Winterthur Gas & Diesel Ltd. X52, Operation Manual

Page 1: ...al X52 Issue 002 2018 11 Winterthur Gas Diesel Ltd Schützenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerland www wingd com ...

Page 2: ...ight holder Winterthur Gas Diesel Ltd makes no representation warranty express or implied in this publication and assumes no responsibility for the correctness errors or omissions of 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 CONT...

Page 3: ...sions in the crankcase 50 2 6 Access to engine spaces 52 3 Design and function of the engine 3 1 Short description of the engine 56 3 2 Use of the engine 58 3 3 The relation between engine and propeller 62 4 Design and function of systems 4 1 General for systems 68 4 2 Cooling water system 70 4 3 Wash water system 72 4 4 System oil system 74 4 5 Servo oil system 76 4 6 Cylinder oil system 78 4 7 S...

Page 4: ...ve supply unit and control elements 5 4 1 Supply unit drive 152 5 4 2 Starting air shut off valve 154 5 4 3 Control air supply 156 5 4 4 Local maneuvering stand 158 5 4 5 Pick up for speed measurement 160 5 5 Group 5 Supply unit pumps and control valves 5 5 1 Servo oil pump 162 5 5 2 Supply unit 164 5 5 3 Fuel pump 166 5 5 4 Pressure control valve 168 5 5 5 Flow limiting valve 170 5 5 6 Exhaust va...

Page 5: ...ION 232 6 4 8 LDU 20 page PAGE INDEX 234 6 4 9 LDU 20 page EXHAUST VALVES 236 6 4 10 LDU 20 page FAILURE LIST 238 6 4 11 LDU 20 page CYLINDER LUBRICATION 240 6 4 12 LDU 20 page USER PARAMETERS 242 6 4 13 LDU 20 page PERFORMANCE DATA DIESEL 244 6 4 14 LDU 20 page TEMPERATURES 246 6 4 15 LDU 20 page SOFTWARE INFO 248 6 4 16 LDU 20 page LOG MESSAGES 250 6 4 17 LDU 20 page LOG ENTRY DATA 252 6 4 18 LD...

Page 6: ...g shutdown period 326 9 Service during operation 9 1 Do an analysis of the system oil 330 9 2 Do an analysis of the cylinder oil 332 9 3 Replace the filter element of the duplex filter 336 9 4 Clean the scavenge air cooler during operation 338 9 5 Do a test of the exhaust waste valve 342 9 6 Running in of new components general 344 9 7 Running in of new components 346 10 Troubleshooting 10 1 Troub...

Page 7: ...ard settings general 420 11 3 List of usual values and safeguard settings 424 11 4 Section views 436 12 Operating media 12 1 Cooling water 440 12 2 Cooling water additives 442 12 3 System oils 446 12 4 Cylinder oils 454 12 5 Different oils and lubricants 460 12 6 List of system oils 462 12 7 List of cylinder oils 464 12 8 List of lubricants for flywheel and pinion gear teeth 468 12 9 Compressed ai...

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Page 9: ...108 4 6 SCR SOFTWARE INFO 109 CHAPTER 5 DESIGN AND FUNCTION OF COMPONENTS 5 1 iELBA control cabinet 194 5 2 iELBA error indication 195 CHAPTER 6 CONTROL SYSTEM 6 1 MAIN 221 6 2 CONTROL LOCATIONS 225 6 3 CA SENSOR STATUS 227 6 4 FUEL SYSTEM 229 6 5 CYLINDER BALANCING DIESEL 231 6 6 MAIN FUEL INJECTION 233 6 7 PAGE INDEX 235 6 8 EXHAUST VALVES 237 6 9 FAILURE LIST 239 6 10 CYLINDER LUBRICATION 241 6...

Page 10: ...oil temperature downstream of a piston is too high 358 10 17 Piston cooling oil flow to a piston is not in the permitted range 358 10 18 TC bearing oil temperature at a turbocharger outlet is too high 358 10 19 TC bearing oil supply pressure upstream of a turbocharger is too low 358 10 20 TC bearing oil temperature at a turbocharger inlet is too high external oil supply 358 10 21 Damper oil supply...

Page 11: ...ol air supply pressure is too low safety supply 366 10 53 Temperature of a thrust bearing pad is too high 367 10 54 Cylinder liner wall temperature is too high 367 10 55 A fuel pump actuator has a failure 367 10 56 Power supply to the power supply box E85 has a failure 368 10 57 Unwanted engine speed decrease 368 10 58 Unwanted engine stop 368 10 59 Examples of failure messages 370 CHAPTER 11 TECH...

Page 12: ... engine without servo oil filter 450 12 9 List of validated system oils SAE 30 November 2018 463 12 10 List of validated cylinder oils and blending on board additives November 2018 465 12 11 List of lubricants for flywheel and pinion gear teeth 16 October 2012 468 12 12 Specifications for HFO 476 12 13 Specifications for distillate fuels 481 CHAPTER 13 SCHEMATIC DIAGRAMS 13 1 Function code 490 13 ...

Page 13: ... oil system generic and simplified 77 4 6 Cylinder oil system generic and simplified with and without iCAT 79 4 7 Starting air system generic and simplified 81 4 8 Scavenge air system 83 4 9 Control air system generic and simplified 85 4 10 Exhaust gas system generic and simplified 87 4 11 Fuel system with FLV generic and simplified 90 4 12 Fuel system with ICU generic and simplified 91 4 13 HP SC...

Page 14: ...eneric 144 5 19 Connecting rod and connecting rod bearing generic 146 5 20 Crosshead and guide shoe example 148 5 21 Piston example 150 5 22 Supply unit drive generic 153 5 23 Starting air shut off valve example 154 5 24 Control air supply generic 156 5 25 Local maneuvering stand 158 5 26 Pick up for speed measurement generic 160 5 27 Servo oil pump example 162 5 28 Supply unit example 164 5 29 Fu...

Page 15: ...16 6 6 LDU 20 color display general items 217 6 7 MAIN 220 6 8 CONTROL LOCATIONS 224 6 9 CA SENSOR STATUS 226 6 10 FUEL SYSTEM 228 6 11 CYLINDER BALANCING DIESEL 230 6 12 MAIN FUEL INJECTION 232 6 13 PAGE INDEX 234 6 14 EXHAUST VALVES 236 6 15 FAILURE LIST 238 6 16 CYLINDER LUBRICATION 240 6 17 USER PARAMETERS 242 6 18 PERFORMANCE DATA DIESEL 244 6 19 TEMPERATURES 246 6 20 SOFTWARE INFO 248 6 21 L...

Page 16: ...rbochargers are defective example 403 10 10 All turbochargers are defective example 404 10 11 Exhaust waste gate example 407 10 12 SCR system covers 413 10 13 SCR system covers 415 CHAPTER 11 TECHNICAL DATA 11 1 Operating range 419 11 2 Signal codes 422 11 3 Engine cross section 436 11 4 Engine longitudinal section 437 CHAPTER 12 OPERATING MEDIA 12 1 Selection of cylinder oil BN related to the fue...

Page 17: ...1 Operation Manual change record 18 1 2 Preface 20 1 3 Technical documentation set 22 1 4 Data module codes descriptive data 24 1 5 Data module codes procedural data 26 1 6 Conventions 28 1 7 List of abbreviations 34 17 ...

Page 18: ... 2018 01 is replaced with the revised issue 002 published on 2018 11 revised Revised issue 001 2018 01 All data modules n a Completely revised Operation Manual The initial issue 001 of the Operation Manual published on 2017 06 is replaced with the revised issue 001 published on 2018 01 New issue 001 2017 06 All data modules n a Initial issue of the Operation Manual X52 AA00 0000 00AAA 003A A Opera...

Page 19: ...X52 AA00 0000 00AAA 003A A Operation Manual Operation Manual change record Page left intentionally blank Winterthur Gas Diesel Ltd 19 Issue 002 2018 11 ...

Page 20: ...his manual are related to drawings from WinGD These data relate to the date of issue of the manual the year of the issue is shown on the title page and on the footer All instructions graphics and illustrations etc can change because of continuous new development and modifications Equipment and tools Keep all equipment and tools for maintenance and operation serviceable and in good condition Spare ...

Page 21: ...X52 AA00 0000 00AAA 018A A Operation Manual Preface Page left intentionally blank Winterthur Gas Diesel Ltd 21 Issue 002 2018 11 ...

Page 22: ...the standard engine with all cylinder numbers alternative designs and special equipment In this manual the engine connections refer to the pipe connection plan are the interface of the description For a description of the plant supply systems refer to the Marine Installation Manual 1 3 2 Maintenance Manual The Maintenance Manual MM contains data about disassembly assembly procedures that are neces...

Page 23: ...The setting tables shop trial documents schematic diagrams and survey certificates of the related engine are given with the first supply of the documentation 1 3 6 Marine Installation Manual The Marine Installation Manual MIM contains data for design engineers and naval architects enabling them to optimize plant items and machinery space and to do installation design work X52 AA00 0000 00AAA 018B ...

Page 24: ...ber 4 numeric char acters 0 9 arbitrary 5551 2 Used for sequential numbering of data modules 2 numeric char acters 0 9 sequential starts with 00 00 1 Used for alternative items differing in de sign but not enough to change the vari ant code 3 alphabetic characters A Z sequential starts with AAA AAA 2 Shipdex information code eg 043 de scription of function attributed to the crew functional breakdo...

Page 25: ...X52 AA00 0000 00AAA 018D A Operation Manual Data module codes descriptive data Page left intentionally blank Winterthur Gas Diesel Ltd 25 Issue 002 2018 11 ...

Page 26: ... of cylinders 2 numeric char acters 0 9 arbitrary 00 2 WinGD design group number 4 numeric char acters 0 9 arbitrary 5556 2 Used for sequential numbering for the physical breakdown of components 00 complete component 01 first break down for illustrated parts tools it is used for sequential numbering of data modules 2 numeric char acters 0 9 sequential starts with 00 00 1 Used for alternative items...

Page 27: ...em has been removed from the prod uct D information related to all three locations A B and C No other combi nations are allowed 1 alphabetic character A D Shipdex specif ic A 1 Placeholder symbol for alphabetic characters 2 Placeholder symbol for numeric characters NOTE For the full list of available Shipdex information codes and more data about the Shipdex specification refer to www shipdex org X...

Page 28: ... In the electronic version a mouse click on the text shows the related section NOTE A link as eg WINGD AA00 HA1 50 0000 00AAA 311D A shows that this cross reference and the related text are not applicable for this manual Instructions In procedures instructions are numbered numeric as steps eg 1 2 3 A detailed description of a step is divided into sub steps eg 2 1 2 2 Notes Notes give more data to ...

Page 29: ...ted procedure to prevent this CAUTION The signal word CAUTION gives a dangerous situation at which moderate or small injury are possible Do the related procedure to prevent this 1 6 3 Groups of components Each component of the engine has a four digit material number WinGD has divided these components related to the first digit of the number into 9 groups Group 1 Framework and bearings Group 2 Cyli...

Page 30: ...h supply of fuel and other operating media FE Free End closed short side ES Exhaust Side long side with discard of the exhaust gas and supply of scavenge air Fig 1 1 Outline drawing long side generic DE FE n n 1 2 1 004 003 001 002 Legend FE Free end DE Driving end 001 Turbocharger 003 Flywheel 002 Auxiliary blower 004 Supply unit X52 AA00 0000 00AAA 018C A Operation Manual Conventions Winterthur ...

Page 31: ...FS ES 001 002 003 005 004 Legend ES Exhaust side FS Fuel side 001 Turbocharger 004 Supply unit 002 Auxiliary blower 005 Rail unit 003 Flywheel X52 AA00 0000 00AAA 018C A Operation Manual Conventions Winterthur Gas Diesel Ltd 31 Issue 002 2018 11 ...

Page 32: ...el In radial direction the numbering starts from the center of the flywheel Fig 1 3 Engine numbering generic FE DE n n 004 003 001 002 n 1 n 1 4 3 2 1 2 1 Legend FE Free end DE Driving end 001 Cylinder number 003 Thrust bearing 002 Main bearing number 004 Flywheel X52 AA00 0000 00AAA 018C A Operation Manual Conventions Winterthur Gas Diesel Ltd 32 Issue 002 2018 11 ...

Page 33: ...X52 AA00 0000 00AAA 018C A Operation Manual Conventions Page left intentionally blank Winterthur Gas Diesel Ltd 33 Issue 002 2018 11 ...

Page 34: ...sumption BSPC Brake Specific Pilot fuel Consumption CAN Controller Area Network CCAI Calculated Carbon Aromaticity Index CCM Cylinder Control Module CCW counterclockwise CMCR Contract Maximum Continuous Rating COC Cleveland Open Cup CPP Controllable Pitch Propeller CS crankshaft CW clockwise Cyl cylinder DBT Delta Bypass Tuning DCC Dynamic Combustion Control DE Driving End DENIS Diesel Engine coNt...

Page 35: ...uel Side FZG Forschungsstelle für Zahnräder und Getriebebau gear research center GAV Gas Admission Valve GSS Gas Safety System GTD General Technical Data GVU Gas Valve Unit HFO Heavy Fuel Oil HFR High Feed Rate HP High Pressure HT High Temperature IACS International Association of Classification Societies iCAT integrated Cylinder lubricant Auto Transfer ICC Intelligent Combustion Control ICM Intel...

Page 36: ... Pressure LT Low Temperature MARPOL International Convention for the Prevention of Pollution from Ships MARine POLlution MCM Main Control Module MCR Maximum Continuous Rating MDO Marine Diesel Oil MEG MonoEthylene Glycol MEP Mean Effective Pressure MGO Marine Gas Oil MIM Marine Installation Manual MM Maintenance Manual Modbus serial communications protocol published by Modicon MPG MonoPropylene Gl...

Page 37: ...eduction SCS Speed Control System SHD shutdown SLD slowdown SOI Start Of Injection SPC Spare Parts Catalogue SPC Steam Production Control TC TurboCharger TDC Top Dead Center UNIC UNIfied Controls USB Universal Serial Bus VCU exhaust Valve Control Unit VEC Variable Exhaust valve Closing VEO Variable Exhaust valve Opening VIT Variable Injection Timing WECS Wärtsilä Engine Control System WHR Waste He...

Page 38: ...X52 AA00 0000 00AAA 005A A Operation Manual List of abbreviations Page left intentionally blank Winterthur Gas Diesel Ltd 38 Issue 002 2018 11 ...

Page 39: ...nd safety rules 40 2 2 Contamination and fire in the scavenge air spaces 42 2 3 Fire fighting in the scavenge air space 44 2 4 Explosions in the crankcase 48 2 5 Prevent explosions in the crankcase 50 2 6 Access to engine spaces 52 39 ...

Page 40: ...s and devices in positions in the engine room near the area where you use them Make sure that all tools have protection from corrosion Make sure that all tools are fixed to prevent from unwanted movement and from damage Spare parts Keep large spare parts as near as possible to the position where they will be installed and near the engine room crane Make sure that the spare parts have protection fr...

Page 41: ...s with applicable materials Do work inside the engine with a safety person on the outside Put covers or protection on opened openings or on removed sealing faces Attach removed parts in the engine room to prevent movement of the parts Replace O rings during an overhaul of components Make sure that after installation all pipes and items are fixed correctly Use lock wires tab washers and lock plates...

Page 42: ...nt The silencer and diffuser on the air side of the turbocharger has contamination The wire mesh and nozzle ring upstream of the turbocharger has contamination The exhaust gas boiler the air cooler and water separator the air flaps in the scavenge air receiver and the scavenge ports have contamination 2 2 1 2 Blow by The causes of blow by are as follows Worn piston rings broken piston rings or pis...

Page 43: ...se a fire You must do regular checks of the bottom of the cylinder block and scavenge air receiver to keep clean the cylinder block and scavenge air receiver refer to 8 5 Do checks during operation general 2 2 3 Indication of a fire The indications of a fire are as follows You can hear the related temperature alarms A large increase in the exhaust gas temperature of the related cylinder and an inc...

Page 44: ...tion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS Refer to 2 2 Contamination and fire in the scavenge air spaces X52 AA00 0000 00AAA 140B A Operation Manual Fire fighting in the scavenge air...

Page 45: ...prevent corrosion 2 If you think there is a fire do the steps as follows 2 1 Shut down the engine 2 2 Fight the fire with the installed fire extinguishing system 3 After approximately 5 minutes to 15 minutes do the checks as follows 3 1 Do a check of the exhaust gas temperature 3 2 Do a careful check of the temperatures of the doors to the piston underside space 4 Find the causes of the problems a...

Page 46: ...CLOSE UP None X52 AA00 0000 00AAA 140B A Operation Manual Fire fighting in the scavenge air space Winterthur Gas Diesel Ltd 46 Issue 002 2018 11 ...

Page 47: ...X52 AA00 0000 00AAA 140B A Operation Manual Fire fighting in the scavenge air space Page left intentionally blank Winterthur Gas Diesel Ltd 47 Issue 002 2018 11 ...

Page 48: ...quently The cause of crankcase explosions is oil mist Oil mist comes from components that have become unusually hot The engine has oil mist detectors refer to 5 9 3 Oil mist detector Correct engine maintenance will help prevent explosions in the crankcase X52 AA00 0000 00AAA 012C A Operation Manual Explosions in the crankcase Winterthur Gas Diesel Ltd 48 Issue 002 2018 11 ...

Page 49: ...X52 AA00 0000 00AAA 012C A Operation Manual Explosions in the crankcase Page left intentionally blank Winterthur Gas Diesel Ltd 49 Issue 002 2018 11 ...

Page 50: ...SN QTY None SAFETY PRECAUTIONS WARNING Danger If an oil mist alarm is activated keep away from the engine There is a risk of explosion WARNING Danger Do not open the crankcase doors or the covers for a minimum of 20 minutes after engine stop If air goes into the crankcase an explosion can occur WARNING Injury hazard The crankcase doors have relief valves To prevent accidents no person must be in t...

Page 51: ...erature decrease for a minimum of 20 minutes 1 4 Find the cause and repair the fault NOTE If no fire extinguishing system is installed or not in use a portable fire extinguisher must be kept ready when the crankcase doors are opened CLOSE UP None X52 AA00 0000 00AAA 012D A Operation Manual Prevent explosions in the crankcase Winterthur Gas Diesel Ltd 51 Issue 002 2018 11 ...

Page 52: ...Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00 0000 00AAA 012E A Operation Manual Access to engi...

Page 53: ...n 6 Engage the turning gear and lock the lever in this position NOTE Other ships in the water cause currents which cause the movement of the propeller and the engine The engine and propeller cannot move when the turning gear is engaged 7 If applicable open the indicator valves or the relief valves on the cylinder cover 8 Make sure that there is sufficient air in the engine spaces eg use a ventilat...

Page 54: ...X52 AA00 0000 00AAA 012E A Operation Manual Access to engine spaces Page left intentionally blank Winterthur Gas Diesel Ltd 54 Issue 002 2018 11 ...

Page 55: ...3 Design and function of the engine 3 1 Short description of the engine 56 3 2 Use of the engine 58 3 3 The relation between engine and propeller 62 55 ...

Page 56: ...er operation Related to the design the engine turns clockwise or counterclockwise for the ahead direction For the astern direction the engine can turn in the other direction The engine control system ECS electronically controls all important engine functions eg speed control overspeed protection and fuel injection The engine control can have different remote controls which are related to the WinGD...

