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Manual
F 240 CONTENTS

CHAPTER 0: GENERAL
0A PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--1
0B DOCUMENTATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--2
0C MANUAL SETUP/PAGE SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--3
1. Manual setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--3
2. Page setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--3
0D DESCRIPTION OF THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
1. Crankshaft and bedplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
2. Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
3. Cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
4. Piston with connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
5. Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
6. Camshaft and valve mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--5
7. Injection equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
8. Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
9. Turbocharging and charge air cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6
10.Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0--6

CHAPTER 1: OPERATION
1A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
1. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
3. Starting and stopping of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
4. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
5. Running--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
6. During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--1
7. After stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2
8. Long shut--downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1--2

CHAPTER 2: BACKGROUND INFORMATION


2A SAFETY ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
1. Safety aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
Risk of crankcase explosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
2. Maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
Last check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--2
2B CRANK DEGREES NINE CYLINDER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2. Reading crank position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--3
2C ENGINE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
2. Tool 9612 F 927 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--4
2D INDEX OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2--5

Ver. 01
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F 240 CONTENTS

CHAPTER 3: TECHNICAL DATA


3A MAIN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
1. Engine specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
2. Weights in kg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
3. Oil contents in liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
4. Cooling water in liters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--1
5. Cylinder numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
6. Combustion sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
7. Standard valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
8. Valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--2
9. Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
10. Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
11. Pump data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--3
3B TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
1. Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
2. Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
3. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--4
4. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
5. Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
6. Main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
7. Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
8. Engine/generator on foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--5
9. Assembly tie rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--6
3C NO GO CRITERIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
1. Piston (2--parts conf.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
2. Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
3. Main bearing (with mounted cylinder block) . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
4. Axial bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--8
5. Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
6. Camshaft drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
7. Valves (inlet and exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9
8. Lubricating oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3--9

CHAPTER 4: INJECTION AND MAINTENANCE


4A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
2. Daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--1
3. Weekly check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--2
4. Observation list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--3
4B INSPECTION AND MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 4--4
1. Maintenance interval/effective life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--4
2. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--4
3. Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--5
4. Weekly maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--6
5. 750--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--7
6. 1500--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--8
7. 3000--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--9
8. 6000--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--10
9. 12000--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--12
10. 24000--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--14
11. 36000--hours overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--16
4C TEST RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--18
1. Test running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--18
2. Running--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--18
3. Functional test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4--20

Ver. 01
xx -- 6
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F 240 CONTENTS

CHAPTER 5: FUEL SYSTEM


5A INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
2. Description of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
Fuel feed pump (01) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
Duplex fuel filter (02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
High pressure fuel pumps (03) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--1
Fuel injector (04) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
Pressure regulating valve (05) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
Leak--off fuel (103,104) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--2
3. Internal fuel system LFO/MDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--3
4. Internal fuel system HFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--4
5B FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
2. HFO requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--5
3. LFO/MDO requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--6
4. Fuel treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--7
5. Steps to avoid difficulties during operation on heavy fuel . . . . . . . . . . . . . 5--9
6. Comments on fuel characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--10
5C FUEL FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--13
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--13
2. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--14
3. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--14
5D INSPECTIONS, MOMENT OF INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--15
1. Tools .......................................................... 5--15
2. Fuel control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--16
3. Verification of moment of injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--17
4. Checking pre--lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--18
5E CONSTANT PRESSURE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--19
1. Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--19
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--19
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--19
2. Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5--19

CHAPTER 6: LUBRICATING OIL SYSTEM


6A INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
2. Description of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
Lubricating oil pump (1.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
Thermostatic three--way valve (1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
Safety overflow valve (1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
Pressure regulating valve (1.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--1
Main lubricating oil manifold (1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
Pre--lubricating pump (4.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
Needle valve (5.6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
Crankcase venting (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--2
6B LUBRICATING OIL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
2. Engine lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
3. Sub--suppliers manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--3
4. Testing engine lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
5. No go criteria for engine lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--4
6C LUBRICATING OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--5
2. Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--6
3. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--6
6D CENTRIFUGAL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
2. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7
3. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--7

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


1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--9
2. Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--9
6F BARRIER OIL SYSTEM HIGH PRESSURE FUEL PUMPS . . . . . . . . . . . . . . . . . . . 6--10
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--10
2. Checking the barrier oil system HP fuel pumps . . . . . . . . . . . . . . . . . . . . . . 6--10
6G INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--11
1. Lubricating oil overflow valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--11
6H LUBRICATING OIL THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--12
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--12
2. Inspection of the thermostatic wax elements . . . . . . . . . . . . . . . . . . . . . . . . 6--12
6J GENERAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6--13

CHAPTER 7: COOLING WATER SYSTEM


7A INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
2. Description of engine parts HT--circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
Cooling water pump (1.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
De--aeration points (1.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
Thermostatic 3--way valve (1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
Water cooler (1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
Cooling water expansion tank (1.7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
Emergency cooling (E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--1
3. Description engine parts LT--circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
Cooling water pump (2.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
Charge air cooler (2.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
Lube oil cooler (2.4) and water cooler (1.5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
Emergency cooling LT--circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--2
7B REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--3
1. Cooling water requirements, treatment and analysing . . . . . . . . . . . . . . . . 7--3
7C COOLING WATER DE--AERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--4
Checking and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--4
7D COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--5
1. Heat exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--5
2. Air cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--5
Insufficient cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--5
7E COOLING WATER THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--6
7F COOLING WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
1. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--7
2. Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--8
7G INSPECTION COOLING WATER SPACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--9
7H GENERAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7--10

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CHAPTER 8: AIR INLET AND EXHAUST SYSTEM


8A INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--1
2. Description of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--1
Inlet air filter (1.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--1
Turbocharger (1.2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--1
Air cooler (1.4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--2
Exhaust manifold (2.1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--2
8B COMBUSTION AIR REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--3
1. Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--3
Reference conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--3
2. Receiver pressure and exhaust gas temnperature . . . . . . . . . . . . . . . . . . . . 8--3
8C CHARGE AIR CONDENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--4
1. Checking discharge opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--4
2. Inspection discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--4
8D TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--5
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--5
2. Cleaning compressor side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--5
3. Cleaning of the air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--6
8E EXHAUST COMPENSATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7
1. Necessary tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7
2. Fitting of the compensator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--7
8F GENERAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8--8

CHAPTER 9: STARTING AND STOPPING SYSTEM


9A INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--1
2. Description of engine parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--1
Starting device (1.--) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--1
Stopping device (2.--) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--1
9B STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
1. Prior to starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
Cooling water system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
Start and stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
Alarm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
Lubricating oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
2. Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
3. Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--2
9C STARTING AIR DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--3
1. Replacing the driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--3
2. Checking the setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--3
3. Setting the distributor disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--4
9D GENERAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9--5

CHAPTER 10: ALARM AND SAFETY SYSTEM


10A DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--1
2. Speed measuring system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--1
3. Alarm and protection switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--3
4. Alarm and protection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--4
5. Co--signaling board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--5
10B TESTING THE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--6
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--6
2. Test, checks and calibrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--6
10C DIAGRAM RPM MEASURING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--8
10D DIAGRAM ALARM AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10--10

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CHAPTER 11: MAIN BEARINGS


11A NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--1
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--1
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--2
Tool C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--3
11B REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--4
11C REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11--5

CHAPTER 13: CYLINDER BLOCK


13A INTERNAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--1
1. Crankshaft space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--1
2. Cooling water spaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13--1

CHAPTER 14: EXPLOSION VALVE


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

CHAPTER 15: CYLINDER LINER


15A NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--1
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--1
15B INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--2
1. Endoscope inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--2
2. Inspection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--2
15C REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--3
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--3
15D FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15--4

