. BD Open the indicator valves. Remove the caps of the cylinder head screws. Ei Remove the cylinder head cover. Tum the engine until both the inlet and exhaust valves are closed and remove the valve rocker arm bracket and the push rods. Remove the fastening screws of the multiduct.nec e kn! u Remove necessary pipes, the injection pipe, the fuel jeak pipe and lube oil pipes. Protect the connections of the injection pipe, oil pipe and exhaust pipes. ayn Pree Siren ty ha Put on the distance sleeves 861156 and hydraulic cylin- | Tighten cylinders by hand. lers 861159 and proceed with opening of cylinder head nuts. Ey Remove the cylinder head nuts. Apply the lifting tool 832004 and lift off the cylinder ead. _ HD Cover the cylinder opening with a piece of plywood or er something similar and apply the eaps to protect the screw ie Meco Serafin threads. 6. Open lear vaive, Lifting of cylinder head {832 004 Litting tool for cylinder head Fig 12-2 aonsecas 12.2.2 General maintenance of the cylinder head General maintenance of the cylinder head includes a thorough . visual check, including water cooling spaces. Possible scale for- mation in cooling spaces can disturb the cooling effect and there- fore it has to be cleaned, see chapter 02. Combustion spaces must be inspected carefully for possible wear, Valve seats and the injection valve sleeve should be in- spected for possible water leakage and replaced if necessary. ‘Valve guides should be checked and replaced if worn. O-rings must be replaced with new ones at very overhaul. Sealing surfaces between the cylinder head and cylinder liner should be inspected and reconditioned if necessary. WARTSILA 20wi FEASSEMBUNG, Sorow on evinces by han 2 Connect hanes. open vane Tigtton eyandoa by nana. 3. Close the vatve ond pune. ‘carfoct olgee 8 Spon the ware ond 12.2.3 Mounting of the cylinder head I Clean the sealing surfaces and put a new cylinder head gasket, new multiduct gasket and new O-rings for the cooling water jacket and push rod protecting pipe. BJ Lubricate the O-ring sealing surfaces with grease or oil. Apply the lifting tool 832004 to the cylinder head. El Lit on the cylinder head. Pay special attention to the multiduct gasket, that it is intact and correctly mounted. Screw on the cylinder head nuts. Put on the distance sleeves 861156, screw on the hy- uulic cylinders 861159 and proceed with tightening of cylin- der head nuts. Tightening in two steps is recommended. Connect the multiduct. Connect the pipes, the fuel leak pipe, lube oil pipes and fe injection pipe. Fit the push rod protecting pipes. Connect the injection pipe. 1D Fit the push rod and the rocker arm bracket. Adjust the valve clearance, see section 12.2.4. See pter 06. for clearances. Put on the cylinder head cover. Apply the protecting caps to the cylinder head serews. Before starting, fill the engine cooling water system. ‘urn the crankshaft two revolutions, with the indicator cocks open. 12.2.4 Adjusting valve clearance and yoke Tum the crankshatt to TDC at ignition for the cylinder concerned. ‘ Loosen the countemuts of the adjusting screws on the rocker arm (2) as well as on the yoke (4), and turn the adjusting screws in counter-clockwise direction to provide ample clear- ance. Press the fixed end of the yoke against the valve stem y pressing down the adjustable end»Screw down the adjusting screw (3) until it touches the valve end and note the position of the spanner (pos. a). Now press down the fixed end. Keep on screwing down while the yoke tilts, until the guide clearance is on the other sidb and the fixed end of the yoke starts lifting from the valve stem. Note the position of the spanner (b). WARTSILA 20Eero a 1. Adjusting screw for rocker arm 2. Counter nut 3. Adjusting screw for valve yoke 4. Counter nut =) Dy Meu Tur the adjusting screw counter-clockwise to the middle position between “a” and “b”, i.e. “c’, and lock the counter nut of the adjusting screw. Put a feeler gauge corresponding to the valve clearance jetween the surface of the yoke and the shoe at the rocker arm. Tighten the adjusting screw (1) until the feeler gauge can be moved to and fro only with slight force. Hold the adjusting screw and tighten the counter nut. Check that the clearance has not changed while tightening. Adjusting valve clearance WARTSILA 20Since kn Exhaust and inlet valves and seat rings 12 12.3 Data and dimensions Materia: High quailty ste! Diameter inlet valve: 73mm -exhaust valve: 66mm Valve seat ring Material: High qualty steel Angle inletseat; 20° -exhaust seat: 30° ‘A-Fastening screw 12.3.1 General description ‘The cylinder head has four valves fitted, two inlet valves and two exhaust valves. All the valves are made of surface-treated heat resistant steel. The inlet valves are bigger than the exhaust valves. ‘The valves move in cast iron guides, which are press fitted in the cylinder head and can be replaced. The valve guides have an O-ring (sealing against the valve stem), which is located at the top of the guide bore. The valves are provided with one valve spring per valve and valve rotating devices or valve spring retainers. Valve seat rings are fitted in the cylinder head for both inlet and exhaust valves. The exhaust valve seat rings are cooled and hence provided with two O-rings. 