lmbo^qfkd fkpqor`qflk

Service, Wrtsil Finland Oy Engine section 11 Crank mechanism Engine type Ref. WFIS Kyttohje Date Issue Driftsinstruktion Document No. 2011Q002GB Page 1(3)

W20

19.01.2004 01

Assembly procedure for connecting rod big end

Engine type Background This Operating Instruction concerns all WRTSIL 20 engines. It is essential to pay attention to the dismantling and assembly procedure of the connecting rod because an incorrect assembly procedure can be a direct reason for a failure at the big end of the connecting rod. Therefore the Instruction Manual has been revised accordingly. See section 11 enclosed. Revised routines The following assembly routines have been revised: Check clearance between the engine block and the distance sleeves after turning the crankshaft to a crank angle of about 55 from top dead center (TDC) towards the operating side for the cylinder concerned. See sections 11.4.3 and 11.4.5.

Operating side

Check the clearance !

Check the clearance !

Lubricate the back side and the end faces of the big end bearing shells to ensure proper bed in of the bearing shells in the bore. See section 11.4.5. Caution: Any use of glue on a bearing shell is prohibited!

Wrtsil Finland Oy Service, Vaasa Wrtsil Finland Oy Service, Turku

P.O. Box 252 (Tarhaajantie 2) FIN-65101 Vaasa, Finland P.O. Box 50 (Stlarminkatu 45) FIN-20811 Turku, Finland

Telecop. +358 10 709 7355 Telecop. +358 6 356 7339 Telecop. +358 10 709 3279 Telecop. +358 10 709 3410

Tel. +358 10 709 0000 Tel. +358 10 709 0000

Business ID 0773744-3 Registered Office: Vaasa

Service, Wrtsil Finland Oy Issue 01

Operating instruction Document No. 2011Q002GB Page 2(3)

Check the bearing shell alignment in the connecting rod before tightening to ensure that the bearing shells are mounted straight in the big end bore. See section 11.4.5.

Check of the exposed connecting rod screw section which is valid only for the connecting rod screw with an end plug. The reference measurement is for guidance only and will reveal the condition of the end plug. See section 11.4.5 and Technical bulletin 2011T004. Caution: - An end plug may under no circumstances be used with the 270 mm long connecting rod screw. Check that no plug remains in the threaded holes of the connecting rod before mounting the screws.

Connecting rod screw Standard routines

Replacement recommendation for the connecting rod screw is at latest every 24000 hours. See Technical Bulletin 2011T004. Wrtsil would also like to emphasize a few important routines mentioned under Dismantling and Reassembling hydraulically tightened screw connection. See chapter 07.3.3 and 07.3.4 in your Engine Instruction Manual. Expel (return) possible oil from the hydraulic cylinders always back to the pump before the tools are taken into use at dismantling and reassembling. Be aware of the correct turning direction when loosening or tightening the screw nut. On loosening turn the nut counter-clockwise (CCW) On tightening turn the nut clockwise (CW) To ensure proper hydraulic tightening, raise the pressure in two steps i.e. pump the pressure to 300 bar and turn the nut in a clockwise direction until it has a contact with the connecting rod cap. Increase the pressure further to stated pressure. Turn the nut until it has a close contact with the face again. This time the nut should move just a limited angle, but approximately the same angle for all nuts of the same kind.

Service, Wrtsil Finland Oy Issue 01

Operating instruction Document No. 2011Q002GB Page 3(3)

50 hrs maintenance Tool maintenance

Check the tightening of the connecting rod screws after the first 50 operating hours on a new engine and after overhaul. See chapter 04.4. The hydraulic tool set should be stored in a suitable place and corrosion protected. The set should be regularly checked and worn or damaged parts replaced. See chapter 07.3.2. Special attention should be paid to the following components. Pressure gauge: Regularly calibration checked. Hydraulic couplings and hoses: Condition check Hydraulic pump: Condition check. Hydraulic cylinder o-ring: Wear and condition check.

Note! If the hydraulic cylinder o-ring has been exposed outside the cylinder the oil has to be removed from the cylinder before the cylinder with the oring can be re-installed. To return the o-ring with the oil in the cylinder will only damage the o-ring. It is prohibited to use a malfunctioning hydraulic tool. Recommendation Replace the old chapters in the Engine Instruction Manual with the new, implement them in the maintenance schedule and follow the revised assembly and maintenance routines. Unless otherwise expressly set forth, no recommendation contained in this document is to be construed as provided due to a defect in the engine, but merely as an improvement of the engine and/or the maintenance procedures relating thereto. Any actions by the owner/operator as a result of the recommendations are not covered under any warranty provided by Wrtsil and such actions will thus be at the owners/operators own cost and expense. Wrtsil Service Network and owners/operators of WRTSIL 20 engines. Until further notice. Chapter 11 of the Instruction Manual.