CHAPTER 16: PISTON AND CONNECTING ROD


16A GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--1
1. Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--1
2. Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--1
16B NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--2
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--2
Item 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--2
Item 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--3
Item 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--3
Item 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--3
Item 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--3
Item 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--4
Item 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--4
Item 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--4
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--5
Tool C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--6
16C REMOVAL BIG END BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--7
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--7
Tool A+B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--7
16D FITTING BIG END BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--9
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--9
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--9
16E REMOVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--11
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--11
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--11
16F REMOVAL OF GUDGEON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--12
16G FITTING OF GUDGEON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--13

Ver. 01
xx -- 10
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F 240 CONTENTS

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


Tool C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--14
16J FITTING OF PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--15
Tool C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--15
16K FITTING PISTON AND CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--16
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--16
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16--17

CHAPTER 17: FUEL INJECTOR


17A NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--1
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--1
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--2
Tool C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--3
Tool D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--4
Tool E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--5
17B REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--6
Fuel injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--6
Removal procedure when injector sticks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--7
17C CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--8
1. Connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--8
2. Checking of the opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--8
3. Checking of the needle seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--8
4. Checking fuel jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--8
5. Test results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--9
17D DISASSEMBLY AND TESTING OF NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--10
1. Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--10
2. Nozzle inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--10
3. Sliding test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--10
4. Inspection of nozzle holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--10
17E ASSEMBLY OF NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--11
17F SETTING OPENING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--12
17G REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--13
Fitting of injector in cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17--13

CHAPTER 18: CYLINDER HEAD


18A NECESSARY TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--1
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--1
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--2
Tool C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--3
18B REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--4
Tool A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--4
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--4
18C FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--5
18D VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--6
1. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--6
2. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--6
3. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--6
18E VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--7
1. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--7
Tool B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--7
2. Inspecting the valve springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--7
3. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--8
18F ADJUSTMENT OF VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--9
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--9
2. Adjustment procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--9

Ver. 01
xx -- 11
Manual
F 240 CONTENTS

18G CYLINDER HEAD SAFETY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--11


1. Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--11
18H STARTING AIR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--12
1. Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--12
2. Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18--12

CHAPTER 19: CAMSHAFT


19A CHECKING VALVE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--1
Exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--1
Inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19--2

CHAPTER 20: GOVERNOR


20A GOVERNOR DRIVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--1
20B GOVERNOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
1. Compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
2. Compensation needle valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
3. Adjustment of the governor after overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
4. Speed droop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--2
20C INTERNAL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20--3

CHAPTER 22: VIBRATION DAMPER


22A SAMPLING OF VISCOUS LIQUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--1
2. Liquid sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22--1

CHAPTER 23: ENGINE ALIGNMENT


23A VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1
1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1
2. Verification of engine alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--1
3. Foundation bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--2
4. Flexible foundation elements (if fitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--2
5. Verification in height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--2
23B CRANKWEB DEFLECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--3
1. Crankweb deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--3
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--4
Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--4
2. Axial bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23--4

Ver. 01
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.0 0 / * 1 * - " =2 / * 1 * % % = 3 = / *
1 *0
- " = $ # %% $ 1 = 10

.0 .0 " = % / =
%/ A # $ / # % % = % $ 0
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / 2 3 / / *
%
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

! 0
) /
"
& " "

% $))/ 4
: 5 *) 7)

0 -0 / 1 * " = $ % / =/ = %= # /10

0 0 , / 7 "/ / 1 # / / / % 3 / # # 0
1 *

0 .0 " / 3 @5 " = / %/ $ / % / 3 0
1 *

0 0 / G / ) "/ / /
1 * 8" " = 3 % % / #
8 "/ *# % 1* 3 E 0

0 0 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 10

0 70 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / 2 3 / / *
%
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

! 0 9
) /
"
& " "

% < 6 .(
6;).0

0 -0 / 1 * " = $ % / =/ = %= # /10

0 0 , / 75 " = ? / 1 / /
1 * 7 "/ / 1 # / / / % 3 /
# #
* " / / ! 1#
" " / / $ 0

0 .0 " / 3 @5 " = / %/ $ / % / 3 0
1 *

0 0 / G / * "/ / /
1 * 8" " = 3 % % / #
8 "/ *# % 1* 3 E 0

0 0 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 10

0 70 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / 2 3 / / *
%
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

! 0 <
) /
"
& " "

9% D 6 .(
6;).0

70 -0 "1/ % %G -8 " = $ /$ / % %E 10
$ /$

70 0 / 1 * " = $ % / =/ = %= # /1
" #/ / / / * 0

70 .0 , / 75 " = ? / 1 / /
1 * ) " / / ! 1#
" " / / $
7 "/ / 1 # / / / % 3 / # # 0

70 0 " / 3 @5 " = / %/ $ / % / 3 0
1 *

70 0 / G / ) "/ / /
1 * 8" " = 3 % % / #
8 "/ *# % 1* 3 E 0

70 70 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 10

70 @0 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / 2 3 / / *
%
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

! 0
) /
"
& " "

<% D 6 .(
6;).0

@0 -0 "1/ % %G -8 " = $ /$ / % %E 10
$ /$

@0 0 / 1 * " = $ % / =/ = %= # /1
" 3 / / / *
-@ " = // CC/ %3 = 2 3 1
# $ /$
# % # /## $
. " = E * * / # *#0

@0 .0 , / 75 " = ? / 1 / /
1 * ) " / / ! 1#
" "/ % $ % / / $
7 "/ / 1 # / / / % 3 / # # 0

@0 0 " / 3 @ # * / 3 % 9
1 * + /
, / /
/
#/ 2 12 %
@5 " = / %/ $ / % / 3 0

@0 0 / G / ) "/ / /
1 * 8" " = 3 % % / #
8 "/ ; < *# % 1* 3 E 0

@0 70 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 10

@0 @0 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / 2 3 / / *
%
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

! 0 ?
) /
"
& " "

% 9D 6 .(
6;).0

80 -0 "1/ % %G - 5 # 1/ % / 1* % #
$ /$ G -8 # // $ /$ % $ /$ 1* % #
1/ % / -8 " = $ /$ / % %E 10

80 0 ) // - " = 3 = 6#/ $ /$
G # B" " = % $ %# * %
-.5 # = #
# $ % $ 0

80 .0 . " = % / % // # % %2 ##/
* / 2 / 6 / / * % % #/
##/ / = % # 61 // 1* =
* #
" = % / 6 / / * / 6 / #/
. " = / *
.5 ) = % / %* 6 / #/ 1 = 0

80 0 / 1 * " = $ % / =/ = %= # /1
" 3 / / / *
" = / # / # *#
-@ #/ 3 #/ % CC/ CC/ /% 2 = /
E %3 =
# $ /$
# % # /## $
" = E * * / # *#0

80 0 " * -B " = * 2 // 2 // /% %#$ $ //10

80 70 , / 75 " = ? / 1 / /
1 * 7 "/ / 1 # / / % 3 / # #
" "/ % $ % / /
7 " = 1 $ /$ % $ / 3 $ /$ %3 = % 0

80 @0 " / 3 @ # * / 3 % 9
1 * + /
, / /
/
#/ 2 12 %
@5 " = / %/ $ / % / 3 0

! 0
) /
"
& " "

6 *5 )2
9D 06 .(

80 80 / G / ' $ *#/ /1 / %2 # % % $ / %
1 * 1
# / / % 1* % #
) "/ / /
8" " = 3 % % / #
# / / % 1* % # % /
/ 2 10

80 B0 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 1
" = / // $ / 3 2 ##/ /
" / *# 3 %# 3 0

80 - 0 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / 2 3 / / *
%
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

80 --0 "
- " =$ //1 / * 1 * 3 % #*
- " =$ //1 / * 1 * 3 % #* %
/ /# ; 3 $ / # %<
- $ # % 1* = 1; * / # % 7 L<0

! 0
) /
"
& " "