Page 57: ... gases expand and push the piston down The pressure in the combustion chamber decreases Sequence 4 1 The scavenge air replaces the exhaust gas as follows At 4 the exhaust valve opens At a the scavenge ports get uncovered Scavenge air enters the cylinder and pushes the exhaust gas into the exhaust gas manifold At b the scavenge ports get covered At 1 the exhaust valve closes The cycle is completed ...

Page 58: ...range Fig 3 2 Operating range R1 R1 R2 R2 R4 R4 R3 S P Legend R1 Highest power at highest speed R3 Highest power at lowest speed R1 Highest power at highest speed extended R4 Lowest power at lowest speed R2 Lowest power at highest speed P Power R2 Lowest power at highest speed extended S Speed The intended use of the engine includes the items that follow Obey this Operation Manual Obey the related...

Page 59: ...rrect use will be the responsibility of the operating company The actions that follow must be looked as examples to be an incorrect use Operation of the engine with disabled changed or defective safety devices Operation of the engine with personnel which is not approved X52 AA00 0000 00AAA 020C A Operation Manual Use of the engine Winterthur Gas Diesel Ltd 59 Issue 002 2018 11 ...

Page 60: ...ypass tuning The delta bypass tuning decreases the fuel consumption below 50 engine power compared to delta tuning For more than 50 of engine power the fuel consumption is the same as delta tuning but the steam production is increased Low load tuning The low load tuning decreases the fuel consumption below 75 engine power compared to delta tuning or delta bypass tuning But it increases the fuel co...

Page 61: ... to the specified rules of the classification societies and of WinGD You can operate the two engines in different operation modes eg engine one is in diesel mode engine two is in gas mode if gas mode is applicable Fig 3 4 Twin engine propulsion Legend 001 Port position 002 Starboard position X52 AA00 0000 00AAA 020C A Operation Manual Use of the engine Winterthur Gas Diesel Ltd 61 Issue 002 2018 1...

Page 62: ...d clean hull the applicable power is lower and the operation point is below the nominal propeller property During operation a higher torque is necessary for the propeller to keep its speed than at the time of the sea trial sea margin because There are changes in wake flow conditions because of marine growth on the hull The cargo load has an effect on the depth of the vessel in the water The propel...

Page 63: ... the timing of dry dock intervals This margin is usually subtracted from the CMCR Thus to get the 100 power line you divide the power at point D by between 0 85 to 0 90 3 3 2 3 Load range limits Fig 3 5 Schematic diagram Relation Speed Power FPP 110 100 95 90 80 70 60 50 40 65 70 80 90 95 104 100 108 Engine power Rx Engine speed Rx Propeller curve without SM EM OM SM 4 3 1 2 5 6 CMCR Rx B A D Engi...

Page 64: ...ngine speed and power is near the data in Line 5 there will be a decrease in scavenge air which has an effect on the engine The area between Lines 1 3 and 5 show the range in which the engine must be operated The area in the nominal propeller property 100 power and Line 3 is recommended for continuous operation The area between the nominal propeller property and Line 5 must be reserved for acceler...

Page 65: ...s calculation Along Line 8 the power increase from 37 point F to 100 power CMCR at 100 speed is the constant speed mode for the shaft generator operation Line 5 is the top load limit and relates to the permitted torque limit The area between 70 and 100 speed and between Line 5 and Line 9 shows the area that an engine with a CPP must be operated Line 7 shows a typical combinator curve for variable ...

Page 66: ...ion with shaft generators During maneuvering the combinator curve follows the Line 9 At sea the engine is operated between point F and 100 power Line 8 at constant speed For manual and or emergency operation different setpoints for speed and pitch are usually supplied An alarm is also usually given in the main engine safety system or the alarm and monitoring system when the engine operates for mor...

Page 67: ...em 70 4 3 Wash water system 72 4 4 System oil system 74 4 5 Servo oil system 76 4 6 Cylinder oil system 78 4 7 Starting air system 80 4 8 Scavenge air system 82 4 9 Control air system 84 4 10 Exhaust gas system 86 4 11 Fuel system 88 4 12 HP Selective catalytic reduction system 92 67 ...

Page 68: ...ine codes in Figure 4 1 Fig 4 1 Line codes for systems 001 002 003 004 007 006 008 009 005 Legend 001 Main supply pipe 006 Double wall pipe 002 Drain leakage pipe 007 Heating pipe 003 Vent pipe 008 Insulated pipe 004 Waste pipe dirty drain pipe 009 Trace heated and insulated pipe 005 Optional pipe X52 AA00 0000 00AAA 043U A Operation Manual General for systems Winterthur Gas Diesel Ltd 68 Issue 00...

Page 69: ...X52 AA00 0000 00AAA 043U A Operation Manual General for systems Page left intentionally blank Winterthur Gas Diesel Ltd 69 Issue 002 2018 11 ...

Page 70: ...01 cylinder cooling water inlet Connection 02 cylinder liner cooling water inlet bypass cooling water system optional Connection 03 cylinder cooling water outlet Connection 05 cylinder cooling water drain outlet Connection 07 SAC LT cooling water inlet not shown Connection 08 SAC LT cooling water outlet not shown If the supply at the engine connection 02 is installed the cylinder liner is supplied...

Page 71: ...1 Automatic venting unit 005 Shut off valve 002 Shut off valve cooling water outlet 006 Drain valve 003 Shut off valve if supply 02 is installed 007 Orifice 004 Shut off valve if supply 02 is not installed 008 Vent valve X52 AA00 0000 00AAA 043A A Operation Manual Cooling water system Winterthur Gas Diesel Ltd 71 Issue 002 2018 11 ...

Page 72: ... 12 air for cleaning plant for TC and SAC inlet Connection 13 oily water from receiver outlet Connection 16 SAC condensate water outlet Connection 17 SAC wash water outlet optional Connection 18 SAC venting Condensation and wash water flow through the cyclone separator and back to the plant at the connection 16 The wash water system has the parts that follow Wash water tank The wash water tank 001...

Page 73: ...ENGINE 13 18 16 06 17 06 005 002 002 003 003 001 004 Legend 001 Wash water tank 004 Cyclone separator 002 Scavenge air cooler SAC 005 Turbocharger 003 Auxiliary blower X52 AA00 0000 00AAA 043P A Operation Manual Wash water system Winterthur Gas Diesel Ltd 73 Issue 002 2018 11 ...

Page 74: ... vertical Connection 25 main oil inlet Connection 26 lubricating oil turbocharger inlet optional Connection 27 lubricating oil turbocharger outlet Connection 30 lubricating oil crosshead inlet optional Connection 37 leakage oil gland box outlet System oil from the bearings and gear wheels drops into the crankcase The system oil system has the parts that follow Oil pipes The oil pipes connect the i...

Page 75: ...gend 001 Turbocharger 007 Crosshead 002 iELBA optional 008 Thrust bearing 003 Torsional vibration damper optional 009 Oil sample valve 004 Axial vibration damper 010 Lever 005 Main bearing 011 Supply pipe to servo oil system 006 Crank bearing 012 Piston X52 AA00 0000 00AAA 043B A Operation Manual System oil system Winterthur Gas Diesel Ltd 75 Issue 002 2018 11 ...

Page 76: ...re oil pipes have double wall Inspection points in the pipes let find oil leaks Service oil pump The service oil pump 005 supplies the servo oil system with oil before the engine start Servo oil pump number related to the configuration The servo oil pumps 004 supply the servo oil system with oil during usual operation Servo oil rail The servo oil rail 007 supplies the exhaust valve control units w...

Page 77: ...n control unit ICU for X82 and X92 006 Oil pipe to exhaust valve 002 Exhaust valve control unit VCU 007 Servo oil rail 003 Square collector pipe 008 Rail unit 004 Servo oil pump 009 Pressure reducing valve 005 Service oil pump 010 Distributor pipe mini rail X52 AA00 0000 00AAA 043Q A Operation Manual Servo oil system Winterthur Gas Diesel Ltd 77 Issue 002 2018 11 ...

Page 78: ...lter The duplex oil filter 004 filters the oil before it flows to the cylinder lubricating pumps The change over valve makes it possible to shut off one filter chamber Cylinder lubricating pump Each cylinder has a cylinder lubricating pump 003 Servo oil operates the cylinder lubricating pumps The ECS controls the cylinder lubricating pumps Lubricating quill The lubricating quills 002 spray oil bet...

Page 79: ...iCAT 007 004 003 002 001 Legend 001 Oil sample valve 005 Square collector pipe 002 Lubricating quill 006 Rail unit 003 Cylinder lubricating pump 007 Change over valve 004 Duplex oil filter 008 Servo oil supply X52 AA00 0000 00AAA 043R A Operation Manual Cylinder oil system Winterthur Gas Diesel Ltd 79 Issue 002 2018 11 ...

Page 80: ...arting air supply pipe 007 supplies the starting valves of each cylinder with starting air The starting air supply pipe has a safety valve 003 and two drain valves 004 Starting valve Each cylinder has a starting valve with a solenoid valve 001 Each starting valve supplies the related cylinder with the specified quantity of starting air at the correct time Valve unit for start E The valve unit for ...

Page 81: ...noid valve 006 Disengaging device turning gear 002 Flame arrestor 007 Starting air supply pipe 003 Safety valve 008 Valve unit for start E 004 Drain valve 009 Starting air shut off valve 005 Control air supply 010 Collector for leakage oil from the air spring X52 AA00 0000 00AAA 043C A Operation Manual Starting air system Winterthur Gas Diesel Ltd 81 Issue 002 2018 11 ...

Page 82: ... blower 010 supplies the scavenge air at the engine start and during low load operation Auxiliary blower switch box The auxiliary blower switch box controls the auxiliary blowers Scavenge air cooler The scavenge air cooler SAC 006 decreases the temperature of the hot compressed air from the turbocharger This increases the mass of air and thus increases the quantity of air that is supplied to the c...

Page 83: ... gas outlet 010 Auxiliary blower 003 Scavenge air inlet 011 Piston underside 004 Turbine 012 Piston 005 Compressor 013 Scavenge air receiver 006 Scavenge air cooler 014 Cylinder liner 007 Water separator 015 Exhaust valve 008 Charging unit X52 AA00 0000 00AAA 043S A Operation Manual Scavenge air system Winterthur Gas Diesel Ltd 83 Issue 002 2018 11 ...

Page 84: ...upply The control air supply 002 decreases the supply air pressure to the specified pressures Air tank The air tank 003 is a container for control air If the two plant air supply systems become defective the air tank supplies control air to the engine for a short period Air bottle The air bottle 001 collects condensation from the starting air Collector for leakage oil from the air spring The colle...

Page 85: ... 003 004 Cyl 1 Cyl n Legend 001 Air bottle 005 Starting air shut off valve 002 Control air supply 006 Valve unit for start 003 Air tank 007 Collector for leakage oil from the air spring 004 Disengaging device X52 AA00 0000 00AAA 043T A Operation Manual Control air system Winterthur Gas Diesel Ltd 85 Issue 002 2018 11 ...

Page 86: ... connection 71 exhaust gas turbocharger outlet in Figure 4 10 marked with a circle The exhaust gas system has the parts that follow Exhaust valve The exhaust valve 004 of each cylinder releases the exhaust gas of the combustion into the exhaust gas manifold Exhaust gas manifold The exhaust gas manifold 003 collects the exhaust gas from the cylinders Turbocharger bypass pipe Usually the engine has ...

Page 87: ... E N G I N E 003 001 002 Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl n 004 Legend 001 Turbocharger bypass pipe 003 Exhaust gas manifold 002 Turbocharger 004 Exhaust valve X52 AA00 0000 00AAA 043D A Operation Manual Exhaust gas system Winterthur Gas Diesel Ltd 87 Issue 002 2018 11 ...

Page 88: ... consumption The ECS cuts out a different injection valve at regular intervals to get an equal thermal load in the combustion chamber There is no time limit to operate the engine at low load The fuel system has the parts that follow Fuel pipes The fuel pipes connect the items of the fuel system All the fuel pipes have a trace heating to keep the fuel warm during operation and for short engine stop...

Page 89: ...not for X82 X92 and RT flex installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity of fuel Injection control unit The injection control units 003 ICU for X82 X92 and RT flex installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity of fuel Injection valve The injection valves 006 supply the fuel into the combustion ...

Page 90: ...3 004 005 006 007 008 009 Cyl 1 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Flow limiting valve FLV 008 Fuel pump 004 Fuel rail 009 Pressure retaining valve 005 Rail unit X52 AA00 0000 00AAA 043E A Operation Manual Fuel system Winterthur Gas Diesel Ltd 90 Issue 002 2018 11 ...

Page 91: ...ANT 001 002 004 005 003 007 008 009 006 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Injection control unit ICU 008 Fuel pump 004 Fuel rail 009 Pressure retaining valve 005 Rail unit X52 AA00 0000 00AAA 043E A Operation Manual Fuel system Winterthur Gas Diesel Ltd 91 Issue 002 2018 11 ...

Page 92: ...it controls the supply of urea solution to the mixing duct Mixing duct The mixing duct has an injection lance which is a double wall pipe In the inner part the urea solution is supplied In the outer part compressed air is supplied In the injection nozzle at the end of the lance the two components are mixed and injected through holes into the exhaust gas flow After the injection of the urea solutio...

Page 93: ...valve FC fail closed V7 Reactor relief valve FO fail open NOTE In the fail condition the engine operates in Tier II mode The turbine bypass valve V4 is also used for other functions of the ECS eg for low load tuning LLT or for steam production control SPC For more data about the function of the valves refer to the chapters that follow Fig 4 13 HP SCR system layout V1 V2 V3 V7 V4 003 001 007 006 00...

Page 94: ...C Use of low sulphur fuel 0 5 S urea injection ON 310 C 470 C Use of high sulphur fuel 0 5 S urea injection ON 1 325 to 340 C 2 470 C 1 Refer to the HP SCR system documentation if the operation of the HP SCR system with high sulphur fuel is permitted 2 The engine control system ECS calculates this value related to the engine load and to the exhaust gas pressure 4 12 2 Operation modes The HP SCR sy...

Page 95: ...ct operation of the HP SCR system is not given eg if a bus connection is defective The valves have the conditions that follow V1 Closed V2 Closed V3 Open V4 Controlled by the ECS V7 Closed can be opened to decrease the pressure in the reactor Fig 4 14 HP SCR system emergency bypass V1 V2 V3 V7 V4 003 001 007 006 005 004 002 00522 Legend 001 Mixing duct 005 Venting sealing unit 002 Reactor 006 Urea...

Page 96: ...crease the exhaust gas temperature V7 Closed can be opened to decrease the pressure in the reactor Then the preservation sequence starts as follows to prevent corrosion of the reactor and of the pipes refer to Figure 4 16 The purging sequence uses compressed air to remove the remaining urea solution from the injection equipment from the pipes and from the reactor The venting sealing unit starts an...

Page 97: ... Engine After that procedure or directly the venting sealing unit supplies compressed air to keep a pressure in the reactor and in the pipes This makes a seal against the exhaust gas to prevent damage of the reactor Make sure that the pressure in the reactor is more than the exhaust gas pressure The valves have the conditions that follow V1 Closed V2 Closed V3 Open V4 Controlled by the ECS V7 Clos...

Page 98: ...Legend 001 Mixing duct 005 Venting sealing unit 002 Reactor 006 Urea solution supply unit 003 Turbine of turbocharger 007 Soot blowing unit 004 Engine X52 AA00 9270 00AAA 043A A Operation Manual HP Selective catalytic reduction system Winterthur Gas Diesel Ltd 98 Issue 002 2018 11 ...

Page 99: ...ed V4 Controlled by the ECS V7 Closed If necessary you can operate the engine in this mode for longer periods eg to be ready for a fast change to Tier III mode Fig 4 18 HP SCR system preparation V1 V2 V3 V7 V4 003 001 007 006 005 004 002 00523 Legend 001 Mixing duct 005 Venting sealing unit 002 Reactor 006 Urea solution supply unit 003 Turbine of turbocharger 007 Soot blowing unit 004 Engine X52 A...

Page 100: ...e air flow and thus to increase the exhaust gas temperature V7 Closed can be opened to decrease the pressure in the reactor Fig 4 19 HP SCR system Tier III V1 V2 V3 V7 V4 003 001 007 006 005 004 002 00524 Legend 001 Mixing duct 005 Venting sealing unit 002 Reactor 006 Urea solution supply unit 003 Turbine of turbocharger 007 Soot blowing unit 004 Engine X52 AA00 9270 00AAA 043A A Operation Manual ...

Page 101: ... the HP SCR system 4 12 3 HP SCR control system The HP SCR control system has the three control boxes that follow Control box E48 Control box E49 Control box E50 Each control box is connected through bus connections or hard wired connections The control box E48 is connected to the engine control system ECS and to the external HP SCR system control through bus connections or hard wired connections ...

Page 102: ...Indication SPC running 002 Option SPC SPC bypass switch 008 Indication urea injection 003 Indication minor failure 009 Indication major failure 004 Indication SCR pre heating on 010 Hour meter 005 Option SPC Indication SPC failure 011 Indication power on 006 Option SPC Indication SPC bypass 012 Power switch X52 AA00 9270 00AAA 043A A Operation Manual HP Selective catalytic reduction system Wintert...

Page 103: ...om and has switches below the LDU 20 Fig 4 22 Control box E49 00562 001 002 003 Legend 001 LDU 20 003 Option SPC SPC bypass switch 002 SCR bypass switch X52 AA00 9270 00AAA 043A A Operation Manual HP Selective catalytic reduction system Winterthur Gas Diesel Ltd 103 Issue 002 2018 11 ...

Page 104: ...as follows SCR ON This message shows that the HP SCR system is set to ON SCR minor failure This message shows a failure that does not have an effect on HP SCR system operation SCR major failure This message shows a failure that has an effect on HP SCR system operation The HP SCR control system stops the HP SCR system operation and changes to Tier II mode 4 12 4 LDU 20 pages For the HP SCR system t...

Page 105: ... 006 Indication Shows the SCR status failure and mode 007 Status indication Shows the control location 008 Status indication Shows the SCR status 009 Button and indication Starts and indicates the related SCR operation mode 010 Button and indication Stops and indicates the external heating system 011 Status indication Shows the status of the SCR system NOTE After boot up of the LDU 20 the main pag...

Page 106: ... control system if the button is on 006 Indication Shows the SCR status failure and mode 007 Status indication Shows the SCR status 008 Value indication Shows the values 009 Indication Shows the V4 setpoint if E48 has control in Tier II mode the ECS controls V4 010 Indication Shows the engine status 011 Indication Shows the current value and the valve setpoint value in percent 0 to 100 012 Indicat...

Page 107: ...49 gets control from the remote control system if button is on 006 Indication Shows the SCR status failure and mode 007 Status indication Shows the control location 008 Status indication Shows the auxiliary blower status in preparation mode and Tier III mode E48 controls the auxiliary blowers 009 Indication Shows different sensor signals 010 Status indication Shows the status of external systems 0...

Page 108: ... SCR status failure and mode 007 Status indication Shows the control location 008 Button and indication Changes and shows between automatic and manual valve movement serviceable only if the manual mode is permitted 009 Indication and input field First value shows the valve value in percent Second value shows the valve setpoint value in percent Third value shows the valve setpoint value in percent ...

Page 109: ...rol from the remote control system if button is active 006 Engine type Shows the applicable engine 007 Manufacturer number Shows the software manufacturer number 008 DB number Shows identification number of the installation 009 Software version Shows the software version number major middle minor eg 1 2 0 010 Software IMO number Shows the software number given from IMO 011 Application CRC Cyclic R...