Warranty

Letter distribution Letter validity Enclosure

2004 Wrtsil Finland Oy All rights reserved No Part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder. Wrtsil Finland Oy makes no representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for information contained herein. Information in this publication is subject to change without notice. NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

20-200349-02

Crank Mechanism

11

11. Crank Mechanism: Crankshaft, Connecting Rod, Piston

11.1 Crankshaft
11.1.1 Description of crankshaft
Data and dimensions Material: Forged, alloyed steel Weight: 750 kg (4L20) 770 kg (5L20) 790 kg (6L20) 1000 kg (8L20) 1110 kg (9L20)

The crankshaft is forged in one piece and provided with two counter-weights per cylinder. The counter-weights are fastened with two screws each. 4L20 has integrated counter-weights. At the driving end of the engine, the crankshaft is equipped with a V-ring for sealing of the crankcase. The axial clearance is controlled by a combined flywheel/thrust bearing. A shrink fitted gear wheel for driving of the camshaft is located in the driving end. The main bearings are described in chapter 10. At the free end, there is a gear for driving of water pumps and the lubricating oil pump. Usually a vibration damper is also installed (separate instructions for the vibration damper are submitted, if the engine is equipped with such). The crankshaft can be turned by a manual turning device operating the flywheel. The lubricating oil is supplied through the side screw holes in the engine block to the main bearings. The oil flows further from the main bearing through the bores in the crankshaft to the connecting rod big end bearing and up in the connecting rod and piston. Due to a special design of the bores in the crankshaft, the flow to the connecting rod is intermittent. The oil is forced to flow in one direction only.

11.1.2 Balancing of crankshaft

Data and dimensions Material: Steel plate Weight: 21 kg

The crankshaft is balanced by means of counterweights on the crank webs, two weights per cylinder. The counter-weights are fastened to the web with two screws (4L20 has integrated counterweights). The counterweight shall always be assembled with the guide pin to make sure the right position, see Fig 11-1

Note!

WRTSIL 20

11 - 1

11

Crank Mechanism

20-200349-02

Positions of counterweights
A Cyl. No. SECTION A-A 1 2 3 4 5 6

Guide pin
A

Fig 11-1

3211599601

11.1.3 Crankshaft alignment

1 Turn crank of the first cylinder near BDC (bottom dead centre) and attach the crankshaft dial indicator to the centre marks in the two crank webs. The distance between the indicator and the connecting rod should be as small as possible. 2 Set indicator at zero. 3 Read deflections when turning crank to the rear side, TDC (top dead centre), operating side and BDC. Record readings in the form Crankshaft alignment. Note! During the alignment procedure the crankshaft should be turned in the anti-clockwise direction, only. 4 Repeat this procedure with other cylinders. 5 Following limits of misalignment are stated for an engine having normal running temperature (within 5 minutes after running at 60 % load or higher for 6 h or more): a) on the same crank The difference between two diametrically opposed readings must not exceed 0.04 mm after installing or realigning. Realignment is necessary if this limit is exceeded by more than 0.02 mm. b) on two adjacent cranks The difference between two corresponding readings must not exceed 0.04 mm. Realignment is necessary if this limit is exceeded.

11 - 2

WRTSIL 20

20-200349-02

Crank Mechanism

11

c) when the crank pin of cyl. 1 is at TDC (reading C) The reading should be negative, max. -0.04 mm (-0.08 mm if flex. coupling). Before realigning the engine and the driven machinery, a control measurement of the main bearings should be made. Note! In an engine having a normal ambient temperature, the corresponding values must be based on experiences from the particular installation. Dial indicator position and reading
+ 0 -

A Operating side

E Rear side

107mm

C As seen from flywheel end

Punched points

Fig 11-2

2011539601

11.2

Flywheel
11.2.1 General description of flywheel

Data and dimension Material : Steel plate Weight: about 350 kg

The steel flywheel is fitted to the crankshaft with four fitted screws and four normal screws. The correct position of the flywheel is determined by three smaller screws. A gear rim is fitted to the flywheel. A crank angle scale is stamped on flywheel. The scale starts from zero for the TDC for cylinder 1 and is divided in 360 crank angle. The TDC is marked for all cylinders. The flywheel position indicator is marked with a scale for reading of the engine crank angles, at an accuracy of one (1) degree crank angle, on the graduation of the flywheel.