?% D 6 .(
6;).0

B0 -0 "1/ % %G - 5 # 1/ % / 1* % #
$ /$ G -8 # // $ /$ % $ /$ 1* % #
1/ % / -8 * $ 1/ % % $ / # 1/ % %2 $ /$ %
$ /$
-8D * $ $ /$ $ / # 0

B0 0 % -7 * $ # 3 % $ / #
% -7 * $ % $ / #
-7 * $ % # $ / # % #
-7 # - # %* # $ 0

B0 .0 ) // - # // 6#/ $ /$ %3 = %
G # B" " = % $ %# * %
-. # = #
# $ % $
-- * $ * $ / #
" = 3 % % 6 1*
% #
" = 3 % %
-8 " = $ /$ / % %E 10

B0 0 . " = % / % // # % %2
* ##/ / 2 / 6 / / * % % #/
##/ / = % # 61 // 1* =
* #
" = % / 6 / / * / 6 / #/
. " = / *
.5 ) = % / %* 6 / #/ 1 = 0

B0 0 / 1 * -@ ' $ // / E $ / %
' $ # / # *# = % % / %
# % # /## $
" = / # / # *# % #/
# $ /$
" = $ % / =/ = %= # /1
" 3 / / / *
" = E * * / # *#0

B0 70 " * -B " = * 2 // 2 // /% %#$ $ //10

! 0
) /
"
& " "

6 *5 )2
D 06 .(

B0 @0 , / 7 #/ / /% # % 1 * 2 = ? / 1
1 * / /
" "/ % $ % / /
= *#/ $ % *# / % % $ 6 * %
7 "/ / 1 # / / % 3 / # #
7 " = 1 $ /$ % $ / 3 $ /$ %3 = % 0

B0 80 " / 3 $ / / 3 # *# '
1 * $ / / 3 # *# ,
@ # * / 3 % 9
+ /
, / /
#/ 2 12 %
@" " = % 0

B0 B0 / G / ' $ *#/ /1 $ / %
1 * @ $ / /
) 3 / / * /
8" " = 3 % % / # 0

B0 - 0 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 1
" = % % ##/ / 1
" = / // $ / 3 2 ##/ /
" =2 % 1 / 2 %E * *# 3 %
# 3 0

B0 --0 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
@5 " = / 3
" = 3 = # % * * $ //1
7" " = # % / / / % 3 /
/ * % %
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

B0 - 0 "
- " =$ //1 / * 1 * 3 % #*
- " =$ //1 / * 1 * 3 % #* %
/ /# ; 3 $ / # %<
- $ # % 1* = 1; * / # % 7 L<0

! 0
) /
"
& " "

% D 6 .(
6;).0

- 0 -0 "1/ % %G -8 $ / 1/ % %
$ /$ G # 1/ % / 3 1/ % / = % 1/ %
1/ % / %
) /
-8D # // $ /$
# %/ % = *

- 0 0 % -7 * $ // # 3 % $ / #
% -7 * $ // % $ / #
-7 * $ // % # $ / # % #
-7D #/ // # %* # $ 0

- 0 .0 ) // ' $ $ % $ $ / %
G # - # // 6#/ $ /$ %3 = %
" = % $ %# * %
-. # = #
-- * $ * : 6 / $ / #
-7 # $ //1 * % =# E /2 3 $
% * / %
" = 3 % % 6 1*
% #
" = 3 % % 0

- 0 0 . " = % / % // # % %2
* ##/ / 2 / 6 / / * % % #/
##/ / = % # 61 // 1* =
* #
" = % / 6 / / * / 6 / #/
. " = / *
.5 ) = % / %* 6 / #/ 1 = 0

- 0 0 / 1 * ' $ // # / # *# = % % / %
-@ ' $ // / E $ / %
' $ $ $ / %
# % // # /## $
" = / # / # *# % 3
" 3 / / / *
" = $ % / =/ = %= # /1
. 0" = / E * // / # *# 0

- 0 70 " * " = * 2 // 2 // /% %#$ $ //1


" = * 6 3 / % %
# // /% / 2 / % / // 1*
% * /1 // /% 0

! 0
) /
"
& " "

6 *5 )2
D 06 .(

- 0 @0 , / # 1 $ /$ % $ / 3 $ /$
1 * $ / / / # *#; <
7' " = 3 6 / * * $ /$ %3 = %
7 "/ / 1 # / / % 3 / # #
75 "/ /# %G / = % 3 / /
= *#/ $ % *# / % % $ 6 * %0

- 0 80 " / 3 $ / 3 # *# '
1 * $ / 3 # *# ,
$ / / / /
@ $ / 3 /
" = 3 6 / * * $ /$ %3 = %
@" " = % 0

- 0 B0 / G / @ $ / /
1 * ' $ *#/ /1 $ / %
* 3 / / * /
8" " = 3 % % / #
# 6 # # ;% 1 % / <0

- 0- 0 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 1
" = / // $ / 3 2 ##/ /
" =2 % 1 / 2 %E * *# 3 %
# 3 0

- 0 --0 " = % / =
%/ A # $ / # % % = % $
" = / %/ $ /
@5 " = / 3
" = 3 = # % * * $ //1
7" " = # % / / / % 3 /
/ * %
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

- 0- 0 " % /
- " =$ //1 / * 1 * 3 % #*
- " =$ //1 / * 1 * 3 % #* %
/ /# ; 3 $ / # %<
- $ # % 1* = 1; * / # % 7 L<0

! 0
) /
"
& " "

% 9D 6 .(
6;).0

--0 -0 "1/ % %G - 5 # // 1/ % / 1* % #
$ /$ G -8 * $ 1/ % % $ / # : # $ / ##
1/ % / 1/ % / 3 1/ % %2 $ /$ % $ /$
-8D * $ $ /$ $ / # 0

--0 0 % -7 * $ # 3 % $ / #
% -7 * $ % $ / # % # %
* % =# E /
-7 * $ % # $ / # % #
-7 # - # %* # $ 0

--0 .0 " * -B " = * 2 // 2 // /% %#$ $ //1


-B " = 6 / * %* 6 / #/ 1
-B " = *
# // /% / 2 / % / // 1 *
% * /1 // /% 0

--0 0 ) // - # // 6#/ $ /$ %3 = %
G # " = % $ %# * %
" = 3 * * % 1 ! "
-.5 # = #
-- #/ // * % 6 /
-. # 1/ % / =
" = 3 % % 6 % 3 // // %
//
" = 3 % %
" = * % 3 /
" = $ % $ % 3 //
-8' " = $ /$ / 10

--0 0 . " = % / % // # % %2
* ##/ / 2 / 6 / / * % % #/
# % # 61 // 1* = *
# 2 ##/ %
" = % / 6 / / * / 6 / #/ ; <
. " = / *
.5 ) = % / %* 6 / #/ 1 = 0

--0 70 / 1 * -@ ' $ // / E $ /% %
' $ # / # *# = % % / %
" = E * * # / # *#
# % # /## $
" = / # - # / # *#2 #/
# $ /$
3 #$ # % // / = %/ = 3
$ % / =
" 3 / / / * 0

! 0 9
) /
"
& " "

6 *5 )2
9D 06 .(

--0 @0 , / 7 #/ / /% # % 1 * 2 = ? / 1
1 * / /
5 "/ % $ % / /
= *#/ $ % *# / % % $ 6 * %
7' " = 3 6 / * * $ /$ %3 = %
7 "/ / 1 # / / % 3 / # #
" = 1 $ /$ % $ / 3 $ /$ %3 = % 0

--0 80 " / 3 $ /
# *# 3 '
1 * $ /
# *# 3 ,
@ # $ /$ / / / / 3 % % #/ 2
12 %
" = 3 6 / * * $ /$ %3 = %
@" " = %
@5 " =/ $ / % / 3 0