Page 110: ...X52 AA00 9270 00AAA 043A A Operation Manual HP Selective catalytic reduction system Page left intentionally blank Winterthur Gas Diesel Ltd 110 Issue 002 2018 11 ...

Page 111: ...gear 144 5 3 5 Connecting rod and connecting rod bearing 146 5 3 6 Crosshead and guide shoe 148 5 3 7 Piston 150 5 4 Group 4 Drive supply unit and control elements 5 4 1 Supply unit drive 152 5 4 2 Starting air shut off valve 154 5 4 3 Control air supply 156 5 4 4 Local maneuvering stand 158 5 4 5 Pick up for speed measurement 160 5 5 Group 5 Supply unit pumps and control valves 5 5 1 Servo oil pu...

Page 112: ...linder lubrication 5 7 1 Cylinder lubrication 188 5 7 2 Integrated electrical balancer iELBA 190 5 8 Group 8 Piping 5 8 1 Exhaust waste gate 196 5 9 Group 9 Monitoring system 5 9 1 Crank angle sensor unit 198 5 9 2 Water in oil monitor 200 5 9 3 Oil mist detector 202 112 ...

Page 113: ...Page left intentionally blank 113 ...

Page 114: ...ft The bottom part of the bedplate is the crankcase and collects lubricating oil This oil flows back to the oil supply system through oil drains 002 The length of the bedplate is related to the number of cylinders Fig 5 1 Bedplate generic 001 002 Legend 001 Bearing girder 002 Oil drain X52 AA00 1115 00AAA 043A A Operation Manual Bedplate Winterthur Gas Diesel Ltd 114 Issue 002 2018 11 ...

Page 115: ...X52 AA00 1115 00AAA 043A A Operation Manual Bedplate Page left intentionally blank Winterthur Gas Diesel Ltd 115 Issue 002 2018 11 ...

Page 116: ...sion is applied to the elastic studs during the install procedure The round nuts 002 keep the bearing cover 003 against the bearing girder Oil flows from the bedplate through the oil inlet 011 to the main bearings The oil flows through the grooves 012 and bores to the running surface of the main bearing Fig 5 2 Main bearing generic 001 002 003 004 005 005 011 006 007 008 005 005 009 009 012 013 01...

Page 117: ...X52 AA00 1132 00AAA 043A A Operation Manual Main bearing Page left intentionally blank Winterthur Gas Diesel Ltd 117 Issue 002 2018 11 ...

Page 118: ... on the driving end adapt the propeller thrust of the astern direction The thrust pads adapt to the clockwise or counterclockwise rotation of the engine The arbor supports 004 prevent circular movement of the thrust pads Bearing oil flows through the oil pipe 002 to the two nozzles 003 The oil flows out of the two nozzles as a spray which becomes an oil layer between the thrust bearing flange 014 ...

Page 119: ...il pipe 010 2 part oil baffle 003 Nozzle 011 Flywheel 004 Arbor support 012 Bedplate 005 Bedplate 013 Thrust pad engine side 006 Thrust pad driving end 014 Thrust bearing flange 007 Bearing cover 015 Column 008 Crankshaft gear wheel X52 AA00 1203 00AAA 043A A Operation Manual Thrust bearing Winterthur Gas Diesel Ltd 119 Issue 002 2018 11 ...

Page 120: ... the fuel side FS the monoblock column has one door 002 per cylinder During normal operation the doors are closed and locked For maintenance or inspection work the doors can be opened Obey the safety rules before you open the doors The length of the monoblock column is related to the number of cylinders Fig 5 4 Monoblock column generic FS ES 001 002 Legend 001 Relief valve FS Fuel side 002 Door ES...

Page 121: ...X52 AA00 1406 00AAA 043A A Operation Manual Monoblock column Page left intentionally blank Winterthur Gas Diesel Ltd 121 Issue 002 2018 11 ...

Page 122: ... 5 Tie rod generic 001 002 003 004 005 001 Legend 001 Protection cover 004 Tie rod 002 Cylinder block 005 Bedplate 003 Column If a tie rod breaks in the bottom area a special device makes sure that the nut of the tie rod does not fall into the crankcase X52 AA00 1903 00AAA 043A A Operation Manual Tie rod Winterthur Gas Diesel Ltd 122 Issue 002 2018 11 ...

Page 123: ...X52 AA00 1903 00AAA 043A A Operation Manual Tie rod Page left intentionally blank Winterthur Gas Diesel Ltd 123 Issue 002 2018 11 ...

Page 124: ...tallic seal 005 A non hardening compound is applied around the surface of the metallic seal to prevent leakage The antipolishing ring 001 is installed in the top part of the cylinder liner 004 The antipolishing ring removes coke contamination at the piston crown during operation Fig 5 6 Cylinder liner generic Legend 001 Antipolishing ring 005 Metallic seal 002 Oil grooves 006 Cylinder jacket 003 L...

Page 125: ...r 002 Figure 5 7 and the exhaust valve cage 001 The cooling water flows back through the cooling water outlet 003 to the cooling water system of the plant To prevent unwanted tension in the top part of the cylinder liner 004 Figure 5 6 the temperature of the cooling water must stay in the permitted range 2 C at constant load 4 C during load changes X52 AA00 2124 00AAA 043A A Operation Manual Cylin...

Page 126: ...s out of the nozzle tip 003 and the lubricating point 004 as a spray Some of the cylinder oil flows into the grooves of the cylinder liner wall The non return valve 009 prevents the exhaust gas to flow back into the oil pipe Fig 5 8 Lubricating quill generic 001 002 003 004 008 007 006 009 005 Legend 001 Piston 006 Cylinder oil inlet 002 Piston ring 007 Holder 003 Nozzle tip 008 Cylinder liner 004...

Page 127: ...X52 AA00 2138 00AAA 043A A Operation Manual Lubricating quill Page left intentionally blank Winterthur Gas Diesel Ltd 127 Issue 002 2018 11 ...

Page 128: ...4 Neutral space 010 Gasket 4 part 005 Cylinder jacket 011 Tension spring 006 Support During operation the two scraper rings 001 Figure 5 9 remove dirty oil from the piston rod The dirty oil flows through oil bores and collects in the bottom of the scavenge space The dirty oil flows out through the leakage oil drain on the fuel side The two gaskets 010 prevent the release of scavenge air into the c...

Page 129: ...X52 AA00 2303 00AAA 043A A Operation Manual Piston rod gland Page left intentionally blank Winterthur Gas Diesel Ltd 129 Issue 002 2018 11 ...

Page 130: ...l system Fuel leakage with a small quantity of lubricating oil flows from the depressurized annular groove 003 through drain pipes to the plant overflow tank Oil from the main oil supply lubricates the control element in the injection valves If for the engine it is necessary to stop the oil flow after engine stop a solenoid valve is installed in the oil supply pipe Thus this solenoid valve closes ...

Page 131: ...X52 AA00 2722 00AAA 043A A Operation Manual Direct controlled injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 131 Issue 002 2018 11 ...

Page 132: ...d closes at the correct crank angle of the related cylinder This makes the piston move down for engine start or makes the piston speed decrease for engine speed decrease As soon as combustion starts the starting air supply stops Fig 5 11 Starting valve example 001 002 003 004 005 006 007 008 009 Legend 001 Solenoid valve 006 Valve spindle 002 Cover 007 Cylinder cover 003 Piston 008 Starting air ou...

Page 133: ...X52 AA00 2728 00AAA 043A A Operation Manual Starting valve Page left intentionally blank Winterthur Gas Diesel Ltd 133 Issue 002 2018 11 ...

Page 134: ...ring piston 011 Air spring 005 Valve spindle 012 Leakage oil collection space 006 Valve cage 013 Hydraulic oil inlet 007 Valve seat 014 Damper The exhaust valve has the parts that follow Inside piston and outside piston The inside piston and the outside piston 002 Figure 5 12 move down when the VCU applies pressurized oil through the hydraulic oil inlet 013 The valve spindle 005 moves down and the...

Page 135: ...e outer piston and inner piston 002 lubricates the air spring piston 004 Oil in the leakage oil collection space 012 drains to the leakage oil drain While the exhaust valve closes oil flows through the air spring piston 004 and into the air spring 011 The air in the air spring 011 changes oil that collects at the bottom of the air spring into a mist The mist lubricates the upper part of the valve ...

Page 136: ...crankshaft gear wheel 005 is part of the thrust bearing On the driving end of the crankshaft there is a flywheel 004 This flywheel decreases the pulsation from the cylinders The length of the crankshaft is related to the number of cylinders Fig 5 13 Crankshaft generic 001 002 003 004 005 Legend 001 Torsional vibration damper optional 004 Flywheel 002 Crank 005 Crankshaft gear wheel 003 Crankshaft ...

Page 137: ...X52 AA00 3103 00AAA 043A A Operation Manual Crankshaft Page left intentionally blank Winterthur Gas Diesel Ltd 137 Issue 002 2018 11 ...

Page 138: ...ions in the shafting system and in other components of the engine If a torsional vibration damper is necessary for the engine one of the two damper types that follow can be used X52 AA00 3130 00AAA 043A A Operation Manual Torsional vibration damper Winterthur Gas Diesel Ltd 138 Issue 002 2018 11 ...

Page 139: ...r If torsional vibrations move the steel springs oil is pressurized on one side of the oil chambers and pushed through small clearances to the other side of the chambers This small oil flow creates the damping effect of the damper The combined effect of spring stiffness and damping decreases the torsional vibrations in the shafting system The damping work causes heat which is dissipated by the oil...

Page 140: ...ent speeds This difference shears the silicone oil and thus decreases the vibration The damping work causes heat This heat increases the temperature of the outer side of the damper The heat dissipates to the ambient air in the crankcase If installed system oil is sprayed on the damper to dissipate more heat The oil drains into the crankcase If the viscous damper gets too much dynamic torque and th...

Page 141: ...X52 AA00 3130 00AAA 043A A Operation Manual Torsional vibration damper Page left intentionally blank Winterthur Gas Diesel Ltd 141 Issue 002 2018 11 ...

Page 142: ...r half 002 Figure 5 16 and a bottom cylinder half 006 Fig 5 16 Axial vibration damper generic Legend 001 Control plate 007 Bearing girder part of bedplate 002 Top cylinder half 008 Small sealing ring 003 Annular space 009 Bearing cover 004 Crankshaft 010 Inlet pipe 005 Large sealing ring 011 Non return valve 006 Bottom cylinder half 012 Oil inlet X52 AA00 3140 00AAA 043A A Operation Manual Axial v...

Page 143: ... bore in the top cylinder half 002 keeps air away from the annular spaces 003 The small oil leakage through the gap of the large sealing rings 005 drains into the crankcase 5 3 3 2 Axial vibration damper monitor The axial vibration damper monitor monitors the oil pressure in the two annular spaces 003 Figure 5 16 of the axial vibration damper The needle valve 004 Figure 5 17 and the throttle 003 p...

Page 144: ...turns the pinion 002 and is attached on the driving end of the engine Related to the ratio of the gear wheels there is approximately one full turn of the crankshaft in ten minutes Fig 5 18 Turning gear generic 001 002 003 Legend 001 Electric motor 003 Flywheel 002 Pinion X52 AA00 3206 00AAA 043A A Operation Manual Turning gear Winterthur Gas Diesel Ltd 144 Issue 002 2018 11 ...

Page 145: ...X52 AA00 3206 00AAA 043A A Operation Manual Turning gear Page left intentionally blank Winterthur Gas Diesel Ltd 145 Issue 002 2018 11 ...

Page 146: ...g oil flows through the guide shoe into the crosshead pin A hole in the crosshead pin lets lubricating oil flow into the bearing shells Fig 5 19 Connecting rod and connecting rod bearing generic Legend 001 Top bearing cover 006 Round nut 002 Bearing shell top end bearing 007 Elastic bolt 003 Top bearing shell bottom end bearing 008 Dowel pin 004 Bottom bearing cover 009 Allen screw 005 Bottom bear...

Page 147: ...X52 AA00 3303 00AAA 043A A Operation Manual Connecting rod and connecting rod bearing Page left intentionally blank Winterthur Gas Diesel Ltd 147 Issue 002 2018 11 ...

Page 148: ... into the crankcase The guide shoes 004 are attached to the crosshead pin 006 and move up and down on the guide ways of the column The guide rails 008 hold the guide shoes 004 and thus the crosshead in the horizontal position Fig 5 20 Crosshead and guide shoe example 003 004 007 009 010 006 005 002 001 008 Legend 001 Oil pipe from piston 006 Crosshead pin 002 Space 007 Compression shim 003 Top bea...

Page 149: ...X52 AA00 3326 00AAA 043A A Operation Manual Crosshead and guide shoe Page left intentionally blank Winterthur Gas Diesel Ltd 149 Issue 002 2018 11 ...

Page 150: ...ified compression ratio System oil is used to keep cool the piston crown 001 This oil flows from the crosshead pin into the space 005 between the oil pipe 007 and the piston rod 004 The oil then flows to the spray plate 010 The oil comes out as a spray from the nozzles 011 into the cooling bores of the piston crown 001 The oil then flows through the oil pipe 007 into the crosshead pin and out thro...

Page 151: ...X52 AA00 3403 00AAA 043A A Operation Manual Piston Page left intentionally blank Winterthur Gas Diesel Ltd 151 Issue 002 2018 11 ...

Page 152: ...eels 004 for the servo oil pumps The camshaft of the gear wheel 005 also operates the fuel pumps Oil flows through an oil inlet to lubricate the bearings of the gear wheels 004 Oil also flows through the nozzles in the bearing housing to lubricate the teeth of the gear wheels 004 and the gear wheel 005 If you hear unusual noises from the area of the supply unit drive you must find the cause and re...

Page 153: ...003 007 Legend 001 Intermediate wheel 005 Gear wheel servo oil pumps 002 Flywheel 006 Intermediate wheel 003 Crankshaft gear wheel 007 Crankshaft 004 Gear wheel servo oil pump X52 AA00 4104 00AAA 043A A Operation Manual Supply unit drive Winterthur Gas Diesel Ltd 153 Issue 002 2018 11 ...

Page 154: ... 005 To test valve 014 Solenoid valve CV7014C 006 Spring 015 Double check valve 007 Valve 016 Solenoid valve CV7013C 008 Starting air inlet 017 Control air inlet 009 Balance bore 018 Lever With the lever 018 Figure 5 23 you can lock the valve in the selected position During usual operation the starting air shut off valve is in position AUTO Starting air flows through the starting air inlet 008 int...

Page 155: ... from the inlet chamber 012 flows through the non return valve 010 to the starting air outlet 011 When the control valve 001 closes starting air flows through the balance bores 009 and fills the inlet chamber 012 again The valve 007 closes The starting air shut off valve has a test valve You can use this test valve for a function check of the starting air shut off valve X52 AA00 4325 00AAA 043A A ...

Page 156: ...d by supply The non return valves 007 and 010 control the automatic change over of the compressed air supply Fig 5 24 Control air supply generic 003 004 005 006 007 008 009 010 011 012 001 002 Legend 001 Pressure transmitter PT4411A 007 Non return valve 35 342HA 002 Pressure transmitter PT4401A 008 Pressure reducing valve 35 23HA 003 Pressure gauge PI4401L 009 Pressure reducing valve 35 19HA 004 3...

Page 157: ...X52 AA00 4605 00AAA 043A A Operation Manual Control air supply Page left intentionally blank Winterthur Gas Diesel Ltd 157 Issue 002 2018 11 ...

Page 158: ... components can look different because the remote control manufacturer supplies the local control panel 001 For data about maneuvering instructions refer to 8 8 Maneuver the ship general Fig 5 25 Local maneuvering stand Legend 001 Local control panel 003 Main engine tachometer 002 LDU 20 004 Telegraph receiver X52 AA00 4618 00AAA 043A A Operation Manual Local maneuvering stand Winterthur Gas Diese...

Page 159: ...0 general ME tachometer The ME tachometer 003 shows the engine speed in the ahead or astern directions Emergency stop button NOTE Not all local control panels have an emergency stop button installed When you operate the emergency stop button not shown the engine stops immediately The fuel pressure control valve PCV releases the pressure in the fuel rail At the same time the fuel pump supply decrea...

Page 160: ...roximity sensors measure the speed of the flywheel 003 Figure 5 26 When the flywheel turns the proximity sensors 002 sense the movement of the teeth The engine control system sends signals to the RCS to monitor the load and speed related functions Data are also sent to the speed indication instruments Fig 5 26 Pick up for speed measurement generic 002 001 003 004 Legend 001 Cover 003 Flywheel 002 ...

Page 161: ...X52 AA00 4628 00AAA 043A A Operation Manual Pick up for speed measurement Page left intentionally blank Winterthur Gas Diesel Ltd 161 Issue 002 2018 11 ...

Page 162: ...e of the servo oil pumps A malfunction of a servo oil pump will show in the alarm and monitoring system If a servo oil pump cannot turn for safety the waisted shaft 003 will break This will prevent too much damage to the supply unit drive Also if one servo oil pump becomes defective the engine can continue to operate at full load NOTE Do not operate the engine with a defective servo oil pump for t...

Page 163: ...X52 AA00 5551 00AAA 043A A Operation Manual Servo oil pump Page left intentionally blank Winterthur Gas Diesel Ltd 163 Issue 002 2018 11 ...

Page 164: ...ne The gear wheels and intermediate wheels in the supply unit operate the fuel pumps and servo oil pumps refer to 5 4 1 Supply unit drive Fig 5 28 Supply unit example Legend 001 Fuel pump 004 Bedplate 002 Supply unit with covers 005 Column 003 Flywheel X52 AA00 5552 00AAA 043A A Operation Manual Supply unit Winterthur Gas Diesel Ltd 164 Issue 002 2018 11 ...

Page 165: ...X52 AA00 5552 00AAA 043A A Operation Manual Supply unit Page left intentionally blank Winterthur Gas Diesel Ltd 165 Issue 002 2018 11 ...

Page 166: ...pression spring 004 The pump plunger 003 then moves up The control grooves in the pump plunger 003 control the fuel quantity When the toothed rack 011 moves the teeth engage with the teeth on the regulating sleeve 010 and the regulating sleeve turns The regulating sleeve 010 turns the driver 009 and thus the pump plunger 003 The quantity of fuel that goes into the plunger chamber is related to the...

Page 167: ...mp Leakage fuel lubricates the pump plunger 003 The leakage fuel and the engine lubricating oil from the regulating sleeve 010 flows through the drain bore into an internal bore in the housing of the fuel pump unit 5 5 3 3 Operation with an unserviceable fuel pump If a fuel pump is unserviceable eg the pump plunger cannot move or the HP fuel pipe is broken between the fuel pump and the fuel rail t...

Page 168: ...djusted pressure If this occurs longer engine operation time must be prevented to save fuel After this operation mode do a check of the valve for a tight seal The seal can be damaged You can hear a loud sound like a whistle Replace the valve seal if necessary Engine stand by During engine stand by the engine software opens the PCV This gives a constant flow of fuel through the fuel system to keep ...

Page 169: ...nd 001 Solenoid valve ZV7061S 005 Fuel return pipe 002 Pressure control valve 10 5562_E0_5 006 Rail unit 003 Relief valve 007 Fuel rail 004 Fuel return pipe 008 Drain pipe X52 AA00 5562 00AAA 043A A Operation Manual Pressure control valve Winterthur Gas Diesel Ltd 169 Issue 002 2018 11 ...

Page 170: ...ion valves are closed the piston 003 moves back to the start position If the injection time is too long eg if an injection valve is stuck open the piston 003 closes the supply If an injection valve is damaged the flow limiting valve sets the maximum limit of fuel that can be injected into the cylinder Fig 5 32 Flow limiting valve generic Legend 001 Fuel outlet 003 Piston 002 Fuel inlet X52 AA00 55...