1 Dismantling valves Ey Fit the tool 846010 according to Fig 12-4. Compress the springs about 15-20 mm by the screw. Knock at the centre of the valve discs with a soft piece of wood, plastic hammer or similar, whereby the valve cotters come loose and can be removed. Unload the tool. Gd Spring retainers and springs can now be removed. Tool assembly for dismantling valves Fig 12-4 sonata 12-6 WARTSILA 20A. Inet valve B. Inlet valve (Exhaust valve D. Exhaust valve Mes 12 Note the marks of the valves or mark them according to 12 so they can be re-installed into the same guide if they are in good condition. Marking of valves Fig 12-5 aorasiara 12.3.3 Checking and reconditioning of valves and seats I Clean the valves, seats, ducts and guides as well as the underside of the cylinder head. Control the burning-off on the valve disc according to ig 12-6. The measure “Y” should be more than 4.5 mm (nomi- nal 5.5 mm) and measure “2” should be less than 2mm. If the measures exceed these limits the valve must be replaced. Control of burning-off on valveNote! Note! ire kee Er EJ Check the sealing faces of the valves and the sealing rings. For this purpose it is recommended to apply a thin layer of fine lapping compound to the valve seat and rub the valve slightly against the seat by hand a few times. If the sealing faces are bright or if there is a coherent sealing face, grinding is not recommended. If there is slight pitting, lapping only is recommended. If the pitting extends over nearly the entire sealing face or, if imperfect sealing is observed, the valve and the seat should be reground. If blow-by has occurred, the O-ring for the corresponding valve seat ring must be changed. Blow-by increases the temperature and the O-ring is “bumed”, which will result in water leakage into the cylinder. Before grinding, check the valve stem clearance. If the clearance is too largey'measure the stem and guide, and change the worn part; the valve guide can be pressed out. Check the bore in the cylinder head. When refitting, cooling in with liquid nitrogen is recommended, but pressing in with oil lubrication can also be accepted. After fitting in, check the guide bore and calibrate, if necessary. 12.3.4 Lapping If there are slight pits on the sealing faces they can be lapped by hand: Fit the turning tool to the valve. Apply a thin layer of lapping compound to the sealing surface of the valve; No.1 for coarse lapping, No.3 for fine lapping. Rotate the valve to and'fro towards the seat with the turning tool 841001. Lift the valve from the seat at intervals while lapping. o Remove the smallest possible amount of material e -cause the sealing faces have hardened during operation and are valuable. It is not necessary to grind off all pits. Clean the valve and seat carefully after lapping. ay 12.3.5 Machine grinding « Ifthere is deep pitting or other damage, the valve and seat should be ground by machine. The valve should be cooled by water during the grinding. 12-8 WARTSILA 20a Note! rome kee Seat face of the inlet valve: The seat angle of the inlet valve is 20° with a tolerance of + 0.25°. Minimum allowable edge thickness after grinding is 4.7 mm; after that, the valve must be replaced by a new one. A Seat face of the exhaust valve: The seat angle of the ex- ‘aust valve is 30° with a tolerance of 0°--0.50° to achieve contact to the seat ring at the periphery of the valve. Minimum allowable edge thickness after grinding is 5.2 mm; after that, the valve must be replaced by a new one. Seat ring for the inlet valve: The seat angle of the inlet valve seat ring is 20° with a tolerance of 0°- +0.25°. The seat can be ground until the outer seat diameter is 78 mm; after that, the ring must be replaced by a new one. Seat ring for the exhaust valve: The seat angle of the ex- ‘aust valve seat ring is 30° with a tolerance of 0°- +0.20°. The seat can be ground until the outer diameter is 67 