WRTSIL 20

11 - 3

11

Crank Mechanism

20-200349-02

Reading of flywheel indicator

12

5 4 3 2 1 0 1 2 3 4 5

350

Cyl 1 TDC

0 CYL 1, 6 TDC

VIEW A

Fig 11-3

2011690119

11.2.2 Replacing the gear rim

If the gear rim is damaged or worn it can be replaced without removing the flywheel as follows: 1 Open the screws which are holding the gear rim and remove the gear rim from the flywheel. 2 Cut the ring in suitable pieces. Ensure that the flywheel is not damaged during this operation. 3 The spare part gear rim is delivered in two pieces, which easily can be mounted on the flywheel. Additional screw holes for the ring half ends are premachined at the factory. 4 Mount the gear rim halves and tighten the fastening screws to stated torque, see section 07.1. 5 Check the base tangent lenght over the number of teeth spanned, see Fig 11-4.

11 - 4

WRTSIL 20

CLOCKWICE ROTATING ENGINE

340

20-200349-02

Crank Mechanism

11

Base tangent lenght over the number of teeth spanned

1. Gear rim half

W/k = 317

.748

-0.320 -0.640

/ 30

Fig 11-4

3211549418

11.3

Turning device
The crankshaft can be turned by a manual turning device operating on the flywheel. The turning device consists of a gear, which is operated with a ratchet. The rotational direction for turning can be reversed by altering the ratch position of the ratchet. Note! The engine must not be started while the turning gear is engaged.

11.4

Connecting rod and piston

11.4.1 General description of connecting rod

Data and dimension Material: Special steel, drop forged Weight: 38 kg Bearing type: Bi-metal bearing

The connecting rod is of the drop-forged type with H-section shaft. The big end is of stepped split line design and precision serrated at the mating surfaces. This design offers the maximum crank pin diameter but still makes it possible to pull the connecting rod through the cylinder liner. The big end bearing shells are, for correct assembling, axially guided by lugs. The design of the crankshaft enables the use of a non-grooved upper bearing shell. The two connecting rod screws are hydraulically tightened. The gudgeon pin bearing bush is stepped to give a larger bearing surface on the more loaded lower side. It is lubricated via bores in the connecting rod. The gudgeon pin is of the full floating design, secured axially with retainer rings. The oil flow from the connecting rod is passed through the gudgeon pin further up to the piston. The gudgeon pin has shrink fitted plugs in the ends. 11 - 5

WRTSIL 20

11

Crank Mechanism

20-200349-02

11.4.2 General description of piston

Data and dimension Composite piston Material skirt: Nodular cast iron or forged steel Material crown: Forged steel Screw: 10.9 Weight: 22 kg

The piston is of composite type with a forged steel or a nodular cast iron skirt and a forged steel crown screwed together. The piston skirt has a phosphate/graphite overlay. The piston crown is cooled with lubricating oil by means of the cocktail shaker effect. The lubricating oil is led from the main bearing, through the bores in the crankshaft, to the big end bearing, and further through the bores in the connecting rod, gudgeon pin and piston skirt, up to the cooling space, from where it is drained back to the oil sump. The pistons are provided with Wrtsil patented skirt lubricating system. The combustion chamber in the top of the piston is deep, preventing the fuel jets to touch the cylinder liner. The compression ring grooves are hardened for better wear resistance. Always handle the pistons with care. Do not damage or remove the phosphate/graphite overlay. The piston ring set consists of two compression rings and one spring-loaded oil control ring. In this three-ring pack, every ring is specially dimensioned and profiled for the task it has to perform. The top ring is provided with a special wear resistant coating. The second compression ring is chrome-plated. The oil control ring is a spring-loaded, chrome-plated oil scraper ring. The side to be upwards of the compression rings is always marked TOP.

Note!