Page 171: ...X52 AA00 5565 00AAA 043A A Operation Manual Flow limiting valve Page left intentionally blank Winterthur Gas Diesel Ltd 171 Issue 002 2018 11 ...

Page 172: ...operates servo oil is released to the slide rod 001 Figure 5 33 This releases servo oil to the piston 003 Thus servo oil from the servo oil outlet 004 opens the exhaust valve Fig 5 33 Exhaust valve control unit VCU example 001 002 003 004 Legend 001 Slide rod 003 Piston 002 Servo oil inlet 004 Servo oil outlet X52 AA00 5612 00AAA 043A A Operation Manual Exhaust valve control unit Winterthur Gas Di...

Page 173: ...X52 AA00 5612 00AAA 043A A Operation Manual Exhaust valve control unit Page left intentionally blank Winterthur Gas Diesel Ltd 173 Issue 002 2018 11 ...

Page 174: ...o fuels pumps are connected to there related actuator The ECS controls the fuel pump actuators During operation the fuel pump actuators move at the same time Each fuel pump actuator has an overload protection Thus you do not have to disconnect a fuel pump actuator if the regulating sleeve of a fuel pump cannot move X52 AA00 5583 00AAA 043A A Operation Manual Fuel pump actuator Winterthur Gas Diese...

Page 175: ...X52 AA00 5583 00AAA 043A A Operation Manual Fuel pump actuator Page left intentionally blank Winterthur Gas Diesel Ltd 175 Issue 002 2018 11 ...

Page 176: ...more data about the scavenge air system refer to 4 8 Scavenge air system Fig 5 34 Scavenge air receiver example 001 002 003 004 005 Legend 001 Scavenge air from turbocharger 004 Auxiliary blower 002 Diffuser 005 Scavenge air receiver 003 Scavenge air cooler The longitudinal wall 002 Figure 5 35 divides the scavenge air receiver into the receiver space 003 and the air space 001 The flaps 005 are at...

Page 177: ...n example 001 002 005 004 003 Legend 001 Air space 004 Outlet to piston underside 002 Longitudinal wall 005 Flap 003 Receiver space X52 AA00 6420 00AAA 043A A Operation Manual Scavenge air receiver Winterthur Gas Diesel Ltd 177 Issue 002 2018 11 ...

Page 178: ...ple Legend 001 Compressor 005 Turbine 002 Air inlet 006 Exhaust gas outlet 003 Silencer 007 Exhaust gas inlet 004 Air outlet If a turbocharger becomes defective you must stop the engine as quickly as possible to prevent damage If repair or replacement of a turbocharger is not immediately possible you can cut out the defective turbocharger refer to 10 13 Temporary isolate a defective turbocharger T...

Page 179: ...X52 AA00 6500 00AAA 043A A Operation Manual Turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 179 Issue 002 2018 11 ...

Page 180: ...t auxiliary blower starts immediately After approximately two to three seconds the other auxiliary blower starts If one of the auxiliary blowers becomes defective you also can start and operate the engine At less than full load there will be more exhaust smoke If the two auxiliary blowers become defective you cannot start the engine When the turbochargers give sufficient pressure in the scavenge a...

Page 181: ...X52 AA00 6545 00AAA 043A A Operation Manual Auxiliary blower Page left intentionally blank Winterthur Gas Diesel Ltd 181 Issue 002 2018 11 ...

Page 182: ... blower No 1 002 Indicator auxiliary blower No 2 overload 008 Control voltage indicator 003 Hour counter auxiliary blower No 2 009 Hour counter auxiliary blower No 1 004 Ampere meter auxiliary blower No 2 010 Indicator auxiliary blower No 1 running 005 Main switch auxiliary blower No 2 011 Indicator auxiliary blower No 1 overload 006 Main switch auxiliary blower No 1 X52 AA00 6547 00AAA 043A A Ope...

Page 183: ...X52 AA00 6547 00AAA 043A A Operation Manual Auxiliary blower switch box Page left intentionally blank Winterthur Gas Diesel Ltd 183 Issue 002 2018 11 ...

Page 184: ... The cooling water flows constantly through the tubes of the SAC and flows back to the cooling water system of the plant The SAC has a cover 004 Figure 5 39 For maintenance you can remove the cover Fig 5 39 Scavenge air cooler generic 001 002 003 004 Legend 001 Air flow 003 Cooling water inlet 002 Cooling water outlet 004 Cover X52 AA00 6606 00AAA 043A A Operation Manual Scavenge air cooler Winter...

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Page 186: ... of wet air Water also occurs during the wash procedure of the SAC The profiles 002 Figure 5 40 hold back the water in the air flow This water collects at the bottom of the frame 003 and then flows back to the drain system Fig 5 40 Water separator generic 003 002 001 Legend 001 Air flow 003 Frame 002 Profile X52 AA00 6708 00AAA 043A A Operation Manual Water separator Winterthur Gas Diesel Ltd 186 ...

Page 187: ...X52 AA00 6708 00AAA 043A A Operation Manual Water separator Page left intentionally blank Winterthur Gas Diesel Ltd 187 Issue 002 2018 11 ...

Page 188: ... the related solenoid valve 004 Figure 5 41 of the cylinder lubricating pump the solenoid valve 004 operates Then a specified quantity of cylinder oil flows through the oil outlet 001 to the related lubricating quills Each cylinder lubricating pump has two bushes for different feed rates The low feed rate LFR bush is installed on the adjustment screw The high feed rate HFR bush is installed in the...

Page 189: ... gives equal lubrication on to the cylinder liner wall The ECS parameters adjust the timing which gives the position and percentage of cylinder oil on the cylinder liner wall and between the piston rings Figure 5 42 The ECS parameters also adjust the timing with its percentage supply of the feed rate during the first commissioning Fig 5 42 Usual vertical oil supply ABOVE 70 INTO 25 BELOW 25 X52 AA...

Page 190: ...the forces F are always canceled The vertical elements Fvert are always added to a resulting vertical force This resulting force operates up and down with the same frequency as the counterweights 002 turn The resulting force is transmitted through the bearings 003 to the column 005 and thus to the engine The rotating speed ω of the counterweights 002 is always two times the engine rotating speed a...

Page 191: ...A function Legend 001 Gear wheel 004 Housing 002 Counterweight 005 Column 003 Bearing X52 AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas Diesel Ltd 191 Issue 002 2018 11 ...

Page 192: ... heavy sea mode the iELBA does not operate The engine can also operate if one or the two balancers do not operate eg in manual mode or if a balancer is defective Then it is possible that there are more vibrations on the hull When the power for the iELBA is set to ON it takes some seconds to complete the initialisation of the system The iELBA operates independently of the engine control system ECS ...

Page 193: ... 45 shows the buttons and indications on the control cabinet of the iELBA Fig 5 45 iELBA control cabinet X52 AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas Diesel Ltd 193 Issue 002 2018 11 ...

Page 194: ...t Shows the state of the running iELBA Lamp blinks iELBA is in swing state Lamp is steady iELBA is in run state H4 Synch OK indicator light Shows the synchronisation state of the iELBA Lamp is steady iELBA is synchronised to the engine Lamp blinks slowly iELBA is 15 from engine syn chronisation Lamp blinks quickly iELBA is 30 from engine syn chronisation S1 Emergency stop button Stops the iELBA im...

Page 195: ...oost to Control Speed Threshold not OK OFF 2 Start OK Setpoint Speed not OK in 60 s OFF 3 Start OK speed OK Phase Synchronisation not OK in 60 s OFF 4 Overspeed error OFF 5 Electric motor error OFF 6 The lubricating oil pressure is too low OFF 7 iELBA pickup sensor error OFF 8 TDC pickup sensor error Usual operation 9 BDC pickup sensor error Usual operation X52 AA00 7752 00AAA 043A A Operation Man...

Page 196: ...eneric 001 002 003 004 005 006 007 008 Legend 001 Air inlet 005 Exhaust gas manifold 002 Compressor 006 Turbine 003 Scavenge air receiver 007 Valve 004 Engine 008 Exhaust gas outlet If the turbochargers deliver too much scavenge air pressure the ECS opens the valve 007 If the valve 007 is controllable the ECS opens it as much as necessary This decreases the performance of the turbochargers and thu...

Page 197: ...X52 AA00 8135 00AAA 043A A Operation Manual Exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 197 Issue 002 2018 11 ...

Page 198: ...teeth on the intermediate wheel The two sets of proximity sensors 003 Figure 5 47 operate independently to sense the teeth on the intermediate wheel 002 Fig 5 47 Crank angle sensor unit on intermediate wheel example Legend 001 Supply unit 003 Proximity sensor 002 Intermediate wheel X52 AA00 9223 00AAA 043A A Operation Manual Crank angle sensor unit Winterthur Gas Diesel Ltd 198 Issue 002 2018 11 ...

Page 199: ... follows First sensor pair to MCM 20 and CCM 20 1 Second sensor pair from CCM 20 2 to CCM 20 n TDC and BDC to all CCM 20 Fig 5 48 Crank angle sensor unit on flywheel example Legend 001 Cover 003 Flywheel 002 Proximity sensor 004 Crank angle mark X52 AA00 9223 00AAA 043A A Operation Manual Crank angle sensor unit Winterthur Gas Diesel Ltd 199 Issue 002 2018 11 ...

Page 200: ...nal to the alarm and monitoring system AMS On the display 001 Figure 5 49 you can see the data that follow aw water activity T temperature in C H2O water content in ppm Fig 5 49 Water in oil monitor generic 002 001 003 Legend 001 Display 003 Connection points 002 Keypad X52 AA00 9313 00AAA 043A A Operation Manual Water in oil monitor Winterthur Gas Diesel Ltd 200 Issue 002 2018 11 ...

Page 201: ...X52 AA00 9313 00AAA 043A A Operation Manual Water in oil monitor Page left intentionally blank Winterthur Gas Diesel Ltd 201 Issue 002 2018 11 ...

Page 202: ...nd and explosions in the crankcase can be prevented The system includes the sensors 002 Figure 5 50 and the control unit 003 on the engine Fig 5 50 Oil mist detector example 004 003 001 002 Legend 001 Data cable 003 Control unit E15 1 002 Sensor 004 Column Each sensor monitors the concentration of oil mist Each sensor has a self test function to make sure that there are no internal faults X52 AA00...

Page 203: ...e adjustments can be programmed in the display unit 001 The menu driven software has three user levels User Read only of data Operator Password protected level for access to most adjustments and functions Service Password protected level for authorized staff of the manufacturer and service personnel NOTE Instructions that relate to adjustments commissioning troubleshooting and maintenance are give...

Page 204: ...X52 AA00 9314 00AAA 043A A Operation Manual Oil mist detector Page left intentionally blank Winterthur Gas Diesel Ltd 204 Issue 002 2018 11 ...

Page 205: ...AUST VALVES 236 6 4 10 LDU 20 page FAILURE LIST 238 6 4 11 LDU 20 page CYLINDER LUBRICATION 240 6 4 12 LDU 20 page USER PARAMETERS 242 6 4 13 LDU 20 page PERFORMANCE DATA DIESEL 244 6 4 14 LDU 20 page TEMPERATURES 246 6 4 15 LDU 20 page SOFTWARE INFO 248 6 4 16 LDU 20 page LOG MESSAGES 250 6 4 17 LDU 20 page LOG ENTRY DATA 252 6 4 18 LDU 20 page SYSTEM STATUS 254 6 4 19 LDU 20 page SOFTWARE TOOLS ...

Page 206: ...to data and system adjustments Input output module IOM 10 The input output module IOM 10 is installed at the rail unit in the terminal box E90 The IOM 10 has the engine control functions eg exhaust waste gate control and redundant sensor and actuator signals of the MCM 11 Cylinder control module CCM 20 The cylinder control modules CCM 20 for each cylinder are installed on the rail unit in the term...

Page 207: ...e main functions of the engine control system are as follows Starting valve control Servo oil pressure control Exhaust valve control Cylinder lubricating control Engine speed and crank angle sensor monitoring Diesel fuel pressure control Diesel fuel injection control For a DF engine also gas injection control X52 AA00 0000 00AAA 043K A Operation Manual Engine control system Winterthur Gas Diesel L...

Page 208: ...to 13 1 Schematic diagrams general NOTE The communications between the systems can be different See the related documentation from the approved propulsion control system manufacturer 6 1 3 1 Propulsion control system The propulsion control system PCS has the subsystems that follow Remote control system The remote control system RCS has the primary functions that follow Start stop and reverse Autom...

Page 209: ...afe and satisfactory engine operation The functions of the AMS are specified in the diesel engine control and optimizing specification DENIS The AMS sends signals to the engine safety system to slow down or shut down the engine For more data see the documentation of the AMS manufacturer X52 AA00 0000 00AAA 043K A Operation Manual Engine control system Winterthur Gas Diesel Ltd 209 Issue 002 2018 1...

Page 210: ...gnals D E N I S U N I C E n g i n e S p e c i f i c a t i o n Fuel Gas Supply System Only for Dual Fuel Engines 2 x AMS CANBus Signals for Alarm Indication Indications Command Orders from RCS Ethernet to ECR Manual Control Signals for Alarm and Slowdown UNIC Alarm Signals Feedback Signals from UNIC Signals for Alarm Signals for Safety Signals for Control Signals for Control Gas SHD and Venting GVU...

Page 211: ...X52 AA00 0000 00AAA 043K A Operation Manual Engine control system Page left intentionally blank Winterthur Gas Diesel Ltd 211 Issue 002 2018 11 ...

Page 212: ...ression and firing pressures in the engine eg injection time offsets and exhaust valve closing time for each cylinder This decreases the excessive wear of engine components This decreases the risk of an engine overload This prevents manual adjustment failures In the ECS you can set to OFF or ON each individual function of the ICC system When all ICC functions are set to OFF the engine operates in ...

Page 213: ...he injection and approximately 20 CA after TDC The pressure increase is the difference between the firing pressure and the compression pressure The ICC sets the pressure increase limit eg to 40 bar to prevent mechanical overload to the engine Fig 6 3 ICC pressure diagram 001 002 Cylinder pressure bar Crank angle Legend 001 Pressure at 0 CA 002 Peak firing pressure X52 AA00 9308 00AAA 043A A Operat...

Page 214: ... the sensors and then transmits these signals to a controller The measured value is adjusted to the correct setpoint value and is related to the engine load This real time site correction and comparison is done for each engine cycle refer to Figure 6 4 Fig 6 4 ICC control schematic Measured values Target values X52 AA00 9308 00AAA 043A A Operation Manual Intelligent combustion control Winterthur G...

Page 215: ...X52 AA00 9308 00AAA 043A A Operation Manual Intelligent combustion control Page left intentionally blank Winterthur Gas Diesel Ltd 215 Issue 002 2018 11 ...

Page 216: ...verview POWER STATUS PUSH SELECT 00209 001 009 008 008 008 008 008 008 007 006 002 003 005 004 Legend 001 Power LED 006 CHECK button used to accept the action or enter data 002 Status LED 007 HOME button push to show the main page 003 Rotary button 16 steps in one turn push to select 008 Multi function buttons function is shown on the display 004 BACK button used to cancel the action or delete dat...

Page 217: ...6 6 An orange arrow 001 shows the active item A 3D rectangle 002 indicates a command button An orange frame 003 indicates the edit mode A black dotted frame 004 around an item shows the position of the cursor A white background 005 shows a parameter which the operator can adjust A grey background 006 shows a parameter which the operator cannot adjust Fig 6 6 LDU 20 color display general items 004 ...

Page 218: ...LURE LIST 6 4 11 LDU 20 page CYLINDER LUBRICATION 6 4 12 LDU 20 page USER PARAMETERS 6 4 13 LDU 20 page PERFORMANCE DATA DIESEL 6 4 14 LDU 20 page TEMPERATURES 6 4 15 LDU 20 page SOFTWARE INFO 6 4 16 LDU 20 page LOG MESSAGES 6 4 17 LDU 20 page LOG ENTRY DATA 6 4 18 LDU 20 page SYSTEM STATUS 6 4 19 LDU 20 page SOFTWARE TOOLS 6 4 20 LDU 20 page SYSTEM SETTINGS 6 4 21 LDU 20 page ETHERNET 6 4 22 LDU ...

Page 219: ...X52 AA00 9606 01AAA 043A A Operation Manual LDU 20 pages general Page left intentionally blank Winterthur Gas Diesel Ltd 219 Issue 002 2018 11 ...

Page 220: ...AIN Fig 6 7 MAIN 002 001 004 003 006 005 008 007 009 014 007 013 011 010 012 016 015 017 022 023 020 021 018 019 X52 AA00 9606 02AAA 043A A Operation Manual LDU 20 page MAIN Winterthur Gas Diesel Ltd 220 Issue 002 2018 11 ...

Page 221: ... a transfer request if one control location requests a control transfer 014 Indication of status Shows the status of different items if applicable 015 Speed Setpoint button Changes to manual speed control mode 016 Manual speed setpoint Manually adjust the rpm between zero and maximum The max imum value is related to the installation specifications rating etc 017 External speed setpoint Shows the s...

Page 222: ...Item Function Effect 023 Fuel Command button Changes to manual fuel command mode X52 AA00 9606 02AAA 043A A Operation Manual LDU 20 page MAIN Winterthur Gas Diesel Ltd 222 Issue 002 2018 11 ...

Page 223: ...X52 AA00 9606 02AAA 043A A Operation Manual LDU 20 page MAIN Page left intentionally blank Winterthur Gas Diesel Ltd 223 Issue 002 2018 11 ...

Page 224: ...CONTROL LOCATIONS Fig 6 8 CONTROL LOCATIONS 00153 002 001 004 003 012 009 007 010 011 008 006 005 X52 AA00 9606 03AAA 043B A Operation Manual LDU 20 page CONTROL LOCATIONS Winterthur Gas Diesel Ltd 224 Issue 002 2018 11 ...

Page 225: ...PCS Communication lines between the ECS and the remote control system Shows OK or ERROR 008 Local button Requests or accepts a control transfer to or from the LDU 20 on the engine 009 ECR manual button Requests or accepts a control transfer to or from the LDU 20 in the ECR 010 ECR remote button Requests or accepts a control transfer to or from the remote control system in the ECR 011 Bridge button...

Page 226: ... LDU 20 page CA SENSOR STATUS Fig 6 9 CA SENSOR STATUS 002 001 004 003 008 006 005 007 X52 AA00 9606 05AAA 043B A Operation Manual LDU 20 page CA SENSOR STATUS Winterthur Gas Diesel Ltd 226 Issue 002 2018 11 ...

Page 227: ...a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Status indication Shows the status of the crank angle sensors Green status OK Red status not OK 008 Reset Status button Resets the status of the crank angle sensors X52 AA00 9606 05AAA 043B A Operation Manual LDU 20 page CA SEN...

Page 228: ... 6 10 FUEL SYSTEM 002 001 004 003 006 005 NOTE Some indications on this LDU 20 page are only applicable for a DF engine X52 AA00 9606 16AAA 043B A Operation Manual LDU 20 page FUEL SYSTEM Winterthur Gas Diesel Ltd 228 Issue 002 2018 11 ...

Page 229: ...D button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page X52 AA00 9606 16AAA 043B A Operation Manual LDU 20 page FUEL SYSTEM Winterthur Gas Diesel Ltd 229 Issue 002 2018 11 ...