--0 B0 / G / ' $ *#/ /1 $ / %


1 * @ $ / /
) 3 / / * /
8" " = 3 % % / #
# 6 ## ;% 1 % / <0

--0 - 0 / * 1 * - " = / * 1 * % % = 3 = / * 1 *
- " = $ # %% $ 1 = 1
" = % % ##/ / 1
" =2 ##/ %2 / // $ / 3
" =2 % 1 / 2 %E * *# 3 %
# 3 0

--0 --0 " = % / =


%/ A # $ / # % % = % $
" = / %/ $ /
" = 3 = # % * * $ //1
7" " = # % / / / % 3 /
/ * %
1 *# %3 % * % 1 =
3 % * /
3 % * / 3 # ## % $ 0

--0 - 0 " % /
- " = # #* $ //1
- " =$ //1 / * 1 * 3 % #* %
/ /# ; 3 $ / # %<
- $ # % 1* = 1; * / # % 7 L<0

! 0 <
) /
"
#

% )(* . 5 , * %G # 3 = # 2 # % *
// 3 %0
% 1 %/ * 60 * . L
#*0

// 3 # $ % % % 0
** % /1 # = 9
6 // =
1 % $ 2 9# 2 *# %/ $ / 0
* 60 * 2 * $ = $ ; # $
** % /1 #<0
" 1 # = # % % -. 0

% 5 , 5 /3 1 1 #/ * # 2 %
1/ % / 2# /1 / * //1 % 0

* % # %G/ % * # % 1/ %
/ / %% 3 # ** 9
# # # ** # # / # 3
6 % # # // ; # # / # 3 %E / # # // <0
# 5 # # ** # 0

# # ** 9
/ % % //1 %
$ 1# % 3 3 / % # 2 #
* $ 1 * // /
# / % / % * * */ % % # %
$ % %0
0 -0 .5 *56 ( 5 *0) +.6,. ::)
3 // /3 1 # / // 3 6 /1 # ** 0
% # % // 2 ##/ % # / 1 #
% % # 0
** % % *#/ # **
## #3 3 / %# $ / $ # %0

0 0 (+)7*56 ( *6 3) 7 ..5)2 6 * 2 .5 , . 5 , 5
" 1 # #
##/ / 0 # 1/ % / * # %2 %
% - 50 # # / # * % / %
#8 % # / % # - % B0

! 0 -
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#

+ *56 *6 15, .) % 2 .)76::) 2)2 *5:)

H % // % 2 0* * *
H 2@ 0 -
H 2 0 2
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3 7 3
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#. +0 # ** # % 1/ % / 0 ".6+ (56 9

JKL
-
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9

0 -0 0 .0 0 0 70 @0 80 B0 - 0 --0 - 0 -.0 - 0 * J0.%L


IIIIIIII H #
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#. +0 & # ** # % 1/ % / 0 #) ). *6. 6+). *56 9

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IIIIIIII H #

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% - 7*56 *)(* * / % / %G
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/ 9

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! 0 -
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION

1. General Good performance of a diesel engine greatly depends on the correct timing, correct
quality and quantity of the fuel and good atomisation of the fuel injection.

2. Description of This paragraph is a general description of the function of engine parts in the fuel
engine parts system.

The main parts of the fuel system are given in the general diagram (Fig. 5--2 and 5--3).
These main parts have a number, which corresponds to the number in the diagram.
This number is placed between brackets in the description below.

Fuel feed pump For LFO/MDO operation only, the fuel system is equipped with an engine driven fuel
(01) feed pump, which is fed from the day tank (starting tank), placed approximately 2m
above the top of the engine.
The fuel flows via the fuel fine filter and main fuel feed line to the high pressure fuel
pumps. The high pressure fuel pumps supply the fuel to the nozzles.
For a good filling and cooling of the high pressure fuel pump the capacity of the fuel
feed pump is approximately 4x higher than the full load consumption of the engine.
The surplus fuel flows from the high pressure fuel pumps into the return line to the day
tanks (starting tank).
The amount of heat collected by the fuel during passage through the high pressure fuel
pump must be dissipated by the return piping and the tank.

Duplex fuel filter The duplex fuel filter serves to remove impurities from the fuel, so that they cannot
(02) enter the fuel system, and inflict damage on the high pressure fuel pumps or the nozz-
les. The fuel filter consists of two compartments, each fitted with a filter element, which
can be removed (also with the engine in operation).
The LFO/MDO filter elements have to be replaced periodically.
The HFO filter elements have to be cleaned and replaced periodically.
The filter elements can be removed separately, during operation.

High pressure The high pressure fuel pump pumps the fuel via the high pressure fuel line and the fuel
fuel pumps injector into the cylinder.
(03)
All fuel pumps have been calibrated accurately and provided with a sealed stop on the
fuel rack. The purpose of this stop is to limit the engine output. If this seal is broken
during the guarantee period, this may have as consequence, invalidation of the
guarantee!

Ver. 4--13154--56--57--58--59 5 -- 1
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION

Fuel Injector The main components of the fuel injector are:


(04) -- nozzle holder (1);
-- nozzle (2).

The nozzles are of the ”multihole type” and actuated


by the fuel pressure.

For maintenance, testing and adjusting of the


opening pressure, see chapter 17.

FIG. 5--1

Pressure For LFO/MDO operation only, a pressure regulating valve is placed at the end of the
regulating valve main fuel line to keep the fuel pressure constant.
(05)

Leak--off fuel The leak--off fuel coming from the nozzles and fuel pumps is drained to the clean
(103,104) leak–off fuel tank. The quantity mainly depends on the number of service hours of the
nozzle, but the quantity of the leak--off fuel is not indicative of the quality of the nozzles.
This fuel can be supplied to the day tank without treatment.

Fuel leakage from renewal of the fuel filter elements will be collected via drains and
has to be stored in a dirty--oil tank.

Ver. 4--13154--56--57--58--59 5 -- 2
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION

3. Internal fuel
system
LFO/MDO

System components Pipe connections


01 Fuel feed pump 101 Fuel inlet
02 Duplex filter 102 Fuel return
03 Injection pump 103 Clean fuel leakage outlet
04 Fuel injector HP--fuel injection pump
05 Pressure regulating valve Fuel injector
103A Leak fuel, HP fuel pipes
104 Dirty fuel leakage outlet
105 Fuel inlet from starting tank

FIG. 5--2

Ver. 4--13154--56--57--58--59 5 -- 3
Manual
F 240 FUEL SYSTEM
5A INTRODUCTION

4. Internal fuel
system HFO

System components Pipe connections


02 Duplex protection filter 101 Fuel inlet
03 Injection pump 102 Fuel return
04 Fuel injector 103 Clean fuel leakage outlet
HP--fuel injection pump
Fuel injector
103A Leak fuel, HP fuel pipes
104 Dirty fuel leakage outlet
151 Fuel injector cooling inlet
152 Fuel injector cooling return

FIG. 5--3

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

Ver. 4--13154--56--57--58--59 5 -- 4
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

1. General The engine is built for continuous operation on heavy fuel oil (HFO) and will operate
satisfactorily on Marine Diesel Oil and Light Fuel Oil (MDO and LFO). Avoid the use
of fuels having a lower viscosity than about 2.0 mm2/s at 40 °C as such fuels may cause
fuel injection pump plunger or fuel nozzle needle seizure.

2. HFO
requirements 2. 1. HFO bunker requirements.

HFO bunker requirements


Viscosity at 50 °C max. [mm2/s] (cSt) 180
Density at 15 °C max. [kg/m3] 980
Water content max. [% volume] 1.0
Sulphur content max. [% mass] 1.0
Ash content max. [% mass] 0.04
Vanadium content max. [mg/kg] 100
Sodium content max. [mg/kg] 30
Conrad carbon max. [% mass] 10
Asphaltenes max. [% mass] 5
Flash point min. [°C] 65
Pour point max. [°C] 21
Aluminium + Silicon max. [mg/kg] 30
Total sediment potential max. [% mass] 0.10
CCAI max. 850

2. 2. HFO requirements on the engine.