11.4.3 Removing and dismantling of piston and connecting rod

Data and dimension Weight: 75 kg

836 003 836 002

1 Remove the cylinder head,see chapter 12 section 12.2.1 Scrape off carbon deposits carefully from the slots of the antipolishing ring and around the upper part of the cylinder liner. It is advisable to cover the piston top with cloth or paper pressed tightly (by an old piston ring) against the cylinder wall to collect the deposits removed. 2 Remove the anti-polishing ring. Use the tool 836002 to extract the ring and 836003 to keep the liner in place during the extracting procedure. By turning the engine, the piston pushes the anti-polishing ring out. 3 Clean the threaded hole in the piston crown and fasten the lifting tool 832002. 4 Turn the crankshaft about 55 from TDC towards the operating side for the cylinder concerned, see Fig 11-5.

11 - 6

WRTSIL 20

20-200349-02

Crank Mechanism

11

5 Lift the distance sleeves 861153 into position on the connecting rod screws and screw on the hydraulic tools 861159 with extension pieces 861157. Note! Check that there is clearance between the distance sleeves and the engine block, before and after applying the pressure on the hydraulic tool. If necessary turn the crankshaft slightly to get the clearance for both sleeves. Dismantling of piston and connecting rod
832 002

Operating side

Check the clearance !

861 153 Distance sleeve 861 157 Extension piece 861 159 Hydraulic cylinder 832 002 Lifting tool for piston

861 153 861 159 861 157 861 159

Check the clearance !

Fig 11-5

2011750240

DISMANTLING 1. Screw on cylinders by hand 2. Connect hoses, open valve. Tighten cylinders by hand.

6 Connect the hoses of the hydraulic pump and proceed to open the connecting rod nuts, see chapter 07., section 07.3 7 Remove the hydraulic tool and the distance sleeve from the connecting rod studs. 8 Open the lower nut and remove the lower stud using the stud extracting tool 803011. The locking screw of the tool has left-hand threads.

Hydraulic oil

3. Screw cylinders 180 counter -clockwise. 4. Close valve, rise pressure. 5. Open the nut about half a turn. 6. Open release valve, remove tool.

9 Repeat the same procedure as above with the upper nut and stud and lift the big end bearing cap together with the bearing shell out of the engine.

WRTSIL 20

11 - 7

11

Crank Mechanism

20-200349-02

10 Lift the piston a little to remove the upper big end bearing shell. When lifting the piston, take care not to damage the crank pin or the cylinder liner wall. 11 Cover crank pin oil holes with tape. 12 Lift the piston together with the connecting rod out of the engine. When lifting the piston, take care not to damage the cylinder liner wall. 13 Remove the retainer ring from the gudgeon pin hole in the piston, on the side where the gudgeon pin drawing number is located, by using the pliers for the retainer ring, 843004. Note! Never compress the retainer ring more than necessary to remove it from the groove. 14 Drive out the gudgeon pin from the opposite side. In low temperatures the gudgeon pin may stick but will be easily removed after heating the piston to about 30C, e.g. in oil. 15 If the rings and grooves require cleaning, measuring etc., remove the piston rings by using the pliers 843003. Before removing, note the position of the rings to ensure mounting in the same grooves. The design of the pliers prevents overstressing of the rings. Using other means may overstress the rings.

11.4.4 Maintenance of piston, piston rings and connecting rod bearings

1 Clean all the parts carefully. Remove the piston rings, and remove burned carbon deposits from the piston and piston ring grooves. Special care should be taken not to damage the piston material. Never use emery cloth on the piston skirt. The cleaning is facilitated if coked parts are soaked in kerosene or fuel oil. An efficient carbon solvent e.g. ARDROX No. 668 or similar should preferably be used to facilitate cleaning of the piston crown. When using chemical cleaning agents, take care not to clean piston skirt with such agents because the phosphate/graphite overlay may be damaged. 2 Measure the height of the piston ring grooves. 3 Dismantle composite piston for inspection of mating surfaces between piston skirt and piston crown. Inspect and clean oil spaces. See tightening procedure mentioned in chapter 07./ Piston. 11 - 8 WRTSIL 20

20-200349-02

Crank Mechanism

11

When mounting a new cylinder liner, all rings are to be replaced by new ones. After honing of a liner, all rings are to be replaced by new ones. 4 Check the gudgeon bearing bush and big end bearing bore . When measuring the big end bearing bore the connecting rod screws are to be tightened to the stated pressure. Wear of bimetal bearing shells can be settled by measuring the thickness. For this purpose a ball anvil micrometer should be used. The wear limits given in chapter 06.2 should be applied. When replacing a big end bearing both the upper and the lower bearing shell should be renewed. Mark new bearings with the bearing number.