Page 230: ...INDER BALANCING DIESEL Fig 6 11 CYLINDER BALANCING DIESEL 002 001 004 003 009 008 006 005 007 X52 AA00 9606 06AAA 043B A Operation Manual LDU 20 page CYLINDER BALANCING DIESEL Winterthur Gas Diesel Ltd 230 Issue 002 2018 11 ...

Page 231: ...INT button Makes a screenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Compr Balancing button Changes the compression balancing function Green ON Red OFF 008 Firing Balancing button Changes the firing balancing function Green ON Red OFF 009 Firing Control button Changes the firing control function Green ON Red OFF X52 AA00 9606 06AAA 04...

Page 232: ... page MAIN FUEL INJECTION Fig 6 12 MAIN FUEL INJECTION 002 001 004 003 009 008 006 005 007 X52 AA00 9606 23AAA 043B A Operation Manual LDU 20 page MAIN FUEL INJECTION Winterthur Gas Diesel Ltd 232 Issue 002 2018 11 ...

Page 233: ...he current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Inj Begin Offset Manually adjust the injection begin offset 1 5 to 1 5 degrees 008 Inj Quant Corr Manually adjust the injection quantity 80 to 110 if there are operation problems in the related cylinder 009 Inj Cutoff select button Manually select the operation mode Auto automatic operation Cutoff no...

Page 234: ...6 4 8 LDU 20 page PAGE INDEX Fig 6 13 PAGE INDEX 002 001 004 003 005 X52 AA00 9606 24AAA 043A A Operation Manual LDU 20 page PAGE INDEX Winterthur Gas Diesel Ltd 234 Issue 002 2018 11 ...

Page 235: ...ne 002 STOP button Stops the engine 003 START AHD button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 Page button Opens the selected page X52 AA00 9606 24AAA 043A A Operation Manual LDU 20 page PAGE INDEX Winterthur Gas Diesel Ltd 235 Issue 002 2018 11 ...

Page 236: ...DU 20 page EXHAUST VALVES Fig 6 14 EXHAUST VALVES 002 001 004 003 008 009 010 006 005 007 X52 AA00 9606 12AAA 043B A Operation Manual LDU 20 page EXHAUST VALVES Winterthur Gas Diesel Ltd 236 Issue 002 2018 11 ...

Page 237: ...tion mode selection button Selects the operation mode of the related exhaust valve On manual operation mode valve opens if conditions are OK Off automatic operation mode valve closes 008 Closing Offset Manually adjust the closing offset of the exhaust valve 009 Open Dead Times Shows the time between the open command to the solenoid valve of the VCU and the exhaust valve stroke start 010 Close Dead...

Page 238: ...4 10 LDU 20 page FAILURE LIST Fig 6 15 FAILURE LIST 002 001 004 003 008 006 005 007 009 X52 AA00 9606 13AAA 043B A Operation Manual LDU 20 page FAILURE LIST Winterthur Gas Diesel Ltd 238 Issue 002 2018 11 ...

Page 239: ...rol transfer to this LDU 20 005 LOG MSG button Opens the LOG MESSAGE page 006 INDEX button Opens the INDEX page 007 Filter button Manually select the applicable type filter for the related failure 008 Filter button Manually select the applicable category filter for the related fail ure 009 Scroll bar Manually scroll through the failure list X52 AA00 9606 13AAA 043B A Operation Manual LDU 20 page F...

Page 240: ...ON 002 001 004 003 016 008 006 005 009 010 011 012 007 014 013 015 NOTE Some indications on this LDU 20 page are only applicable for a DF engine X52 AA00 9606 08AAA 043B A Operation Manual LDU 20 page CYLINDER LUBRICATION Winterthur Gas Diesel Ltd 240 Issue 002 2018 11 ...

Page 241: ...on mode of the cylinder lubrication with the green indicator 010 On Off button Sets to ON and OFF the auxiliary electric servo oil pump servo oil service pump NOTE If necessary start this pump only in engine stop mode 011 Num of Inj Manually set the number of injections for lubrication at engine stop mode range 0 to 255 012 Man Lub Cyl Manually select the cylinder for manual lubrication Set 100 fo...

Page 242: ...R PARAMETERS Fig 6 17 USER PARAMETERS 00159 002 001 004 003 006 005 010 009 008 007 011 013 012 015 014 X52 AA00 9606 37AAA 043B A Operation Manual LDU 20 page USER PARAMETERS Winterthur Gas Diesel Ltd 242 Issue 002 2018 11 ...

Page 243: ...rank angle determination failure the related indicator is on 009 FQS Manually adjust the parameter for the fuel quality setting FQS from 5 to 5 A negative correction angle makes an earlier injection start and thus increases the maximum firing pressure A positive correction angle makes a later injection start and thus decreases the maximum firing pressure 010 VIT button Sets to ON and OFF the varia...

Page 244: ... page PERFORMANCE DATA DIESEL Fig 6 18 PERFORMANCE DATA DIESEL 002 001 004 003 006 005 X52 AA00 9606 25AAA 043B A Operation Manual LDU 20 page PERFORMANCE DATA DIESEL Winterthur Gas Diesel Ltd 244 Issue 002 2018 11 ...

Page 245: ...HD button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page X52 AA00 9606 25AAA 043B A Operation Manual LDU 20 page PERFORMANCE DATA DIESEL Winterthur Gas Diesel Ltd 245 Issue 002 2018 11 ...

Page 246: ...6 4 14 LDU 20 page TEMPERATURES Fig 6 19 TEMPERATURES 002 001 004 003 006 005 X52 AA00 9606 36AAA 043B A Operation Manual LDU 20 page TEMPERATURES Winterthur Gas Diesel Ltd 246 Issue 002 2018 11 ...

Page 247: ...HD button Starts the engine in ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page X52 AA00 9606 36AAA 043B A Operation Manual LDU 20 page TEMPERATURES Winterthur Gas Diesel Ltd 247 Issue 002 2018 11 ...

Page 248: ...6 4 15 LDU 20 page SOFTWARE INFO Fig 6 20 SOFTWARE INFO 002 001 004 003 006 005 007 X52 AA00 9606 31AAA 043B A Operation Manual LDU 20 page SOFTWARE INFO Winterthur Gas Diesel Ltd 248 Issue 002 2018 11 ...

Page 249: ...n ahead direction 004 CTRL TR button Sends a signal for a control transfer to this LDU 20 005 PRINT button Makes a screenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 IMO CRC INFO PAGE button Opens the IMO CRC INFO page X52 AA00 9606 31AAA 043B A Operation Manual LDU 20 page SOFTWARE INFO Winterthur Gas Diesel Ltd 249 Issue 002 2018 11 ...

Page 250: ...LDU 20 page LOG MESSAGES Fig 6 21 LOG MESSAGES 00164 002 001 004 003 008 007 009 010 006 005 X52 AA00 9606 22AAA 043B A Operation Manual LDU 20 page LOG MESSAGES Winterthur Gas Diesel Ltd 250 Issue 002 2018 11 ...

Page 251: ...eenshot of the current screen refer to 6 4 24 LDU 20 page SCREENSHOT 006 INDEX button Opens the INDEX page 007 Selected log message Shows the selected log message with a blue background 008 List of log messages Shows the messages with the latest message at the bottom 009 Filter button Manually select the applicable filter for the log messages 010 Scroll bar Manually scroll through the log messages...

Page 252: ... 20 page LOG ENTRY DATA Fig 6 22 LOG ENTRY DATA 00165 002 001 005 007 009 010 008 006 004 003 X52 AA00 9606 39AAA 043B A Operation Manual LDU 20 page LOG ENTRY DATA Winterthur Gas Diesel Ltd 252 Issue 002 2018 11 ...

Page 253: ...on Sends a signal for a control transfer to this LDU 20 005 INDEX button Opens the INDEX page 006 Acknowledge button Has no function 007 Module identifier Shows the source module that sent this log entry 008 Message type Shows the message type Shows Info Error Event Safety 009 Description Shows general data about the log entry 010 Recommended action Shows recommended action that the operator can d...

Page 254: ...8 LDU 20 page SYSTEM STATUS Fig 6 23 SYSTEM STATUS 00166 002 001 004 003 006 007 008 005 X52 AA00 9606 34AAA 043B A Operation Manual LDU 20 page SYSTEM STATUS Winterthur Gas Diesel Ltd 254 Issue 002 2018 11 ...

Page 255: ...to synchronize the module with the rest of the system Pre operational synchronization Module is booting up and waits for synchronization Pre operational ready Module is booting up every thing set up successfully and is ready to enter Opera tional state Operational Module operates correctly System soft ware and application initialized successfully None Module is set to OFF or disconnected from the ...

Page 256: ...DU 20 page SOFTWARE TOOLS Fig 6 24 SOFTWARE TOOLS 00167 007 008 006 009 002 001 005 003 004 X52 AA00 9606 33AAA 043B A Operation Manual LDU 20 page SOFTWARE TOOLS Winterthur Gas Diesel Ltd 256 Issue 002 2018 11 ...

Page 257: ...TR button Sends a signal for a control transfer to this LDU 20 005 INDEX button Opens the INDEX page 006 Mount Unmount button Handles the USB drive 007 Export button Exports all log messages to a file on a USB drive if connected 008 Start Wizard button Starts the partial upgrade wizard 009 Add User Not used X52 AA00 9606 33AAA 043B A Operation Manual LDU 20 page SOFTWARE TOOLS Winterthur Gas Diese...

Page 258: ...M SETTINGS Fig 6 25 SYSTEM SETTINGS 00169 007 008 010 009 016 015 012 011 014 013 002 001 003 004 006 005 X52 AA00 9606 35AAA 043B A Operation Manual LDU 20 page SYSTEM SETTINGS Winterthur Gas Diesel Ltd 258 Issue 002 2018 11 ...

Page 259: ... off display Adjusts the time period to turn off the display after inactivity Set to between 1 min and 100 min Set to 0 to never turn off the display 011 Test screensaver button Starts and stops the screensaver mode 012 Logo Selects the picture to use in the screensaver mode 013 Timeout Adjusts the time period to turn off the display after inactivity Set to between 1 min and 100 min 014 Screensave...

Page 260: ...21 LDU 20 page ETHERNET Fig 6 26 ETHERNET 002 001 004 003 008 009 010 012 013 011 006 005 007 X52 AA00 9606 41AAA 043B A Operation Manual LDU 20 page ETHERNET Winterthur Gas Diesel Ltd 260 Issue 002 2018 11 ...

Page 261: ...fault is 010 001 001 001 008 Enabled button Manually enable or disable the ethernet ports ETH 1 plug X31 ETH 2 plug X32 The two ports must be enabled by default 009 Address field Manually configure the TCP IP address for each ethernet port LDU 20 Local LDU 20 ECR 010 Netmask field Manually configure the TCP IP netmask 011 Duplex button Manually configure the ethernet duplex mode auto default half ...

Page 262: ...6 4 22 LDU 20 page DATE Fig 6 27 DATE 002 001 004 003 008 009 010 012 011 006 005 007 X52 AA00 9606 40AAA 043B A Operation Manual LDU 20 page DATE Winterthur Gas Diesel Ltd 262 Issue 002 2018 11 ...

Page 263: ...s 006 Cancel button Cancels the changes and goes back to the last saved settings 007 Time Synchronization Mode button Selects a Network Time Protocol NTP Not used 008 Local time Shows the time offset from UTC 009 UTC time Shows the coordinated universal time 010 Timezone button Opens a list with all available time zones 011 Set Date field Manually adjust the date setting 012 Set Time field Manuall...

Page 264: ...WG optional 002 001 004 003 006 005 007 008 009 010 This LDU 20 page is only applicable if the engine has a controllable exhaust waste gate X52 AA00 9606 29AAA 043B A Operation Manual LDU 20 page SCAVENGE AIR EWG optional Winterthur Gas Diesel Ltd 264 Issue 002 2018 11 ...

Page 265: ...he INDEX page 007 Activate Manual Command button Activates the manual exhaust waste gate command For a con trollable exhaust waste gate valve manually adjust the opening of the valve from 0 closed to 100 open 008 Manual Open Close Cmd button Sends a signal for a manual command to open close the ex haust waste gate 009 Manual Control Mode button Sends a signal for a mode change 010 Deposit Cleaning...

Page 266: ...ottom right hand corner of the display If no USB drive is connected or if there was an error during the save procedure to the USB drive the pop up message shows USB Mounting failed NOTE When the export is done disconnect the USB drive from the LDU 20 This prevents an unwanted LDU 20 shutdown because of a too high power consumption X52 AA00 9606 30AAA 043B A Operation Manual LDU 20 page SCREENSHOT ...

Page 267: ...X52 AA00 9606 30AAA 043B A Operation Manual LDU 20 page SCREENSHOT Page left intentionally blank Winterthur Gas Diesel Ltd 267 Issue 002 2018 11 ...

Page 268: ... page iELBA Control optional Fig 6 29 iELBA Control 002 001 004 003 005 006 007 008 009 X52 AA00 9606 42AAA 043B A Operation Manual LDU 20 page iELBA Control optional Winterthur Gas Diesel Ltd 268 Issue 002 2018 11 ...

Page 269: ...l Auto Mode Changes between automatic and manual control mode of the iELBA 007 Free End ON OFF In manual mode starts and stops the iELBA on the related en gine end 008 Operator Phase Setpoint In manual mode manually adjust the crank angle setpoint for the related engine end in manual mode 009 Auto Phase Setpoint In manual mode manually adjust the crank angle setpoint for the related engine end in ...

Page 270: ...ob completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine control system must be set to on X52 AA00 0000 00AAA 131I A Operation Manual Operate the local display unit LDU 20 Winte...

Page 271: ... the navigation menu 2 To edit a selected item on a LDU 20 page do the steps that follow NOTE Values and settings that the operator can change are shown with a white background 2 1 Use the rotary button to select the item NOTE While in edit mode the text field has an orange frame 2 2 Push and turn the rotary button To increase the value turn the rotary button clockwise To decrease the value turn t...

Page 272: ...lockwise to decrease 5 4 Push the rotary button again to go out of the edit mode WARNING After an air run the crankshaft can turn suddenly when the pressurized air in the cylinder releases There is a risk of death serious injury or damage to components Before you do maintenance on the engine engage the turning gear or start the Crank Angle Determination Algorithm ADA a second time Make sure that t...

Page 273: ... up or down 8 6 When the cursor a blue highlight in the list is on a selected log message push the rotary button This shows a different screen which has more data about this log entry 9 To export a screenshot from the LOG ENTRY page do the steps that follow 9 1 Connect a USB drive to the USB port on the rear of the LDU 20 Make sure that the USB drive has a compatible data format FAT32 9 2 Wait unt...

Page 274: ...rom the SOFTWARE TOOLS page do the steps that follow NOTE You use the partial upgrade wizard to adjust software parameters which the user does not usually have access A file from WinGD stored on a USB drive is necessary NOTE Connect the USB drive to the USB port on the back of the LDU 20 12 1 Use the rotary button to put the cursor on the Start Wizard button 12 2 Push the rotary button to select S...

Page 275: ...7 Installation 7 1 Installation 276 275 ...

Page 276: ...sses Outline views Platform arrangement Engine seating Engine coupling Propulsion shaft earthing Engine stays Extinguishing system Auxiliary systems NOTE The latest version of the Marine Installation Manual and the installation drawings are available on the WinGD website https www wingd com X52 AA00 0000 00AAA 910A A Operation Manual Installation Winterthur Gas Diesel Ltd 276 Issue 002 2018 11 ...

Page 277: ...9 Maneuver the ship 302 8 10 Change over the diesel fuel general 304 8 11 Change over the diesel fuel automatically 308 8 12 Change over from HFO to MDO manually 310 8 13 Change over from MDO to HFO manually 312 8 14 Stop the engine general 314 8 15 Stop the engine 316 8 16 Emergency stop the engine general 318 8 17 Emergency stop the engine 320 8 18 Prepare the engine after stop general 322 8 19 ...

Page 278: ...g oil is available at the engine connection 25 main lubricating oil inlet Make sure that crosshead lubricating oil is available at the engine connection 30 lubricating oil crosshead inlet Make sure that the lubricating oil system is full Cylinder oil system Make sure that the quality of the cylinder oil refers to 12 4 Cylinder oils Make sure that cylinder oil is available at the engine connection ...

Page 279: ...at the engine connection 78 gas supply inlet Pilot fuel system Make sure that the quality of the pilot fuel refers to 12 11 Diesel engine fuels Make sure that pilot fuel is available at the engine connection 76 supply unit fuel pilot valve inlet Make sure that the pilot fuel system is full and the pilot fuel can flow NOTE You can start a DF engine only in diesel mode 8 1 2 Preparation if component...

Page 280: ...ompletion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS Refer to 8 1 Prepare the engine before start general X52 AA00 0000 00AAA 121A A Operation Manual Prepare the engine before start Winter...

Page 281: ...ut off valve 02 Connection 02 cylinder liner cooling water inlet 002 Shut off valve 05 Connection 05 cylinder cooling water drain outlet 01 Connection 01 cylinder cooling water inlet 3 1 1 Close all shut off valves 001 in the cylinder cover supply pipes engine connection 01 NOTE This increases the pressure and thus the flow rate at the engine connection 02 3 1 2 Let the cooling water flow through ...

Page 282: ...through the other cylinder liners for approximately ten minutes 3 2 3 Open the shut off valves 001 in the cylinder liner supply pipes of the first half of cylinders 3 2 4 Do Step 3 2 1 to Step 3 2 3 again for the second half of cylinders eg cylinder 4 and 5 or 4 to 6 3 3 Set all valves to their correct positions for operation 3 4 Release the unwanted air in the cooling water pipes and the scavenge...

Page 283: ...check of the exhaust valves for correct function 6 1 1 For UNIC do the check as follows 6 1 1 1 On the local control panel in the LDU 20 get the MAIN page 6 1 1 2 Get the EXHAUST VALVES page 6 1 1 3 For cylinder No 1 manually open and close the exhaust valve 6 1 1 4 Do Step 6 1 1 3 for a minimum of four times 6 1 1 5 Do Step 6 1 1 3 and Step 6 1 1 4 again with the other cylinders 6 1 2 For WECS do...

Page 284: ...mes out of the indicator valves do a check of the related components that follow and repair if necessary Cylinder liner Cylinder cover Piston Injection valve 15 Do a check of all the running gears for correct operation 16 Stop and disengage the turning gear and lock the lever 17 If you have started the servo oil service pump set to OFF the servo oil service pump 18 On the starting air shut off val...

Page 285: ...X52 AA00 0000 00AAA 121A A Operation Manual Prepare the engine before start Page left intentionally blank Winterthur Gas Diesel Ltd 285 Issue 002 2018 11 ...

Page 286: ... You can find data about the barred speed ranges near the telegraph on the bridge near the local control panel and in the related documentation of vibration calculations 8 3 2 Start conditions limits With some limits you also can start the engine if parts of the engine are not prepared for operation eg One or more turbochargers are defective One or more cylinders are unserviceable The cooling wate...

Page 287: ...ine is at least 10 to approximately 15 related to the power of the auxiliary blowers 8 3 2 2 One or more cylinders are unservicable Obey the rules for operation if one or more cylinders are unserviceable Operate the engine only at decreased load It is possible that the turbochargers surge This makes a loud sound and causes large differences in the scavenge air pressure In this condition decrease t...

Page 288: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS Refer to 8 3 Start the engine general X52 AA00 0000 00AAA 131A A Operation Manual Start the engine Winterthur Gas Diesel Ltd 28...