The fuel, supplied to the engine, must be conditioned:


-- centrifugal separated on water and dirt
-- filtered
-- heated to obtain the correct viscosity.

Engine requirements HFO


Fuel viscosity before the
H.P. fuel pumps [mm2/s] 16 -- 24
Max. fuel temperature 120
Water content after separation
maximum [% volume] 0.1
Fineness filter [µm] 10

Ver. 4--13154--56--57--58--59
5 -- 5
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

3. LFO/MDO
requirements 3. 1. LFO/MDO bunker requirements.

LFO MDO
Viscosity at 40 °C max. [mm2/s] 6 11
Water content max. [%volume] -- 0.3
Sulphur content max. [% mass] 1.5 2.0
Ash content max. [% mass] 0.01 0.01
Sediment by extraction max. [% mass] -- 0.07
Cetane number min. 40 35
Carbon content (acc. to
Ramsbottom) max. [%] 0.2 0.3
Flash point min. [°C] 60 60
Pour point
-- Summer max. [°C] 0 6
-- Winter max. [°C] -- 6 0

It is possible that some fuels contain paraffin, which at a temperature below 50 °C


solidify. The fuel filter can become clogged with these particles within a very short
period of time. The best solution for this problem is to heat up the fuel to minimum
50 °C, so that the paraffin are dissolved.
The main characteristics of the fuel above also correspond to the
demands of:
-- CIMAC:1990, DX, DA and DB
-- ISO 8217, F--DMX, DMA and DMB
-- BSMA 100: 1989 class M2.

3. 2. LFO/MDO requirements on the engine

The fuel, supplied to the engine, must be conditioned:


-- centrifugal separated on water and dirt
-- filtered
-- cooled to remain below 50 °C.

LFO MDO
Water content max. [% vol] -- 0.2
Fineness filter back flushing filter [µm] 10 10
Fuel temperature max. [°C] 50 50

Ver. 4--13154--56--57--58--59
5 -- 6
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

4. Fuel treatment

Heating
Keep the HFO temperature about 10 °C above the minimum storage temperature
indicated in the diagram to eliminate the risk of paraffin formation.

centi Stokes

FIG. 5--4

When converting viscosities from one of the units on the abscissa to centistokes
(=mm 2/s) or vice--versa, keep in mind that the result obtained is valid only at one and
the same temperature. When converting the viscosity in any unit at a given
temperature to a viscosity at another temperature a viscosity--temperature diagram or
conversion rule must be used.

Ver. 4--13154--56--57--58--59
5 -- 7
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

Sufficient heating capacity is needed to make centrifuging at recommended levels


possible. It is important that the temperature fluctuations are as minimal as possible
(2 °C before centrifuge) when centrifuging high viscosity fuels with densities
approaching or exceeding 0.991 g/ml at 15 °C.

mm2/s

FIG. 5--5

Example: A fuel oil with a viscosity of 380 mm 2/s (A) at 50 °C (B) or 80 °C (C) must be
preheated up till 115--130 °C (D--E) before entering the fuel injection pumps, up till
98 °C (F) at the centrifuge and till minimum 40 °C (G) in storage tanks. The fuel oil is
not transferable below 36 °C (H).

To obtain temperatures for intermediate viscosities, draw a line from the known
viscosity/temperature point in parallel to the nearest viscosity / temperature line in
diagram.

Example: Known viscosity 60 mm 2/s at 50 °C. The following can be read along the
dotted line: viscosity at 80 °C = 20 mm 2/s, temperature at fuel injection pumps
74--87 °C, centrifuging temperature 86 °C, minimum storage tank temperature 28 °C.

Conversion from various current and obsolete viscosity units to centi Stokes can be
made in the diagram, Fig. 5--5. The diagram should be used only for conversion of
viscosities at the same temperature. The same temperatures should then be used
when entering the viscosity / temperature point into the diagram.

Ver. 4--13154--56--57--58--59
5 -- 8
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

Purification
Heavy fuel (residuals, and mixtures of residuals and distillate) must be purified in an
efficient working centrifuge before entering the day tank. The fuel is to be heated
before centrifuging.
Recommended temperatures, depending on the fuel viscosity, are stated in the
diagram, see fig. 5--5.
Be sure that the correct gravity disc is used. Never exceed the flow rates
recommended for the centrifuge for the grade of fuel in use. The lower the flow rate
the better the purification efficiency.

Recommended centrifuge flow rate


Viscosity at 100 °C [mm2/s] -- 10 15 25 35 45 55
Viscosity at 50 °C [mm2/s] 12 50 90 205 350 530 730
Centrifuge flow
[% of rated capacity] 100 60 40 30 25 20 15

Sufficient separating capacity is required. The best and most disturbance--free results
are obtained with purifier and clarifier in series. Alternatively the main and stand--by
separators may run in parallel, but this makes heavier demands on correct gravity disc
choice and constant flow and temperature control to achieve optimum results. Flow
rate through the centrifuges should not exceed the maximum fuel consumption by
more than 10%.
In case pure distillate fuel is used, centrifuging is recommended as fuel may be
contaminated in storage tanks. The full rated capacity of the centrifuge may be used
provided the fuel viscosity is less than 12 mm2/s at centrifuging temperature. Marine
Gas Oil viscosity is less than 12 mm2/s at 50 °C.

Viscosity control
An automatic viscosity controller, or a viscosity meter at least, should be installed in
order to maintain the correct viscosity of the fuel before the fuel enters the engine fuel
system. See section 2.2, “HFO requirements on the engine”.

5. Steps to avoid The engine is built for operation on HFO with characteristics according to section 2.
difficulties under all operating conditions. Good running temperatures are important. In order to
during operation avoid difficulties mind the following points:
on heavy fuel
A Charge air temperature must be sufficiently high special at low load, (cold
corrosion).
B Injection fuel temperature. For requirements see ”Fuel viscosity / temperature
in the engine” section 2. Poor fuel quality will, adversely influence wear, engine
component life time and maintenance intervals.
C Clean the turbocharger turbine side regularly straight from the beginning. Fuels
with high vanadium and sodium contents in unfavourable ratio, may lead to
rapid contamination of the turbine and creates higher gas temperatures. More
frequent cleaning is necessary in that case.

Ver. 4--13154--56--57--58--59
5 -- 9
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

D Limit maximum continuous output as much as operating conditions permits if


fuel is known or suspected to have high vanadium content (above 100 ppm) and
especially if the sodium content simultaneously is 30% of the vanadium content.
E Limit low load operation as much as operating conditions permit if fuel is known
or suspected to have high sulphur content (above 1%), carbon content
(Conradson carbon above 10%) and/or asphaltene content (above 5%).
F Avoid unstable and incompatible fuels (precipitation of heavy components in
the fuel), by avoiding if possible blending of fuels unless the fuels are known to
be compatible. Store fuels from different deliveries in separate tanks.
If stability and compatibility problems occur, never add distillate fuel, as this will
probably increase precipitation. A fuel additive with highly powerful dispersing
characteristics can be of help until a new fuel delivery takes place.
G Some of the difficulties may occur when operating on heavy fuels blended from
cracked residuals, see section 6.