11.4.5 Assembling and mounting of piston and connecting rod

1 Lubricate the gudgeon pin, and mount from the same side from where it was removed, with the end marked with the drawing number in the same direction. The cylinder number is stamped on the piston crown and connecting rod. When changing the piston, mark the new piston with the same cylinder number in the same place as on the replaced one. At low temperatures, the gudgeon pin may stick but will be easily fitted after heating the piston to about 30C, e.g. in oil. 2 Mount the retainer ring. Note! Never compress the retainer ring more than necessary to fit into the groove. If the ring is loose in its groove after mounting, it must be replaced by a new one. 3 Fasten the lifting tool 832002 to the piston crown . 4 Turn the crankshaft about 55 from the TDC towards the operating side for the cylinder concerned, see Fig 11-5. 5 Mount the piston rings by using the pliers 843003. If rings are reused, take care not to turn them upside down. Before new rings are mounted, check the height of the ring grooves. The height must not exceed the wear limit. The rings should be placed with gaps located 120 in relation to each other. Note the mark TOP near the ring gap. 6 Lift the piston and connecting rod.

WRTSIL 20

11 - 9

11

Crank Mechanism

20-200349-02

7 Lubricate the piston and place the clamp device for piston rings, 843002, around the piston, checking that the piston rings slide into their grooves. 8 Spread a thin oil film on the upper big end bearing shell running surface and on its back side. Both end faces to be lubricated with grease or oil. Mount the bearing shell with the lug guiding in its groove into the connecting rod. Check that the shell is mounted straight. Caution! Any use of glue on a bearing shell is prohibited. 9 Take off the protecting tape from the crank pin oil holes and lubricate the crank pin with clean engine oil. 10 Lower the piston/connecting rod carefully into the cylinder liner. 11 Lower the piston further until the connecting rod can be placed on the crank pin. 12 Spread a thin oil film on the lower bearing shell running surface and on its back side. Both end faces to be lubricated with grease or oil. Mount the bearing shell with the lug guiding in its groove into the bearing cap. Check that the shell is mounted straight. On a connecting rod screw with an end plug the condition of the plug should be checked before assembly. Connecting rod screws
262 With plug

Plug

270 Without plug

Fig 11-6 Caution!

2011810349

An end plug may under no circumstance be used with the 270mm long connecting rod screw.

11 - 10

WRTSIL 20

20-200349-02

Crank Mechanism

11

Check that no plug remains in the threaded holes of the connecting rod before mounting the screws. 13 Lift the bearing cap in place and mount the upper screw tightening it by hand. Mount the nut. The serrations of the bearing cap/connecting rod and bearing shell ends must be in the right relative position to each other. Tighten the nut by hand. Check of the bearing shell alignment

Incorrect

Correct
2011820349

Fig 11-7

14 Mount the lower screw and tighten both screws with the tool 803011 to torque, see chapter 07 section 07.3. Screw on the lower nut and tighten it by hand. Caution! Overtightenig of the screws will damage the plug at the end of the screws.

REASSEMBLING 1. Screw on nuts, attach distance sleeve. Screw on cylinders by hand. 2. Connect hoses, open valve. Tighten cylinders by hand.

Hydraulic oil

15 Lift the distance sleeves 861153 and the hydraulic tools, 861159, together with extension pieces 861157, into position. Check again the alignment of the upper serration and bearing shell ends by hand before proceeding with tightening of connecting rod nuts. There is no guiding pin for the upper serration. It is recommended that the pressure is applied in two steps according to description in chapter 07., section 07.3.4.

3. Close the valve and pump pressure to the stated value. 4. Screw the nuts until close contact to face. 5. Open the valve and remove tool set.

WRTSIL 20

11 - 11

11

Crank Mechanism

20-200349-02

Note!

Check before and during the tightening that distance sleeves do not touch the engine block. Check that the connecting rod is movable axially after tightening. 16 Check of the exposed section , that is valid only for the connecting rod screws with end plug according to Fig 11-6. The reference measurements are only for guidance to reveal the condition of the end plug. If the length is out of limits, check the condition of the plug in the end of the connecting rod screw. Connecting rod screw check
+1.1 -0.9

Note!

35.7

32.7

+1.1 -0.9

Fig 11-8 17 Mount the side covers. 18 Mount the anti-polishing ring.

2011579446

19 Mount the cylinder head, see chapter 12 section 12.2.3

11 - 12

WRTSIL 20