Page 289: ...ximately 30 4 2 For WECS do as follows 4 2 1 Push the button FUEL CONTROL MODE 4 2 2 Turn the rotary button to set the fuel injection quantity to approximately 15 5 Push the button START AHD or START AST to start the engine NOTE The ECS starts an automatic pre lubrication sequence with a specified number of pulses NOTE The ECS increases the engine speed 6 If new cylinder liners or piston rings wer...

Page 290: ...fferences in the values find the causes and repair the faults Do not open the covers of the rail unit during engine operation NOTE For data about regular maintenance work refer to the Maintenance Manual When the engine is at standstill do also regular checks of the alarm and safety system refer to 8 7 Do regular safety checks This prevents damage to the engine if settings have changed or malfuncti...

Page 291: ...X52 AA00 0000 00AAA 130B A Operation Manual Do checks during operation general Page left intentionally blank Winterthur Gas Diesel Ltd 291 Issue 002 2018 11 ...

Page 292: ...nts after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine is running X52 AA00 0000 00AAA 131B A Operation Manual Do checks during operation Winterthur Gas Diesel Ltd 2...

Page 293: ... fault 10 Do regular checks of pipes for leaks If there are leaks find the cause and repair them 11 Do a careful check of the dirty oil drain pipes for differences in temperature NOTE Different temperatures show a blockage in the pipes 12 If there is an unusual temperature difference remove the blockage of the pipe as soon as possible 13 Do weekly the checks and the servicing that follow 13 1 Do a...

Page 294: ...sage release the unwanted air from the cooling water for an engine with bypass cooling water system refer to WINGD AA00 HA1 50 0000 00AAA 231A A CLOSE UP None X52 AA00 0000 00AAA 131B A Operation Manual Do checks during operation Winterthur Gas Diesel Ltd 294 Issue 002 2018 11 ...

Page 295: ...X52 AA00 0000 00AAA 131B A Operation Manual Do checks during operation Page left intentionally blank Winterthur Gas Diesel Ltd 295 Issue 002 2018 11 ...

Page 296: ...mp 94050 1 Smoke test instrument N A 1 Ampere meter N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Equipment Hazard Leaks can cause faults in the engine control systems and damage to engine components Leaks that are found during the engine control system checks must be repaired to prevent damage to equipment PRELIMINARY OPERATIONS The en...

Page 297: ... switch NOTE For the related SHD pressure refer to 11 2 List of usual values and safeguard settings general 1 4 3 Make sure that the pressure switch opens 1 4 4 Decrease the pressure to less than the SHD pressure 1 4 5 Make sure that the pressure switch closes at the related pressure 1 4 6 If the pressure switch does not close find the cause and repair the fault 1 4 7 Disconnect the pressure calib...

Page 298: ...minal 1 4 12 On the IOM 10 PT4044C disconnect the cable from X13 terminal 2 4 13 Connect an ampere meter between the connection and the related cable 4 14 Make sure that the transmitter output 4 mA to 20 mA is related to the simulated pressure 0 bar to 6 0 bar If necessary replace the applicable transmitter 4 15 On the MCM 11 PT4043C connect the cable to X41 terminal 1 4 16 On the IOM 10 PT4044C c...

Page 299: ...tion CLOSED 6 4 2 Make sure that there is no air in the starting air supply pipe 6 5 On the LDU 20 select the button CTRL TR to get control 6 6 Select the button START AHD 6 7 Make sure that the indication Turning Gear Engaged is shown on each LDU 20 6 8 Make sure that no start command is released 6 9 Do Step 6 1 to Step 6 8 again from the locations that follow LDU 20 on the ECR manual control pan...

Page 300: ...on Load changes must be done slowly to let the piston rings adapt the new conditions This also prevents increased wear and contamination of the piston rings and the cylinder liners The total time to increase the engine load from leaving port to sea speed must not be less than 30 minutes The total time to decrease the engine load from sea speed to port approach must not be less then 15 minutes Usua...

Page 301: ...If there are unusual indications you must decrease the load power The load indication fuel injection quantity and the exhaust gas temperature upstream of the turbocharger show the engine load The cooling water temperatures must stay in their usual ranges The maximum permitted position of the load indication fuel injection quantity is given in the acceptance records The adjustments are only permitt...

Page 302: ...Requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 0000 00AAA 131C A Operation Manual Maneuver the ship Winterthur Gas Diesel Ltd 302 Issue 002 2018...

Page 303: ... the ship general 3 To operate the engine in the opposite direction do the steps that follow 3 1 Use the rotary button to select the fuel command button 3 2 Turn the rotary button to set the fuel injection quantity to approximately 30 3 3 Push the related button START AHD or START AST NOTE After some minutes the engine operates in the opposite direction CLOSE UP None X52 AA00 0000 00AAA 131C A Ope...

Page 304: ...l components eg fuel pump plungers The safety functions decrease the risk of damage because of thermal loads You can do the change over procedure at a load of up to 100 CMCR The time period for automatic change over is less than that of a manual change over 8 10 2 Manual fuel change over When you do a manual change over of the fuel you must make sure that the change over is safe refer to the relat...

Page 305: ... has no iCAT system integrated Cylinder lubricant Auto Transfer system WinGD recommends to monitor the change over of the cylinder oil Do a calculation of the cylinder lubricant quantity and make sure that you know the cylinder lubricating feed rate refer to Figure 8 3 1 Make sure that you know the cylinder lubricant quantity that is between the change over valve and the lubricating quills includi...

Page 306: ...nsity of the cylinder lubricant can be found in the technical data sheet If not available an average value of 920 3 is suitable for this purpose Lead time until new lubricant is in use 1000 ℎ ℎ ℎ 00595 X52 AA00 0000 00AAA 130D A Operation Manual Change over the diesel fuel general Winterthur Gas Diesel Ltd 306 Issue 002 2018 11 ...

Page 307: ...X52 AA00 0000 00AAA 130D A Operation Manual Change over the diesel fuel general Page left intentionally blank Winterthur Gas Diesel Ltd 307 Issue 002 2018 11 ...

Page 308: ...ialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS WinGD recommends to always do this automatic change over procedure when possible There is no load limit of the engine to do an automatic fuel change over X52 AA00 0000 00AAA 131E A Oper...

Page 309: ...utomatic change over procedure refer to the instructions of the manufacturer CLOSE UP None X52 AA00 0000 00AAA 131E A Operation Manual Change over the diesel fuel automatically Winterthur Gas Diesel Ltd 309 Issue 002 2018 11 ...

Page 310: ...lization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS WinGD recommends to do a manual change over only if an automatic change over system is not installed or if the automatic change over system is unserviceable X52 AA00 0000 00AAA 131D A Ope...

Page 311: ...re Try to decrease the temperature as linearly as possible 9 When the temperature of the fuel is near the applicable value you can start the cooler slowly to give a linear and smooth temperature change at minimum viscosity NOTE The viscosity of the fuel must not be less than 2 cSt 10 Do a check of the temperature viscosity and pressure of the supplied fuel 11 If the temperature viscosity or pressu...

Page 312: ...lization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS WinGD recommends to do a manual change over only if an automatic change over system is not installed or if the automatic change over system is unserviceable X52 AA00 0000 00AAA 131H A Ope...

Page 313: ...e larger the mixing tank the less decrease in load is necessary 8 Set the viscosimeter to 13 cSt to increase the temperature of the fuel NOTE The viscosimeter controls the end heater which keeps the fuel temperature at the necessary viscosity 9 Follow the instructions of the plant to slowly change over the fuel supply from MDO to HFO Make sure that you increase the fuel temperature a maximum of 2 ...

Page 314: ...t cannot turn 360 the ECS sends a signal for an exhaust ventilation request The ESS or ECS sends a cancelable shutdown signal The engine safety system ESS or the ECS sends a cancelable shutdown signal when a related failure or defect occurs The procedures are as follows The ECS changes to diesel mode thus the related control system stops the gas supply and releases the pressure in the gas inlet pi...

Page 315: ...X52 AA00 0000 00AAA 130G A Operation Manual Stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 315 Issue 002 2018 11 ...

Page 316: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS Refer to 8 14 Stop the engine general X52 AA00 0000 00AAA 131G A Operation Manual Stop the engine Winterthur Gas Diesel Ltd 316...

Page 317: ...ontrol panel push the STOP button NOTE The ECS shuts down the engine in a controlled manner 4 For a DF engine start the exhaust ventilation sequence if there is a ventilation request CLOSE UP None X52 AA00 0000 00AAA 131G A Operation Manual Stop the engine Winterthur Gas Diesel Ltd 317 Issue 002 2018 11 ...

Page 318: ...ine general To stop the engine in an emergency do the procedure given in 8 17 Emergency stop the engine X52 AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Winterthur Gas Diesel Ltd 318 Issue 002 2018 11 ...

Page 319: ...X52 AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 319 Issue 002 2018 11 ...

Page 320: ...mpletion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS In some conditions the ECS starts an automatic shutdown X52 AA00 0000 00AAA 141A A Operation Manual Emergency stop the engine Winterthur...

Page 321: ...ter an emergency stop you must reset the EMERGENCY STOP button CAUTION Damage Hazard Do this step only as a last alternative selection if the EMERGENCY STOP button is not working Damage to the engine can occur 4 In the power supply boxes E85 1 to E85 set to OFF the electrical power to the ECS 5 Find the cause of the emergency stop and repair the fault CLOSE UP None X52 AA00 0000 00AAA 141A A Opera...

Page 322: ...ed the temperature of engine parts become as stable as possible For a short period after an engine stop of one week or less usually you keep the auxiliary systems in operation refer to 8 19 Prepare the engine for a short service break For a long period after an engine stop of more than one week or for maintenance of the engine you do the work in 8 20 Prepare the engine for a long shutdown period X...

Page 323: ...X52 AA00 0000 00AAA 150A A Operation Manual Prepare the engine after stop general Page left intentionally blank Winterthur Gas Diesel Ltd 323 Issue 002 2018 11 ...

Page 324: ... man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped Refer to 8 18 Prepare the engine after stop general X52 AA00 0000 00AAA 151A A Operation Manual Prepare the engine for a ...

Page 325: ...zard Before you operate the turning gear make sure that no personnel are near the flywheel or in the engine 5 Operate the turning gear for a short period at the intervals that follow Daily in damp climate Weekly in usual climate 6 Stop the turning gear so that the pistons stop in different positions each time CLOSE UP None X52 AA00 0000 00AAA 151A A Operation Manual Prepare the engine for a short ...

Page 326: ... man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped Refer to 8 18 Prepare the engine after stop general X52 AA00 0000 00AAA 151B A Operation Manual Prepare the engine for a ...

Page 327: ...let and of engine connection 30 lubricating oil crosshead inlet 6 5 Release the pressure in the oil pipes and the oil rail 6 6 Drain the oil systems of the engine 7 Stop the cooling water supply to the engine as follows 7 1 Stop the cooling water supply system from the plant 7 2 If installed close the shut off valves upstream of engine connections 01 and or 02 cylinder cooling water inlet 7 3 Rele...

Page 328: ...in the power supply box E85 10 2 Set to OFF the engine control system ECS and the remote control system RCS 11 Do a check of the rail unit as follows 11 1 Open the covers 11 2 Make sure that there is no condensation or corrosion 11 3 If you find condensation or corrosion do the steps that follow 11 3 1 Clean the related part 11 3 2 Find the cause and repair the fault 11 4 If necessary apply anti c...

Page 329: ...an analysis of the cylinder oil 332 9 3 Replace the filter element of the duplex filter 336 9 4 Clean the scavenge air cooler during operation 338 9 5 Do a test of the exhaust waste valve 342 9 6 Running in of new components general 344 9 7 Running in of new components 346 329 ...

Page 330: ... None Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard The system oil is hot Put on gloves and safety goggles to prevent injuries Do the work carefully PRELIMINARY OPERATIONS The oil pump is running The system oil has operating temperature The periodicity of 3000 working hours applies for regular oil analysis The peri...

Page 331: ...il analysis 5 l for FZG and particle count analysis 2 3 Close the sample valve 2 4 Close the sample bottle tight 3 Write the data that follows on the sample bottle Name of the ship Type and serial number of the engine Date of the sampling Location of the sample point Operating hours of the oil and of the engine Brand and type of the oil 4 If applicable do Step 1 to Step 3 again for the other sampl...

Page 332: ...ecialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard The cylinder oil is hot Put on gloves and safety goggles to prevent injury Do the work carefully PRELIMINARY OPERATIONS The engine must be in stable operation for a minimum of 12 hou...

Page 333: ...lve 001 to flush out oil and possible dirt 2 4 Close the oil sample valve 001 2 5 Open the ball valve 002 to drain the remaining oil from the dirty oil pipe 003 2 6 Close the ball valve 002 3 Get a sample of the drain oil 3 1 Make sure that the label on the sample bottle refers to the related cylinder 3 2 Wait approximately 10 minutes to 60 minutes 3 3 Put the sample bottle under the oil sample va...

Page 334: ...ls 8 Send the oil samples to a laboratory for an oil analysis 8 1 Make sure that the sample bottles are tightly closed 8 2 Put the sample bottles in an applicable package 9 Compare the oil analysis from the laboratory with the oil analysis from on board 10 If the oil analyses are different do the applicable recommended procedures related to the oil analysis from the laboratory refer to 12 4 Cylind...

Page 335: ...X52 AA00 0000 00AAA 371A A Operation Manual Do an analysis of the cylinder oil Page left intentionally blank Winterthur Gas Diesel Ltd 335 Issue 002 2018 11 ...

Page 336: ...fter job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY Filter element HA1 59 9613 01 002 pc 1 SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 7200 00AAA 200A A Operation Manual Replace the filter element of the duplex filter W...

Page 337: ... Clean the filter chamber 6 Clean the filter element or take a new filter element 7 Install the new filter element into the filter chamber 8 Install the cover on the filter chamber 9 Make sure that the cleaned filter chamber has no leaks CLOSE UP None X52 AA00 7200 00AAA 200A A Operation Manual Replace the filter element of the duplex filter Winterthur Gas Diesel Ltd 337 Issue 002 2018 11 ...

Page 338: ...nts after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 6600 00AAA 200A A Operation Manual Clean the scavenge air cooler during operation Winterthur...

Page 339: ...A LS 4071A PI 1361L TI 1371L TI 1381L PT 1361A TE 1371A TE 1381A Washing Plant SAC PLANT ENGINE PLANT ENGINE 003 00520 004 005 006 007 008 009 001 002 1 Decrease the engine power to approximately 45 X52 AA00 6600 00AAA 200A A Operation Manual Clean the scavenge air cooler during operation Winterthur Gas Diesel Ltd 339 Issue 002 2018 11 ...

Page 340: ...alve in the supply pipe stays closed 3 3 Close the shut off valve 009 in the water supply pipe 3 4 Close the vent valve 002 and the valve 007 of the tank 006 4 Open the shut off valve 001 in the compressed air supply pipe to pressurize the tank 006 5 Clean the scavenge air cooler 005 as follows 5 1 Open the shut off valve 003 5 2 After no more cleaning water comes out close the shut off valve 003 ...

Page 341: ...X52 AA00 6600 00AAA 200A A Operation Manual Clean the scavenge air cooler during operation Page left intentionally blank Winterthur Gas Diesel Ltd 341 Issue 002 2018 11 ...

Page 342: ...tion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine load must be less than 70 or the engine can be stopped X52 AA00 8135 00AAA 320A A Operation Manual Do a test of the exhaust waste valve ...

Page 343: ...1 3 2 On the PERFORMANCE DATA page make sure that the scavenge air pressure decreases 2 For WECS do the test as follows 2 1 On the flexView ExhWgt page or on the USER page set the manual command OPEN NOTE The exhaust waste valve opens for 20 seconds 2 2 During this period make sure that the exhaust waste gate is open 3 If the check is incorrect find the cause and repair the fault CLOSE UP None X52...

Page 344: ...emporary higher feed rate refer to Figure 9 3 WinGD recommends an inspection of the cylinder liners and of the piston rings after 24 operation hours and after 72 operation hours 001 Figure 9 3 For this running in procedure it is not necessary to have a special loading up apart from vessel specific loading up protocols Fig 9 3 Feed rate adjustments running in 001 001 X52 AA00 0000 00AAA 950B A Oper...

Page 345: ...X52 AA00 0000 00AAA 950B A Operation Manual Running in of new components general Page left intentionally blank Winterthur Gas Diesel Ltd 345 Issue 002 2018 11 ...

Page 346: ...ription Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS This procedure is only applicable if you have done an overhaul or you have installed new components of the piston running system X52 AA00 0000 00AAA 950A A Operation Manual ...

Page 347: ... to 1 1 g kWh 7 Operate the engine for 24 hours 8 Set the feed rate to 1 0 g kWh 9 Operate the engine for 24 hours 10 Inspect the components for damage 11 If damage occurs find the cause and repair the fault 12 If you have to replace parts of the piston running system start with Step 1 again 13 Set the feed rate to 0 9 g kWh CLOSE UP After 72 hours you can set the feed rate to the usual settings R...

Page 348: ...X52 AA00 0000 00AAA 950A A Operation Manual Running in of new components Page left intentionally blank Winterthur Gas Diesel Ltd 348 Issue 002 2018 11 ...

Page 349: ...for fuel leakage 382 10 8 Temporary cut out a defective injection valve 386 10 9 Temporary cut out a defective exhaust valve drive 388 10 10 Temporary isolate a cylinder with cooling water leakage 390 10 11 Disconnent the fuel pump 394 10 12 Connect the fuel pump 398 10 13 Temporary isolate a defective turbocharger 402 10 14 Temporary isolate the exhaust waste gate 406 10 15 Isolate a defective en...

Page 350: ...epair malfunctions on the engine The tables give the data that follow Title of the table The title of the table gives the description of the malfunction Indication This list specifies the number of the signal related to the value The list can also contain text or be empty Possible cause This list gives possible causes that have activated the alarm or have started the malfunction Refer to the speci...

Page 351: ...X52 AA00 0000 00AAA 410B A Operation Manual Troubleshooting general data Page left intentionally blank Winterthur Gas Diesel Ltd 351 Issue 002 2018 11 ...

Page 352: ...a servo oil pump inlet is too low Table 10 14 Bearing oil temperature at a bearing outlet is too high Table 10 15 Oil mist concentration is too high Table 10 16 Piston cooling oil temperature downstream of a piston is too high Table 10 17 Piston cooling oil flow to a piston is not in the permitted range Table 10 18 TC bearing oil temperature at a turbocharger outlet is too high Table 10 19 TC bear...

Page 353: ...e is too low Table 10 43 Condensation flow at a water separator is too high Table 10 44 Condensation flow upstream of a water separator is too high Table 10 45 Scavenge air temperature in the piston underside is too high Table 10 46 Starting air supply pressure is too low Table 10 47 Pressure of the air spring air supply is too high Table 10 48 Pressure of the air spring air supply is too low Tabl...

Page 354: ...le 10 1 Supply pressure of the cylinder cooling water is too low Do the repair shown there The cooling water supply tempera ture is too high Find the cause and repair the fault A cylinder liner cylinder cover or exhaust valve cage is defective Find the cause and repair the fault A piston ring is defective As a temporary procedure cut out the injec tion of the related cylinder As a temporary proced...

Page 355: ...Table 10 4 Supply pressure of the cooling water to the SAC is too low Do the repair shown there This is a result of the malfunction in Table 10 5 Supply temperature of the cooling water to the SAC is too low Do the repair shown there X52 AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Winterthur Gas Diesel Ltd 355 Issue 002 2018 11 ...