6. Comments on A Viscosity is not a measure of the fuel quality, but determines the complexity of
fuel the fuel heating and handling system, which should be considered when
characteristics estimating installation economy.
B Fuel oils having high density in combination with low viscosity may have low
ignition quality.
C High sulphur content increases the risk for corrosion and wear, particularly at
low loads, and may contribute to high--temperature deposit formation. The
lubricating oil specification must be matched to this.
D High ash content causes abrasive wear, and may cause high temperature
corrosion and contributes to formation of deposits. The most harmful ash
constituents are vanadium--sodium combinations.
E High vanadium content causes hot corrosion on exhaust valves particularly in
combination with high sodium content. The corrosion increases with increased
temperatures (increased engine output).
F Sodium (Na)contributes to hot corrosion on exhaust valves in combination with
high vanadium (V) content. Sodium also contributes strongly to fouling of the
turbine blading of the turbocharger at high exhaust gas temperature. The
maximum content of Na is 30 mg/kg and Na max. ≤ 20% V content.
G High Conradson carbon may cause deposit formation in combustion chamber
and exhaust system, particularly at low engine output.
H High content of asphaltenes may contribute to deposit formation in combustion
chamber and exhaust systems (at low loads). Asphaltenes may under certain
circumstances, precipitate from the fuel and will block filters and/or cause
deposits in the fuel system. Precipitating asphaltenes may also cause
excessive centrifuge sludge.
I Heavy fuels may contain up to 1% water at delivery. Water may also originate
from the installation bunker tanks. To avoid difficulties in the engine fuel injection
system water must be removed.

Ver. 4--13154--56--57--58--59
5 -- 10
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

J Reduced ignition and combustion quality can be caused by using HFO from
modern refinery processes compared with ”traditional” heavy fuels. HFO from
modern refinery processes may approach at least some of the limits of fuel
characteristics given in the table in section 2.

Ignition quality is not defined, nor limited, in marine residual fuel standards. The
same applies to ISO--F--DMC marine distillate fuel. The ignition quality of these
fuels cannot for a variety of reasons be determined by methods used for pure
distillates, i.e. Diesel Index, Cetane Index and Cetane Number.

Low ignition quality may cause trouble during starting and at low load operation,
especially at too low charge air temperature. This may also result in long ignition
delay and as a consequence, in high firing pressure rise ratio. The combustion
will be more noisy in this case, known as ”Diesel knock”, i.e. hard, high pitch
combustion noise. The effects of diesel knock are increased mechanical load
on components surrounding the combustion space, increased thermal load,
increased lube oil consumption and increased lube oil contamination. Basically
a low viscosity in combination with a high density will result in a low ignition
quality.

[mm2/s at 50 °C] [kg/m3 at 15 °C]

FIG. 5--6

Ver. 4--13154--56--57--58--59
5 -- 11
Manual
F240 FUEL SYSTEM
5B FUEL REQUIREMENTS

What do the values mean?


Straight run residues show CCAI values in the 770 to 840 range and are very good
igniters. Cracked residues delivered as bunkers may range from 840 to in exceptional
cases above 900. Most bunkers remain in the 850 to 870 range at present.

Normal diesel engines should accept CCAI values up to 850 with no difficulties. CCAI
values between 850 and 870 may cause difficulties under unfavourable conditions:
low charge air temperatures, insufficient pre--heating of the engine at the start, fuel
injection system not functioning properly (in particular, badly maintained nozzles).

CCAI values between 870 and 890 are more demanding; the above mentioned
systems must function perfectly in order to avoid difficulties. In severe cases it is
advisable to increase the charge air temperature. CCAI values above 900 are
damaging.

Note:
Although low ignition quality produces long ignition delay, advancing the ignition timing
makes things only worse; fuel is injected at a lower compression temperature and this
will produce even longer ignition delay.

K Aluminum + Silicon. Fuels may contain highly abrasive particles composed of


aluminium and silicon oxides known as ”catalytic fines” from certain refining
processes. If not removed by efficient fuel treatment, wear down of high
pressure fuel pumps, nozzles and cylinder liners in a few hours may be
expected.

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

Ver. 4--13154--56--57--58--59
5 -- 12
Manual
F 240 FUEL SYSTEM
5C FUEL FILTER ELEMENT

Before starting work, consult:


-- chapter 2, ”BACKGROUND INFORMATION”.

1. General The fuel filter consists of two compartments, each having one filter element.
The fuel filter has a 3--way cock permitting change--over during operation and the
fouled filter to be renewed.

2. Removal Only open the inactive filter compartment!

2. 1. Disengage the filter compartment with the fouled filter element.


The 3--way cock shows which filter compartment is active/inactive.

2. 2. Slacken the locking nut of vent screw A and open this screw.

2. 3. Drain the filter compartment by unscrewing drain plug B or the


corresponding plug in the drain line.

2. 4. Disconnect the vent line from the filter cover.

2. 5. Remove bolt C together with ring, filter cover and O--ring.

2. 6. Remove the filter element.

B B

Ver. 4--13154--56--57--58--59 5 -- 13
Manual
F 240 FUEL SYSTEM
5C FUEL FILTER ELEMENT

3. Fitting

3. 1. Clean the filter compartment and the cover with clean gasoil.

3. 2. Check the O--ring for damage. Replace it, if necessary.

3. 3. Check that the seat edges of the filter compartment and of the filter cover are
properly cleaned and undamaged.

3. 4. Fit the drain plug, using a new joint ring.

3. 5. Fit a new filter element (LFO/MDO).


Clean or renew the filter element (HFO).

3. 6. Fit an O--ring around the cover seat.

3. 7. Place the cover on the filter compartment and secure it, using bolt C.

3. 8. Screw the vent lines onto the filter cover.

3. 9. Put the 3--way cock in the central position. Once the filter compartment has
been vented, tighten the vent screw and lock it with the relevant nut.
Then switch to the desired filter compartment.

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

Ver. 4--13154--56--57--58--59 5 -- 14
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION

Before starting work, consult:


-- chapter 2, ”BACKGROUND INFORMATION”.

1. Tools The following tools are used.

Tool A Tool to check the beginning of the fuel injection.


Capillary tube

capillary tube

union nut

constant
pressure valve

Tool B Adjusting plate for checking/adjusting the


pre--lifting of a new or overhauled H.P. fuel
pump. cam follower

adjusting
plate

fuel cam

Ver. 4--13154--56--57--58--59 5 -- 15
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION

Tool C dummy The ”dummy” consists of a teflon model with the same dimensions as the constant
pressure valve, sealed by an O--ring or an old constant pressure valve with the inside
valves and springs removed.

EMPTY ”DUMMY”
TEFLON ”DUMMY”

2. Fuel Control Examine the fuel control system for:


System -- Smooth operation of the mechanism.
-- Rust and other deposits on the fuel pump control rods.
-- Wear and / or fracture of the fuel control return spring.
-- Wear and / or fracture of the springs between fuel pump control rods and
common fuel control shaft.
-- Proper condition of the pivoted joints and the linkage at the governor.

Lubricate the fuel pump control rods, pivoted joints, guide rollers, and common fuel
control shaft with a mixture of 50% lubricating oil and 50% gas oil.
Governor

Spring between high pressure fuel pump


and control rod common fuel control shaft
Control rod tension spring

Ver. 4--13154--56--57--58--59 5 -- 16
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION

3. Verification of
moment of
injection 3. 1. Disconnect the high pressure fuel line.

3. 2. Fit tool A (capillary tube) with the union nut.

3. 3. Move the fuel pump control rod to its full load


position. Capillary tube

3. 4. Turn the crankshaft until the crank of the rele-


vant cylinder is at 30° before T.D.C. of the com- Union nut

pression stroke.
Constant
pressure
3. 5. Turn the crankshaft in the direction of rota- valve
tion until the fuel is seen to rise in the capillary
tube (without air bubbles). This means that the
fuel passages in the constant pressure valve
are filled with fuel.

3. 6. Turn the crankshaft back (against the direction


of rotation) until the crank of the relevant cylin-
der is positioned at least 30° before T.D.C.

3. 7. Turn the crankshaft slowly in the direction of


rotation and stop turning as soon as the fuel
rises in the capillary tube. At this point the ef-
fective compression stroke begins. On the
flywheel the moment of injection can be found
and read off in crank degrees.