mm; after that, the ring must be replaced by a new one. After grinding a light lapping is recommended to provide contact between valve and seat 12.3.6 Change of seat ring 12.3.6.1 Removal of the old ring ‘The exhaust seat ring can most conveniently be removed hydrau- lically by using tool 846050, which can be ordered from the engine manufacturer. In case the special tool is not available a scrapped valve can be used. Fit a scrapped valve to the seat and weld it to the seat y means of electric beam welding, Preferably the valve disc should be machined to a diameter 55-60 mm to get a better welding. Press or knock out the ting but be careful not to damage e valve guide, 12.3.6.2 Fitting a new inlet valve seat ring a Check the bore diameter in the cylinder head, see sec- 06.2. The ring can be assembled py freezing in with liquid ni- trogen of -190°C, the cylinder head temperature being min. 20°C, or by pressing in with a guided arbor. Check the eccentricity of the sealing face in relation to the valve guide, ‘and if it exceeds 0.1 mm, the seat surface must be ground in a seat grinding machine. WARTSILA 20Peer 12.3.6.3 Fitting a new exhaust valve seat ring a Clean the bore carefully with a grit 400 or finer emery loth. Check the bore diameter in the cylinder head, see sec- tion 06.2 in this manual. Cool the seat ring to -20 --25°C prior to fitting. Note that a temperature lower than -25°C may damage the O-rings at mounting. Heat up the entire cylinder head to 100°C by means of either steam heating, e.g. put the cylinder head into a closed box, or a gas burner. Note! It is important that the entire cylinder head is heated up, not only the seat bore. = Apply Loctite 290 to the bores in the cylinder head at ie sealing surfaces, . Gl Mount the sealing rings on the cooled valve seat. Mount the exhaust valve seat by using one of following methods: Put the seat rings into a guiding bush and press in the seat with a guided arbor. A special tool is also available. This tool can be ordered from the engine manufacturer. # Insert the seat ring by using an exhaust valve. Knock on the valve until the seat ring is correctly seated. Note! Mounting of a exhaust valve seat ring should be done carefully ‘so that the seat ring is correctly led. ~ i check the eccentricity of the sealing face in relation to the valve guide, and if it exceeds 0.1 mm, the seat surface should be ground in a seat grinding machine. 7 EJ Keep the cylinder head temperature at min. 20°C for six hours to harden the locking fluid if time is available. Pressure test the cylinder head water side before Mounting with a test pressure of 10 bar if possible. 12. Reassembling of the engine valves Check the valve springs for cracks, corrosion or wear marks, and if any, replace the springs by new ones. Ey Put new seal rings in the valve guides. Lubricate the valve stems with engine oil. 12-10 WARTSILA 20TR Put in the valves and check for free movement. Put on the springs and spring discs or rotators. Replace | the valve rotators if they are worn or damaged. | Compress the springs with the tool set. EZ Putin the vaive cotters and unload the springs. El check that the vaive cotters fit properly. 12.4 Indicator valve = 12.4.1 Operation and maintenance of the indicator valve ao The inside construction of the indicator valve is such that the pressure in the cylinder tightens it. Consequently the force needed to close the valve is relatively low. The valve has a left-handed screw and is opened and closed respectively as fol- lows, Fig 12-7. Use the T-handle wrench 808001 to open and close the indicator valve. El When starting the engine the indicator valves should be closed using only so weak a force that the sealing surfaces go together. The pressure of the cylinder will push them tightly together. When stopping the engine, the indicator valves should be opened only half a turn. Then the tightening caused by a temperature decrease cannot have an effect. Ey when opening the indicator valve for measuring the b cylinder pressure, tightening to open position by force must be — avoided. Gl when closing the indicator valve after measuring the cylinder pressure, only a weak torque is needed. A so called “finger torque” is usually enough. Eh Aad a high temperature lubricant (up to 100°C) to the valve stem threads when you feel that it is not moving easily. Use the right T-handle wrench to open and cae the indicator valve. - WARTSILA 20 12-11(STE mud Open and close indicator valve The cock moves u Aways use ne special ‘when closing clock wi handle when closing! : Fig 12-7 3212588095 12-12 WARTSILA 20