Page 356: ...dication Possible cause Procedure TE2011A TE2012A if applica ble The oil supply system is defective Find the cause and repair the fault Tab 10 10 Lubricating oil supply pressure upstream of the crossheads is too low Indication Possible cause Procedure PT2021A The crosshead oil supply system is defective Decrease the engine load Find the cause and repair the fault Tab 10 11 Servo oil pressure in th...

Page 357: ...nnA TE2201 nnA TE2301 nnA This is a result of the malfunction in Table 10 7 Lubricating oil supply pressure at the engine inlet is too low Do the repair shown there A bearing is defective Find the cause and repair the fault The oil does not have the specified properties Use correct oil Tab 10 15 Oil mist concentration is too high Indication Possible cause Procedure AE2401 nnA crankcase AE2415A gea...

Page 358: ...g oil temperature at a turbocharger outlet is too high Indication Possible cause Procedure TE2601 nnA This is a result of the malfunction in Table 10 9 Lubricating oil supply temperature at the engine inlet is too high Do the repair shown there A turbocharger is defective Refer to the turbocharger manual Tab 10 19 TC bearing oil supply pressure upstream of a turbocharger is too low Indication Poss...

Page 359: ...ement is clogged Change over to the other filter chamber Replace or clean the clogged filter element The cylinder oil tank is empty Fill the cylinder oil tank Tab 10 24 Cylinder oil flow is too low Indication Possible cause Procedure This is a result of the malfunction in Table 10 23 Cylinder oil supply pressure is too low Do the repair shown there This is a result of the malfunction in Table 10 1...

Page 360: ...28 Leakage flow from the rail unit is too high Indication Possible cause Procedure LS3444 45A An item of the rail unit is defective Find the cause and repair the defective item refer to 10 6 Examine the rail unit for leak age Tab 10 29 Fuel leakage flow from fuel rail items is too high engine with FLV Indication Possible cause Procedure LS3446A A flow limiting valve FLV or a pipe is defective Find...

Page 361: ...is a leakage in the gas sys tem Find the cause and repair the defective item Tab 10 32 Difference pressure of pilot fuel filter is too high Indication Possible cause Procedure PS3464A The pilot fuel filter is clogged Replace the filter element X52 AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Winterthur Gas Diesel Ltd 361 Issue 002 2018 11 ...

Page 362: ... system eg crack in cylinder liner Find the cause and repair the fault There is a fire in the piston under side Do the procedure in 2 3 Fire fighting in the scavenge air space Tab 10 34 Exhaust gas temperature difference downstream of all cylinders is too high Indication Possible cause Procedure TE3701 nnA An injection nozzle is defective Repair or replace the defective injection nozzle The fuel s...

Page 363: ...ring air pressure is too low Find the cause and repair the fault The opening oil pressure is too low Find the cause and repair the fault An exhaust valve is defective pis ton cannot move or a piston is de fective Repair the exhaust valve Tab 10 38 Smoke is too dark Indication Possible cause Procedure The engine has too much load Decrease the fuel injection quantity There is unwanted material in th...

Page 364: ...alfunction in Table 10 5 Supply temperature of the cooling water to the SAC is too low Do the repair shown there Tab 10 41 Scavenge air pressure is too high Indication Possible cause Procedure PT4043 nnC A turbocharger surges As a temporary procedure decrease the en gine load If applicable open the exhaust waste gate valve Refer to the turbocharger manual A safety valve is defective Repair or repl...

Page 365: ...re is fire in the piston underside Refer to 2 3 Fire fighting in the scavenge air space A piston ring is defective As a temporary procedure decrease the load and cut out the injection of the related cylinder As a temporary procedure increase the feed rate of the cylinder oil of the related cylinder Repair or replace the piston rings The engine has too much load Decrease the fuel injection quantity...

Page 366: ...l air supply system is de fective Find the cause and repair the fault There is an incorrect setting of the control air supply Set the control air supply to the correct val ue Tab 10 51 Control air supply pressure is too low stand by supply Indication Possible cause Procedure PT4411A The starting air supply system is defective Find the cause and repair the fault There is an incorrect setting of the...

Page 367: ...the defective injection nozzle This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low or in Table 10 3 Cylinder cooling wa ter temperature downstream of a cylinder is too high Do the repair shown there There is air in the cooling water system Release the unwanted air from the cooling water system for an engine with bypass cooling water system ref...

Page 368: ...njection quantity from the speed control system is decreased A procedure is not necessary because the control system prevents too much load in heavy sea The fuel injection system is defec tive Find the cause and repair the fault Tab 10 58 Unwanted engine stop Indication Possible cause Procedure The fuel injection system is defec tive Find the cause and repair the fault This is a result of the malf...

Page 369: ...X52 AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Page left intentionally blank Winterthur Gas Diesel Ltd 369 Issue 002 2018 11 ...

Page 370: ... SHD shutdown The SLD sub group contains failures that cause one cylinder to cut off The AMS sends a slowdown signal to the ECS The SHD sub group contains failures that prevent an engine operation The engine safety system ESS sends a shutdown signal to the ECS UNIC stops the fuel injection These two sub groups are not shown in internal or external interfaces Thus they are only used on the applicat...

Page 371: ...ed cable connections Do a check of the related cable or plugs for damage Do a check of the related item for damage Use a multimeter to do a check of the power supply Use a multimeter to do a check of the sensor signal Use a multimeter to do a check for a short circuit or a ground fault If applicable do a check of the terminating resistors for correct connection Repair the faults or temporarily rep...

Page 372: ...g the Requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS PRELIMINARY OPERATIONS None X52 AA00 0000 00AAA 311A A Operation Manual Examine the supply unit for servo oil leakage Winterthur Gas Diesel ...

Page 373: ...e for an X82 engine 5 Do a check of the level switch LS2076A if applicable also LS2077A for free flow If necessary clean the bore of the pipe of the level switch 6 Carefully do a check of the temperature of the oil leakage pipe of each valve control unit VCU to find the leakage pipe that has an oil flow NOTE There is an oil flow in the leakage pipe that has a higher temperature than the other leak...

Page 374: ...ir it at the next occasion refer to the Maintenance Manual 8 4 Tighten the screw plug 8 5 Do Step 8 1 to Step 8 4 again for the other connecting pipe CLOSE UP None X52 AA00 0000 00AAA 311A A Operation Manual Examine the supply unit for servo oil leakage Winterthur Gas Diesel Ltd 374 Issue 002 2018 11 ...

Page 375: ...X52 AA00 0000 00AAA 311A A Operation Manual Examine the supply unit for servo oil leakage Page left intentionally blank Winterthur Gas Diesel Ltd 375 Issue 002 2018 11 ...

Page 376: ... Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on gloves and safety goggles when you do work on hot or pressurized components When you open the screw plugs fuel can come out as a spray and cause injury PRELIMINARY OPERATIONS None X52 AA00 0000 00AA...

Page 377: ...pe 005 at the highest inspection point 004 for leaks 4 1 Carefully loosen the screw plug a maximum of two turns 4 2 Do a check for fuel flow 4 3 If there is fuel flow repair the cause of the fuel flow as soon as possible refer to the Maintenance Manual 8752 1 NOTE The fuel system has high pressure Replace a defective HP fuel pipe only when the engine has stopped and the pressure in the system is r...

Page 378: ...he fuel pump refer to the Maintenance Manual 5556 1 NOTE If the defective HP fuel pipe cannot be replaced immediately or the engine must continue to operate the related fuel pump must be cut out CLOSE UP None X52 AA00 0000 00AAA 311B A Operation Manual Examine the supply unit for fuel leakage Winterthur Gas Diesel Ltd 378 Issue 002 2018 11 ...

Page 379: ...X52 AA00 0000 00AAA 311B A Operation Manual Examine the supply unit for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 379 Issue 002 2018 11 ...

Page 380: ...cialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on gloves and safety goggles when you do work on hot or pressurized components Fuel can come out as a spray and cause injury PRELIMINARY OPERATIONS None X52 AA00 0000 00AAA 311E A Operat...

Page 381: ...ch 2 Carefully look into the rail unit to find the cause of the leakage NOTE Possible causes can be a defective pipe to the exhaust valve a defective flange or an other defective item 3 Repair the defective item CLOSE UP None X52 AA00 0000 00AAA 311E A Operation Manual Examine the rail unit for leakage Winterthur Gas Diesel Ltd 381 Issue 002 2018 11 ...

Page 382: ... Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on gloves and safety goggles when you do work on hot or pressurized components When you open the screw plugs fuel can come out as a spray and cause injury PRELIMINARY OPERATIONS None X52 AA00 0000 00AA...

Page 383: ...ws 3 1 Make sure that the screws 002 are tightened correctly refer to the Maintenance Manual 8733 1 3 2 On the fuel leakage pipe 004 carefully loosen the screw in union 003 a maximum of two turns 3 3 Do a check for fuel flow 3 4 If fuel continues to flow from the screw in union 003 do as follows an HP fuel pipe 001 is defective 3 4 1 Stop the engine 3 4 2 Remove each of the HP fuel pipes 001 until...

Page 384: ... union 007 a maximum of two turns 4 3 Do a check of the fuel flow 4 4 If fuel flows from the screw in union 007 more than usual compared to the amount of leakage from the other FLV the piston rod is defective Replace the defective piston rod refer to the Maintenance Manual 5564 1 4 5 Tighten the screw in union 007 4 6 Do Step 4 1 to Step 4 5 again for the other FLV CLOSE UP None X52 AA00 0000 00AA...

Page 385: ...X52 AA00 0000 00AAA 311C A Operation Manual Examine the FLV or fuel pipes for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 385 Issue 002 2018 11 ...

Page 386: ...the Requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 0000 00AAA 662A A Operation Manual Temporary cut out a defective injection valve Winterthur Gas Dies...

Page 387: ...onnect the electrical connection from the injection valve 4 For an engine with conventional injection valves Disconnect the electrical connection from the injection control unit ICU 5 If it is necessary to operate the engine with the injection cut out for an extended period do as follows 5 1 Record the settings of the cylinder oil feed rate 5 2 Decrease the cylinder oil feed rate for the related c...

Page 388: ...Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00 0000 00AAA 662D A Operation Manual Temporary cut ...

Page 389: ...to the related exhaust valve control unit VCU 3 Repair the fault as soon as possible refer to the Maintenance Manual CLOSE UP The engine can be started and operated at decreased load refer to 8 3 Start the engine general X52 AA00 0000 00AAA 662D A Operation Manual Temporary cut out a defective exhaust valve drive Winterthur Gas Diesel Ltd 389 Issue 002 2018 11 ...

Page 390: ...Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY Pressure element 94259 A R Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00 0000 00AAA 662B A Operation Manual Te...

Page 391: ...nstall the pressure element 003 Fig 10 4 Exhaust valve with pressure element 001 002 003 004 Legend 001 Top housing 003 Pressure element 002 Damper 004 Shim 4 Cut out the defective cylinder from the injection refer to 10 8 Temporary cut out a defective injection valve 5 Disconnect the electrical connection to the related exhaust valve control unit VCU 6 Disconnect the control signal connection fro...

Page 392: ...e started and operated at decreased load refer to 8 3 Start the engine general X52 AA00 0000 00AAA 662B A Operation Manual Temporary isolate a cylinder with cooling water leakage Winterthur Gas Diesel Ltd 392 Issue 002 2018 11 ...

Page 393: ...X52 AA00 0000 00AAA 662B A Operation Manual Temporary isolate a cylinder with cooling water leakage Page left intentionally blank Winterthur Gas Diesel Ltd 393 Issue 002 2018 11 ...

Page 394: ...crew Basic 1 Support equipment Description Part No CSN QTY Flange 94569 pc 1 Flange 94569A pc 1 Roller lifting tool 94430 pc 1 Claw 94430A pc 1 Screw 94430B pc 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00...

Page 395: ... to the Maintenance Manual 3 Install the flange 005 to the fuel pump 002 4 Install the flange 006 to the HP fuel pipe 007 5 Remove the related cover from the supply unit 003 6 Remove the related plug 004 from the supply unit 003 Fig 10 6 Fuel pump example cut out 007 002 X 006 001 003 004 005 00546 X52 AA00 5556 00AAA 510B A Operation Manual Disconnent the fuel pump Winterthur Gas Diesel Ltd 395 I...

Page 396: ...ool 002 with the mark 001 points down 9 Turn the roller lifting tool 002 180 until the mark 001 points up NOTE This gives a clearance X and thus the cam 006 cannot move the roller 007 10 Install the claw 004 with the screw 003 to lock the roller lifting tool 002 11 Install the cover to the supply unit 005 CLOSE UP None X52 AA00 5556 00AAA 510B A Operation Manual Disconnent the fuel pump Winterthur...

Page 397: ...X52 AA00 5556 00AAA 510B A Operation Manual Disconnent the fuel pump Page left intentionally blank Winterthur Gas Diesel Ltd 397 Issue 002 2018 11 ...

Page 398: ...crew Basic 1 Support equipment Description Part No CSN QTY Flange 94569 pc 1 Flange 94569A pc 1 Roller lifting tool 94430 pc 1 Claw 94430A pc 1 Screw 94430B pc 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00...

Page 399: ...pipe 001 to the fuel pump 002 For the applicable procedure refer to the Maintenance Manual 5 Remove the related cover from the supply unit 003 Fig 10 8 Fuel pump example cut in 007 002 X 006 001 003 004 005 00546 WARNING Injury Hazard Make sure that no personnel are near the flywheel or the engine before you operate the turning gear X52 AA00 5556 00AAA 730B A Operation Manual Connect the fuel pump...

Page 400: ...oints down 9 Remove the roller lifting tool 002 10 Install the plug 004 Figure 10 7 to the supply unit 003 11 Install the cover to the supply unit 003 12 Make sure that the fuel pump 002 operates correctly 13 Make sure that the HP fuel pipe 001 has no leaks CLOSE UP None X52 AA00 5556 00AAA 730B A Operation Manual Connect the fuel pump Winterthur Gas Diesel Ltd 400 Issue 002 2018 11 ...

Page 401: ...X52 AA00 5556 00AAA 730B A Operation Manual Connect the fuel pump Page left intentionally blank Winterthur Gas Diesel Ltd 401 Issue 002 2018 11 ...

Page 402: ...on 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Cover 94653A A R Cover 94653B A R Cover 94653C A R Cover 94653D A R Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 6500 00AAA 662A A Operation Manual Temporary isolate a defective ...

Page 403: ...uction duct Fig 10 9 Not all turbochargers are defective example Legend 001 Cover 94653A 005 Expansion joint 002 Cover 94653B 006 Turbocharger 003 Cover 94653C 007 Expansion joint 004 Cover 94653D 3 If all turbochargers are defective isolate the defective turbochargers from the scavenge air system NOTE This step is applicable for an engine with one two or three turbochargers ie no turbocharger is ...

Page 404: ...the air supply to the engine room is satisfactory 5 Make sure that the oil supply pressure to the serviceable turbochargers is satisfactory 6 Start the engine with the given limits refer to 8 3 Start the engine general CLOSE UP None X52 AA00 6500 00AAA 662A A Operation Manual Temporary isolate a defective turbocharger Winterthur Gas Diesel Ltd 404 Issue 002 2018 11 ...

Page 405: ...X52 AA00 6500 00AAA 662A A Operation Manual Temporary isolate a defective turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 405 Issue 002 2018 11 ...

Page 406: ...the Requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Winterthur Gas Diesel Lt...

Page 407: ...02 Cardan rod 007 Ball valve 50 8135_E0_3 air spring air 003 Positioner and feedback with EMC module 008 Flange 004 Actuator 009 Valve 005 Plate 1 Stop the engine X52 AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Winterthur Gas Diesel Ltd 407 Issue 002 2018 11 ...

Page 408: ...wo middle screws 3 Turn the flange 008 to close the exhaust waste gate 4 Tighten the screws to attach the flange 008 5 Start the engine CLOSE UP None X52 AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Winterthur Gas Diesel Ltd 408 Issue 002 2018 11 ...

Page 409: ...X52 AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 409 Issue 002 2018 11 ...

Page 410: ...the Requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS None X52 AA00 0000 00AAA 662C A Operation Manual Isolate a defective engine at twin engine installation Winterthur...

Page 411: ...available disengage the shaft clutch NOTE This decreases the resistance of the propeller by the wind milling effect 5 If available move the controllable propellers to the position with the lowest resistance 6 Find the cause of the malfunction NOTE Do not go near movable engine parts unless you are sure that in each condition no part can move 7 If possible repair the fault Obey the rules for the ac...

Page 412: ...nnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Cover 94820 2 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00 9270 00AAA 720C A Operation Manual Temporar...

Page 413: ...ve V1 2 Install the Cover 001 Figure 10 12 to the flange 3 Remove the pipe to the SCR system from the flange upstream of the valve V2 4 Install the cover 001 to the flange CLOSE UP None X52 AA00 9270 00AAA 720C A Operation Manual Temporary isolate the HP SCR system Winterthur Gas Diesel Ltd 413 Issue 002 2018 11 ...

Page 414: ...Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS PRELIMINARY OPERATIONS The engine must be stopped and prepared for maintenance refer to 8 18 Prepare the engine after stop general X52 AA00 9270 00AAA 520C A Operation Manual Connect the ...

Page 415: ...V1 2 Install the pipe to the SCR system to the flange 3 Remove the cover 001 from the flange upstream of the valve V2 4 Install the pipe to the SCR system to the flange CLOSE UP None X52 AA00 9270 00AAA 520C A Operation Manual Connect the HP SCR system after isolation Winterthur Gas Diesel Ltd 415 Issue 002 2018 11 ...

Page 416: ...X52 AA00 9270 00AAA 520C A Operation Manual Connect the HP SCR system after isolation Page left intentionally blank Winterthur Gas Diesel Ltd 416 Issue 002 2018 11 ...

Page 417: ...11 Technical data 11 1 Engine data 418 11 2 List of usual values and safeguard settings general 420 11 3 List of usual values and safeguard settings 424 11 4 Section views 436 417 ...

Page 418: ...ard reference conditions Total barometric pressure is 1 0 bar Suction air temperature is 25 C Relative humidity is 30 Cooling water temperature at the engine inlet is 25 C BSFC This list gives the Brake Specific Fuel Consumption BSFC for fuel of lower heating value 42 7 MJ kg 10 200 kcal kg and standard tuning Mean piston speed This list gives the mean piston speed in m s MEP This list gives the M...

Page 419: ...020 160 6 1 15 8 190 Fig 11 1 Operating range R1 R1 R2 R2 R4 R4 R3 S P Legend R1 Highest power at highest speed R3 Highest power at lowest speed R1 Highest power at highest speed extended R4 Lowest power at lowest speed R2 Lowest power at highest speed P Power R2 Lowest power at highest speed extended S Speed X52 AA00 0000 00AAA 030A A Operation Manual Engine data Winterthur Gas Diesel Ltd 419 Iss...

Page 420: ...oint or the range for usual operation Signal number This list gives the signal number as follows refer also to Para 11 2 2 First two letters XX Function code Four digit number of the signal eg 10NN First two numbers Function group Second two numbers Running number nn If more than one signal of the same type is applicable eg TE2501 nnA is TE2501A TE2502A TE2503A etc Last letter Applied system Funct...

Page 421: ...maximum concentration For the level switches LS and flow switches FS min minimum or no flow max maximum flow Delay This list gives the delay of the action in seconds after the trigger value occurs X52 AA00 0000 00AAA 030K A Operation Manual List of usual values and safeguard settings general Winterthur Gas Diesel Ltd 421 Issue 002 2018 11 ...