For the correct moment of injection see the value specified in the test bed report. The
tolerance allowed for the setting is  1°. If a greater variation is found, the pre--lifting
must be adjusted.

Ver. 4--13154--56--57--58--59 5 -- 17
Manual
F 240 FUEL SYSTEM
5D INSPECTIONS, MOMENT OF INJECTION

4. Checking After fitting a new or reconditioned high pressure fuel pump, the pre lifting has to be
pre--lifting checked and/or adjusted. Proceed as follows:

4. 1. Close the fuel supply to the


engine.

4. 2. Remove the camshaft co-


ver from the housing.

4. 3. Turn the corresponding fu-


el cam on its base circle.

4. 4. Remove the constant pres-


sure valve and fit tool C
(dummy).

4. 5. Place tool B (adjusting pla-


te) between the cam follo-
wer and the base circle of Adjusting bolt
the fuel cam.

4. 6. Slacken the locking nut of


the fuel pump adjusting Lock nut
bolt.

4. 7. Bring the fuel control rod of Cam follower


the fuel pump to its maxi-
mum position.
Adjusing plate
4. 8. Open the fuel supply to the
engine.

4. 9. Turn the adjusting bolt an-


ti--clockwise until fuel flows
out of the ”dummy”. Slowly
turn the adjusting bolt
clockwise until fuel flow out
of the ”dummy” stops.
Next secure the bolt in po-
sition by means of the loc-
king nut.

4. 10.Close the fuel supply and withdraw tool B and C.


Replace the constant pressure valve.

4. 11. Re--check the setting of the fuel timing, from point 3.6 and further.

4. 12.If the setting is outside the permitted tolerance the fuel cam position must be
corrected.

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

Ver. 4--13154--56--57--58--59 5 -- 18
Manual
F 240 FUEL SYSTEM
5E CONSTANT PRESSURE VALVE

Before starting word, consult:


--chapter 2, ”BACKGROUND INFORMATION”.

1. TOOL Tool for testing constant pressure valve.

Tool A 1 Testing pump 9612 SW 416

Tool B Tool 66626 900, consists of:


-- Connecting pieces
-- Flexible high pressure lines (2x)
-- Manometers and non--return valve

Please contact the Service Department


for ordering this tool.

2. Testing

2. 1. Check, if tool B is still under pressure at 120 bar, when the line is plugged off.
(If necessary, inspect the non--return valve of this tool).

2. 2. Remove the high pressure fuel line.

2. 3. Check if the fuel control rod is in zero position.

2. 4. Connect tools A and B to the high pressure fuel pump, with the help of tool A,
increase pressure to 120 bar.

2. 5. No go criteria is:
If the pressure drops from 120 bar to 80 bar within 5 seconds. In this case
renew the constant pressure valve.

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

Ver. 4--13154--56--57--58--59 5 -- 19
Manual
F 240 FUEL SYSTEM
5E CONSTANT PRESSURE VALVE

Ver. 4--13154--56--57--58--59 5 -- 20
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Manual
F 240 COOLING WATER SYSTEM
7A INTRODUCTION

1. General During the combustion process in the engine, heat is transfered to various engine
parts. To protect these parts against overly high temperatures it is necessary to
dissipate the heat by means of cooling water systems.

This paragraph is a general description of the function of engine parts in the cooling
water system.

The main parts of the cooling water system are shown in the general diagram
(paragraph 7H). These main parts have a number which corresponds to the number
in the diagram. Numbers placed between brackets in the description below also refer
to the numbers which can be found in the diagram.

2. Description of The cooling process (= heat dissipation) consists of two separate systems, namely the
engine parts high temperature system (HT--circuit) and the low temperature system (LT--circuit).
HT--circuit (Other system combinations are also possible).
To prevent the forming of rust and scale in the cooling water system, an inhibitor must
be added.

The HT--circuit includes the engine and if a two stage air cooler is fitted, the first stage
of the air cooler.

Cooling water Standard the engine is provided with an engine driven centrifugal cooling water pump,
pump that circulates the water through the HT--circuit. The cooling water pump is built onto
the gear box as standard and is driven by the crankshaft through gear transmission.
Valves directly before and after the cooling water pump have to be used in case of
emergency operation.

The cooling water pump pushes the cooling water via the cooling water inlet manifold,
through the engine block, the turbocharger and, if applied, through the first stage of
the air cooler. From the engine the cooling water flows through the cooling water outlet
manifold to the thermostatic three--way valve (standard).

De--aeration De--aeration points, with a Ø3 mm restriction, are provided on the cooling water outlet
points manifold of the engine and on the cooling water outlet pipe of the turbocharger.
For checking of the de--aeration, consult section 7C.

Thermostatic Standard the engine is provided with a thermostatic three--way valve. This valve
three--way controls the outlet temperature of the cooling water. Depending on this temperature
valve the cooling water flows back to the engine (by--pass), or via the cooling water cooler
to the engine.
For maintenance and checking, consult section 7E.

Water cooler A heat exchanger (cooler) is used to dissipate the heat of the HT--circuit. The heat
(05) exchanger can vary per installation.
For maintenance, consult section 7D.

Cooling water The purpose of the expansion tank is to compensate volume changes in the cooling
expansion tank water system and it also serves to vent the system and to provide sufficient static
(08) pressure.

Ver. 01a--13154--56--57--58--59 7 -- 1
Manual
F 240 COOLING WATER SYSTEM
7A INTRODUCTION

3. Describtion The LT--circuit includes the charge air cooler, or if fitted, only the second stage of a two
engine parts stage air cooler, the lubricating oil cooler and optionally heat exchangers.
LT--circuit

Cooling water The cooling water pump for the LT--circuit is of the same construction as the cooling
pump water pump of the HT--circuit. This pump is not of the self--suction type.

Charge air From the cooling water pump the cooling water flows to the charge air cooler. In the
cooler (03) LT--circuit 2 butterfly valves and a pneumatically controlled three--way valve are
provided, to control the quantity of cooling water to the charge air cooler. The quantity
of cooling water to the charge air cooler is dependent on the cooling water inlet
temperature.

For checking and maintenance, consult section 7D.

Lube oil cooler After the charge air cooler the cooling water flows to the lubricating oil cooler and then
(04) and water to the water cooler.
cooler (06).
For checking and maintenance, consult section 7D.

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

Ver. 01a--13154--56--57--58--59 7 -- 2
Manual
F 240 COOLING WATER SYSTEM
7B REQUIREMENTS

1. Cooling water The cooling water requirements can be found in Operating Instruction 4619Q002GB,
requirements, which can be found at the end of this chapter.
treatment and
analysing

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

Ver. 01a--13154--56--57--58--59 7 -- 3
Manual
F 240 COOLING WATER SYSTEM
7C COOLING WATER DE--AERATION

Before starting work, consult:


-- chapter 2, ”BACKGROUND INFORMATION”.

General Cooling water de--aeration on the engine takes place via the highest points of the cooling
water system. Orifices are provided in the de--aeration connections.
These orifices must be checked periodically.

Checking and
inspection 1. Drain the cooling water expansion tank.

2. Clean the expansion tank internally.

3. Loosen the connections of the de--aeration lines on the de--aeration points.

4. Check whether the orifices are open (diameter orifice openings 3 mm.).

5. Check whether the lines to and from the expansion tank are not clogged.

6. Connect the de--aeration lines correctly to the de--aeration points.

Attention!
In case the cooling water system is equipped with an automatic de--aeration
device, it must be removed, cleaned, and checked on good working and then
re--fitted.

7. Refill the cooling water expansion tank to the required level.

Automatic de--aeration
device
Orifice

Orifice

Automatic de--aeration
device

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

Ver. 01a 7 -- 4
Manual
F 240 COOLING WATER SYSTEM
7D COOLERS

Before starting work, consult


-- chapter 2, ”BACKGROUND INFORMATION”.

1. The heat Cleaning and Inspection of lube oil or water cooler:


exchangers Cleaning Intervals depend heavily on the operating conditions and the state of the
cooling water. If these are less than optimal, cleaning should be effected at least twice
a year.

See sub--suppliers manuals for internal cleaning and inspection.

2. The air cooler Cleaning:


Cleaning intervals depend heavily on the operation conditions and the state of the
cooling water and the suction air.

To ensure effective cleaning of the cooler, this job has to be carried out by a specialist
firm. However, if it is unavoidable to clean the cooler on the spot,
proceed as follows:

Water section:
The water section can be cleaned by means of chemicals, or mechanically, by
brushing. See sub--suppliers manuals.

Air section:
The air section must be cleaned with an agent capable of dissolving the deposits that
have been built up. See sub--suppliers manuals.

If the air cooler has soft iron sacrificial anodes, these must be examined each time the
cooler is cleaned. In some types of air coolers the air flow must have a specific direc-
tion, indicated on one side of the side plates. When assembling and mounting such
coolers make sure that the air flows in the proper direction.

Insufficient Cooling Possible causes and remedies:


-- Air in the water section -- open vent plug. If an automatic de--aerator is fitted, this
must be checked for proper functioning.
-- Insufficient water supply -- examine supply lines.
-- Deposits on cooling fins and / or in the water section -- clean cooler.

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

Ver. 01a 7 -- 5
Manual
F 240 COOLING WATER SYSTEM
7E COOLING WATER THERMOSTATS

Before starting work, consult:


-- chapter 2, ”BACKGROUND INFORMATION”.

The thermostatic three--way valve is equipped with three elements. In cold condition, the
thermostatic elements are closed and no water can flow through the heat exchanger.
When the temperature of the water rises, the wax elements expand, and causes the
elements to open against spring pressure, so that the passage to the heat exchanger is
released.
If the water becomes excessively hot or remains too cold, the three thermostatic
elements must be examined.
Inspection of the thermostatic elements:

1. Drain the cooling water by removing the drain plug from the thermostat housing
(proceed carefully when the engine is still hot).

2. Remove the thermostat cover

3. Place the elements in a basin filled with water. Heat the water and with the aid of a
calibrated thermometer check whether the element opens at the correct temperature.
If the element does not open at the correct temperature, it must be renewed.

4. Refit all parts in the reversed order.

Drain plug

Cover

Thermostatic 3--way valve


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

Ver. 01a 7 -- 6
Manual
F 240 COOLING WATER SYSTEM
7F COOLING WATER PUMP

1. Disassembly If oil and / or water is seen to run out of the leak indicator F, all sealing rings have to
be renewed.

1. 1. Remove the suction and delivery pipe from the pump.

1. 2. Remove the pump casing.

1. 3. Slacken the nut for impeller attachment one full turn.

1. 4. Remove the pump from the gearbox.

1. 5. Remove the inner circlip A.

1. 6. Dislodge the impeller from its cone by tapping the nut with a hammer and
support the backside of the impeller. If the impeller is not coming loose, warm
up the impeller till approx. 120 °C.

1. 7. Unscrew the nut completely and withdraw the impeller, (and if applied the
key) the sliding ring seal B and pump shaft with bearings.

1. 8. Withdraw the oil sealing ring C and the ceramic stationary seal ring D from
the pump bracket.

1. 9. If the inner ring E of the pump shaft shows wearing grooves, it must be
renewed.
Release the inner ring by heating it to approx. 200 °C.
Remove all the residual Loctite from the pump shaft.

1. 10.Inspect the double--ball angular contact bearing and the single ball bearing.
In most cases they shall have to be renewed.
pump casing

D
E
C B

A
O--ring

Ver. 01a 7 -- 7
Manual
F 240 COOLING WATER SYSTEM
7F COOLING WATER PUMP

2. Reassembly Fitting a new inner ring should be done as follows:

2. 1. Clean and degrease the pump shaft on the location, for the inner ring.
2. 2. Degrease the new inner ring.
2. 3. Lubricate the ball bearings sparingly with bearing grease to prevent Loctite
from adhering to the balls of the bearing.
2. 4. Smear the location for the inner ring with Loctite.
2. 5. Slide the inner ring onto the pump shaft and up to the correct position.
2. 6. Remove all surplus Loctite.
2. 7. Allow the Loctite to harden at least 20 minutes before fitting the shaft.

After fitting the new inner ring, reassemble and fit the cooling water pump as follows:

2. 8. Clean and inspect all parts of the cooling water pump thoroughly and check if
the leak indicator hole (F) is open.
2. 9. Rub the pump shaft splines with Molykote. Just smearing the splines is
not enough.
2. 10.Fit the oil sealing ring (two--side seal) in the cooling water pump bracket.
2. 11. Fill the space formed by the V of the oil sealing ring with grease.
2. 12.Fit the ceramic stationary seal ring carefully in the pump bracket.
2. 13.Fit the bearings on the pump shaft and position the shaft in the pump bracket
and fit the inner circlip.
2. 14.Check that the pump shaft runs lightly.
2. 15.Position the sliding ring seal.
2. 16.Degrease the cone of the pump shaft with a solvent agent. Do the same with
the conical inside part of the impeller and the nut.
2. 17.Warm up the impeller till 100 °C.
2. 18.Sparingly apply Loctite to the shaft cone and the nut thread.
2. 19.Fit the impeller in a turning movement, fit immediately the impeller nut to the
correct torque (50 Nm.).
2. 20.Remove all surplus Loctite.
2. 21.Fit the pumping casing with gasket to the pump bracket.
2. 22.Place the O--ring onto the pump bracket.
2. 23.Fit the pump to the gearbox.
2. 24.Reconnect the suction pipe and the delivery pipe.
Note :
When the engine has been started a slight cooling water leakage may be observed,
but this should stop after approx. 1 hour. Such leakage is due to the fact that the sliding
ring seal may require time to wear in on the ceramic stationary seal ring.

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

Ver. 01a 7 -- 8
Manual
F 240 COOLING WATER SYSTEM
7G INSPECTION COOLING WATER SPACE

This consists of a general visual examination of the cylinder block cooling water space.
Attention should be paid to the following:

-- Serious corrosion
-- Signs of cavitation
-- Sludge formation
-- Line deposits and other undesirable phenomena
-- Gas leakage

Gas leakage is noticeable to:

-- Altering cooling water pressure


-- Higher cooling water temperatures
-- Gas bells in cooling water expansion tank
-- Deteriorating cooling water quality.

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

Ver. 01a 7 -- 9
Manual
F 240 COOLING WATER SYSTEM
7H GENERAL DIAGRAM

1. Cooling water
system HT/LT

System components
01 Engine and turbocharger (5x) 09 Three way valve thermostat
02 HT air cooler (5x) 10 LT cooling water pump
03 LT air cooler (5x) 11 HT cooling water pump
04 Lub oil cooler (5x) 12 Valve
05 Central HT cooler 13 Flexible pipe connection
06 Central LT cooler 14 Flow meter
07 Expansion tank LT system 15 Adjustable restriction
08 Expansion tank HT system

Ver. 01a--13154--56--57--58--59 7 -- 10
Manual
F 240 COOLING WATER SYSTEM
7H GENERAL DIAGRAM

2. HT Cooling water
system / engine

System components
3 Turbocharger
5 Flexible pipe connection
6 Needle valve
7 Pressure gauge
8 Thermometer
9 Valve
11 Air cooler
16 Valve

Ver. 01a--13154--56--57--58--59 7 -- 11
Manual
F 240 COOLING WATER SYSTEM
7H GENERAL DIAGRAM

3. LT Cooling water
system / engine

System components
2 Air cooler(s)
3 Lubricating oil cooler
5 Flexible pipe connection
12 Pneumatic operated three way valve
13 Valve

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

Ver. 01a--13154--56--57--58--59 7 -- 12
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