Page 422: ...code Code First position Second position A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Temperature Transmitter V n a Valve X Unclassified Unclassified Y Vibration Relay Z Position binary n a X52 AA00 0000 00AAA 030K A Operation Manual List of usual values and safeguard settings general Winte...

Page 423: ... to 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals to the engine Miscellaneous Tab 11 5 Applied system Code Description A Alarm and monitoring system C Control system L Local M Measured indication Local control panel S Safety system W Wrong way alarm X Miscell...

Page 424: ...XX2NNN part 1 Table 11 8 Oil systems XX2NNN part 2 Table 11 9 Oil systems XX2NNN part 3 turbocharger bearing oil Table 11 10 Oil systems XX2NNN part 4 Table 11 11 Fuel system XX34NN Table 11 12 Exhaust gas system XX37NN Table 11 13 Air systems XX40NN to XX44NN Table 11 14 Miscellaneous items XX45NN to XX52NN X52 AA00 0000 00AAA 033B A Operation Manual List of usual values and safeguard settings Wi...

Page 425: ...nnA ALM H 95 0 SLD H 97 60 Scavenge air cooler SAC SAC LT cooling water pressure bar en gine inlet connection 07 2 5 to 4 PT1361A ALM L 2 0 0 SAC LT cooling water temperature C engine inlet connection 07 10 to 36 3 TE1371A ALM L 6 4 0 SAC LT cooling water temperature C outlet each SAC 10 to 75 TE1381 nnA ALM H 80 0 1 This value is applicable for stable operation condition 2 This value is applicabl...

Page 426: ...et injectors 4 2 to 5 PT2003A ALM L 2 6 6 0 Bearing oil Main bearing oil temperature C outlet each main bearing optional 45 to 60 TE2101 nnA ALM H 65 0 SLD H 70 60 Crank bearing oil temperature C outlet each crank bearing optional 45 to 60 TE2201 nnA ALM H 65 0 SLD H 70 60 Crosshead bearing oil temperature C outlet each crosshead bearing optional 45 to 60 TE2301 nnA ALM H 65 0 SLD H 70 60 1 This v...

Page 427: ... H max 0 AS2401A ALM H max 0 AS2401S SLD H max 60 Oil mist concentration gearcase AE2415A ALM H max 0 Oil mist concentration fuel supply unit AE2421A ALM H max 0 Piston cooling oil Piston cooling oil temperature C outlet each cylinder 45 to 75 TE2501 nnA ALM H 80 0 SLD H 85 60 Piston cooling oil flow l min outlet each cylinder FS2521 nnS SHD H max 15 SHD L min 15 1 The trigger values are not appli...

Page 428: ...arger 45 to 80 TE2621A ALM H 85 0 SLD H 90 60 TC bearing oil temperature C outlet each turbocharger 45 to 120 TE2601 nnA ALM H 130 0 SLD H 140 60 Bearing oil turbocharger MHI MET with internal oil TC bearing oil pressure bar inlet each turbocharger 1 0 to 5 0 PT2611 nnA ALM L 0 7 5 SLD L 0 6 60 PS2611 nnS SHD L 0 4 5 TC bearing oil temperature C outlet each turbocharger 45 to 80 TE2601 nnA ALM H 8...

Page 429: ...ial vibration damper space aft side 1 8 to 5 0 PT2721A ALM L 1 7 60 Damper oil pressure bar axial vibration damper space fore side 1 8 to 5 0 PT2722A ALM L 1 7 60 Cylinder oil Cylinder oil pressure bar cylinder oil rail 0 3 PT3124A ALM L 0 1 30 1 The setpoint and trigger values can be different For the applicable values refer to the specification of the damper manufacturer X52 AA00 0000 00AAA 033B...

Page 430: ...mperature C inlet fuel supply unit 3 20 to 150 TE3411A ALM H 50 to 160 0 ALM L 20 to 130 0 Fuel leakage flow outlet fuel supply unit LS3426A ALM H max 0 Fuel leakage flow outlet fuel rail items LS3446A ALM H max 0 Rail unit Leakage flow outlet rail unit LS3444A ALM H max 0 1 This measurement is not included in the standard engine supply the viscometer is a yard supply item 2 When the engine has st...

Page 431: ...st gas temperature C outlet each cylinder TE3701 nnA ALM H 515 0 ALM D 50 0 SLD H 530 60 SLD D 70 60 Exhaust gas temperature C inlet each turbocharger TE3721 nnA ALM H 515 0 SLD H 530 60 Exhaust gas temperature C outlet each turbocharger TE3731 nnA ALM H 480 0 SLD H 500 60 X52 AA00 0000 00AAA 033B A Operation Manual List of usual values and safeguard settings Winterthur Gas Diesel Ltd 431 Issue 00...

Page 432: ...arting air supply Starting air supply pressure bar engine inlet connection 40 20 to 30 Control air supply unit Control air supply pressure bar engine inlet connection 45 7 to 9 Control air pressure bar outlet usual sup ply 6 5 PT4401A ALM L 6 0 0 Control air pressure bar outlet stand by supply 6 0 PT4411A ALM L 5 5 0 Control air pressure bar air tank for safety supply 6 5 6 0 PT4421A ALM L 5 0 15 ...

Page 433: ...ore side 230 TE4841 nnC ALM H 250 0 SLD H 270 60 Powertrain Crankshaft speed of CMCR crankshaft ST5111 12S SHD H 110 0 Tachometer turbocharger Impeller shaft overspeed rpm each ABB turbocharger ST5201 nnA ALM H refer to note 1 0 Impeller shaft overspeed rpm each MHI turbocharger ST5201 nnA ALM H refer to note 2 0 1 for ABB A175 L34 16 000 for ABB A180 L34 14 140 for ABB A180 L35 12 860 for ABB A18...

Page 434: ... to Table 11 15 Failure messages Tab 11 15 Failure messages Medium location Signal number Delay Failure of oil mist detector XS2411A 0 Failure of fuel heating XS3463A 0 Failure of fuel pump actuator XS5046A 0 X52 AA00 0000 00AAA 033B A Operation Manual List of usual values and safeguard settings Winterthur Gas Diesel Ltd 434 Issue 002 2018 11 ...

Page 435: ...X52 AA00 0000 00AAA 033B A Operation Manual List of usual values and safeguard settings Page left intentionally blank Winterthur Gas Diesel Ltd 435 Issue 002 2018 11 ...

Page 436: ... cross section 2751 2708 8103 2124 6509 6420 3326 3603 8357 1704 1115 4120 3303 2303 2105 3403 5562 5612 8733 8460 2722 DAAD089776 X52 AA00 0000 00AAA 034A A Operation Manual Section views Winterthur Gas Diesel Ltd 436 Issue 002 2018 11 ...

Page 437: ... 4 Engine longitudinal section 2751 3403 1903 8752 8447 5556 4106 3103 2708 2124 1406 1717 DAAD089789 X52 AA00 0000 00AAA 034A A Operation Manual Section views Winterthur Gas Diesel Ltd 437 Issue 002 2018 11 ...

Page 438: ...X52 AA00 0000 00AAA 034A A Operation Manual Section views Page left intentionally blank Winterthur Gas Diesel Ltd 438 Issue 002 2018 11 ...

Page 439: ...System oils 446 12 4 Cylinder oils 454 12 5 Different oils and lubricants 460 12 6 List of system oils 462 12 7 List of cylinder oils 464 12 8 List of lubricants for flywheel and pinion gear teeth 468 12 9 Compressed air 470 12 10 Scavenge air 472 12 11 Diesel engine fuels 474 439 ...

Page 440: ...nds as follows Fully desalinate the raw water before you fill it into the system You can use condensate water eg from the fresh water generators or from auxiliary steam systems but it must have additives Condensate water is highly corrosive and must have corrosion inhibitors to prevent problems Use potable water or process water from the local mains only as a last option for a short period The har...

Page 441: ... 10 12 1 3 Antifreeze CAUTION Damage Hazard Antifreeze decreases the heat transfer rate of the cooling water This can cause damage to the engine If the concentration of the antifreeze is more than 20 you can operate the engine only at decreased load During usual operation it is not necessary to use antifreeze WinGD recommends to use antifreeze only if the engine is stopped for a long period in con...

Page 442: ... Sodium nitrite borate Sodium nitrite borate Sodium nitrite borate Chevron Global Lubricants USA www chevronlubricants com Havoline XLI Organic Acid Technology GE Water and Process Technolo gies Belgium www gewater com CorrShield NT 4293 Sodium nitrite borate GE Water and Process Technolo gies USA www gewater com CorrShield NT 4200 Sodium nitrite borate Korves Oy Finland 358 14 338 4001 Fax Pekar ...

Page 443: ...er level of the given range This is because the quantity of active corrosion inhibitors decreases during the service life of the engine Tab 12 3 Dosage and concentration of cooling water additives Brand Dosage of 1 m3 of system ca pacity Concentration Diaprosim RD11 RD11M 5 kg 1250 ppm as NO2 Havoline XLI 50 to 100 litres 1 8 to 3 7 Brix of active compounds measured with a supplier s refractometer...

Page 444: ...2 1000 to 2400 ppm as NO2 1 8 to 3 7 Brix of active compounds measured with a supplier s refractometer Nalcool 2000 Engine Water Treatment 9 108 32 to 48 litres 2 25 to 3 40 litres 1000 to 1500 ppm as NO2 670 to 1000 ppm as NO2 The nitrite content of nitrite based cooling water additives usually decreases during use If the nitrite content decreases below the given limits the risk of local corrosio...

Page 445: ...X52 AA00 0000 00AAA 101D A Operation Manual Cooling water additives Page left intentionally blank Winterthur Gas Diesel Ltd 445 Issue 002 2018 11 ...

Page 446: ...commends to install a self cleaning centrifugal separator in the plant oil system Thus you can keep the system oil in good condition for a long period There is always a risk that water specially sea water can enter the system oil and cause corrosion on engine parts Water contamination can also cause bacterial contamination of the system oil which gives a decrease in lubrication performance and giv...

Page 447: ...SO 14635 1 1 m m means by mass eg a water content of 0 20 m m means that the water content is 0 20 of the mass of the total solution 2 To do the FZG gear oil test is recommended one time each year NOTE Use these limits as a guide You cannot make an estimate of the system oil by one parameter Get also other oil parameters to find the causes of problems 12 3 4 Particle count and size classes The req...

Page 448: ...0 000 16 000 000 24 4 000 000 8 000 000 23 2 000 000 4 000 000 22 1 000 000 2 000 000 21 6 μm max 500 000 1 000 000 20 250 000 500 000 19 130 000 250 000 18 14 μm max 64 000 130 000 17 32 000 64 000 16 16 000 32 000 15 8 000 16 000 14 4 000 8 000 13 2 000 4 000 12 1 000 2 000 11 500 1 000 10 250 500 9 130 250 8 64 130 7 32 64 6 16 32 5 8 16 4 4 8 3 2 4 2 1 2 1 0 1 0 X52 AA00 0000 00AAA 030F A Oper...

Page 449: ...ber of particles per 100 ml for particle size ranges μm Cleanliness class 5 to 15 15 to 25 25 to 50 50 to 100 100 to 150 14 4 096 000 729 600 129 600 23 040 4 096 13 2 048 000 364 800 64 800 11 520 2 048 12 1 024 000 182 400 32 400 5 760 1 024 11 512 000 91 200 16 200 2 880 512 10 256 000 45 600 8 100 1 440 256 9 128 000 22 800 4 050 720 128 8 64 000 11 400 2 025 360 64 7 32 000 5 700 1 012 180 32...

Page 450: ...without servo oil filter Tab 12 7 Recommended NAS limits for an engine with servo oil filter Particle size ranges μm 5 to 15 15 to 25 25 to 50 50 to 100 100 to 150 System oil Cleanliness class 12 11 10 8 5 Particles per 100 ml 1 024 000 91 200 8 100 360 8 Servo oil Cleanliness class 12 11 8 5 0 Particles per 100 ml 1 024 000 91 200 2 025 45 0 Tab 12 8 Recommended NAS limits for an engine without s...

Page 451: ...rocedures are as follows Increase the purification in the separator decrease the flow rate and or adjust the temperature Treat the oil in a renovating or settling tank Replace a part of the system oil If an alert value is given stop the engine and do the correct procedures If a condemnation value is given immediately replace a part of the system oil until the values are satisfactory If you cannot ...

Page 452: ...rn components in the engine Repair the related components Make a replenishment of the system oil This can include a change of some of the oil or of all of the oil in the oil system This prevents damage from abrasive particles of the related engine parts 12 3 7 Recommended procedure for gear wheels If you install a new gear wheel or if you have polished a gear wheel the FZG load stage of the system...

Page 453: ...X52 AA00 0000 00AAA 030F A Operation Manual System oils Page left intentionally blank Winterthur Gas Diesel Ltd 453 Issue 002 2018 11 ...

Page 454: ...of the fuel NOTE The Base Number BN measured in mg KOH g test method ASTM D 2896 gives the alkalinity of the oil The BN of the cylinder oil is not an index for detergency or for other properties of the cylinder oil You find a list of applicable and validated cylinder oils in 12 7 List of cylinder oils 12 4 2 Recommended procedures WinGD recommends the procedures that follow to get good performance...

Page 455: ... 0 1 5 2 0 2 5 3 0 3 5 3 5 001 BN 100 BN 70 to 80 BN 40 to 60 LNG NOTE For liquefied natural gas LNG WinGD recommends a cylinder oil of BN 15 to BN 25 For all hatched areas in Figure 12 1 WinGD recommends as follows 1 Do a regular piston underside drain oil sampling and an interpretation of the oil analysis refer to Figure 12 2 and Figure 12 3 Make sure that you operate the engine in the safe area...

Page 456: ... etc related to the sailing conditions 3 For each load do a piston underside drain oil sampling refer to Para 12 4 2 3 4 For each load do an interpretation of the oil analysis refer to Para 12 4 2 4 or Para 12 4 2 5 12 4 2 3 Piston underside drain oil sampling Do a piston underside drain oil sampling and an oil analysis of each cylinder refer to the procedure in 9 2 Do an analysis of the cylinder ...

Page 457: ...as shown in Figure 12 2 Use the data that follows for an interpretation of the oil analysis Safe area If the residual BN is BN 10 or higher and the iron Fe content is less than 200 mg kg the operation is thought to be safe Alert area If the residual BN is BN 10 or higher and the iron Fe content is between 200 mg kg and 500 mg kg damage of the piston running system can occur Danger area If the resi...

Page 458: ...BN 50 and the iron Fe content is less than 200 mg kg the operation is thought to be safe Alert area The lower alert range for piston underside residual BN is between BN 10 and BN 25 In this area there might be a risk of corrosion This is because the base additives could be not sufficient to neutralize the sulphuric acid from the fuel The upper alert limit for piston underside residual BN is above ...

Page 459: ...the analysis shows operation in the danger area do as quickly as possible as follows a Increase or decrease the feed rate or change the BN of the cylinder oil to get the operation in the safe area NOTE WinGD has made a tool piston underside drain oil analysis for easier interpretation of the oil analysis If necessary the tool gives you recommendations and procedures to make the cylinder oil system...

Page 460: ...th are given in 12 8 List of lubricants for flywheel and pinion gear teeth For other applicable lubricants speak to the lubricant supplier Environmentally acceptable lubricants Environmentally Acceptable Lubricants EAL are currently necessary for ships operating in USA waters and this area may be extended in future These lubricants which are necessary for all oil to sea interfaces and include ster...

Page 461: ...X52 AA00 0000 00AAA 030H A Operation Manual Different oils and lubricants Page left intentionally blank Winterthur Gas Diesel Ltd 461 Issue 002 2018 11 ...

Page 462: ...f the WinGD group The oil supplier along with other possible manufacturers and distributors of the related products shall indemnify compensate and hold harmless WinGD and companies that are part of the WinGD group from and against any claims damages and losses caused by the used system oils NOTE For system oils that are not listed in the table and for new system oils speak to or send a message to ...

Page 463: ...vigo 6 CO 6 Pertamina Medripal 307 7 Petrobras Marbrax CAD 308 8 PetroChina KunLun DCC3008 8 KunLun DCC3005H 1 5 Premier Six Opt Max Shieldguard 3008 8 Puma Energy Marine System Oil TBN 5 SAE 30 5 Shell Melina S30 5 SINOPEC Marine System Oil 3005 5 Marine System Oil 3006 6 Marine System Oil 3008 8 SK Supermar AS 2 5 Total Atlanta Marine D 3005 5 1 This system oil is under testing and not yet valid...

Page 464: ...are part of the WinGD group The oil supplier along with other possible manufacturers and distributors of the related products shall indemnify compensate and hold harmless WinGD and companies that are part of the WinGD group from and against any claims damages and losses caused by the used cylinder oils NOTE The Base Number BN measured in mg KOH g test method ASTM D 2896 gives the alkalinity of the...

Page 465: ...ilube Oil CO 700 Marilube Oil CO 1000 Plus Marilube Oil CO 700 Plus Marilube Oil CO 1000 SP ENI Punica 525 BN 25 Punica 570 ExxonMobil Mobilgard 525 BN 25 Mobilgard 560VS BN 60 Mobilgard 570 Mobilgard 5100 8 FL Selenia MECO 5070 GazPromNeft Ocean CCL 17 ULSF BN 17 Ocean CCL 40 LSF 1 Ocean CCL 70 Ocean CCL 100 HSF Gdanska Marinol RG 7050 Gulf Oil Ma rine GulfSea Cyl care ECA 50 BN 17 GulfSea Cyl ca...

Page 466: ...x CID 57 PetroChina KunLun DCA 5070H Premier Six Opt Max BoB 300 additives for on board blended cylinder oils BN 40 to BN 120 9 Opt Max Shieldguard 5040 Opt Max Shieldguard 5070 Opt Max Shieldguard 50110 BN 110 Opt Max Flexguard 140 BN 140 1 Puma Energy Marine Cylinder Oil TBN 25 SAE 50 Marine Cylinder Oil TBN 70 SAE 50 Marine Cylinder Oil TBN 100 SAE 50 Shell Alexia S3 BN 25 Alexia S4 BN 60 SAE 4...

Page 467: ...ons of this product are available Not all of them are validated Speak to the supplier for more data about the validated products 4 Use in combination with 0 1 sulphur ECA fuel is validated by field test for up to 100 h continuous operation 5 Use in combination with 0 1 sulphur ECA fuel is validated by field test for up to 200 h continuous operation 6 Use in combination with 0 1 sulphur ECA fuel is...

Page 468: ...l supplier along with other possible manufacturers and distributors of the related products shall indemnify compensate and hold harmless WinGD and companies that are part of the WinGD group from and against any claims damages and losses caused by the used lubricants Tab 12 11 List of lubricants for flywheel and pinion gear teeth 16 October 2012 Supplier Brand Lubrication Engineers Inc LE 5182 PYRO...

Page 469: ...X52 AA00 0000 00AAA 101C A Operation Manual List of lubricants for flywheel and pinion gear teeth Page left intentionally blank Winterthur Gas Diesel Ltd 469 Issue 002 2018 11 ...

Page 470: ... starting air bottles must be drained regularly to remove condensation 12 9 2 Control air The control air and air spring air supplied from the plant system must be clean and dry X52 AA00 0000 00AAA 030E A Operation Manual Compressed air Winterthur Gas Diesel Ltd 470 Issue 002 2018 11 ...

Page 471: ...X52 AA00 0000 00AAA 030E A Operation Manual Compressed air Page left intentionally blank Winterthur Gas Diesel Ltd 471 Issue 002 2018 11 ...

Page 472: ...ner piston rings turbocharger compressor etc to a minimum Silencers are installed to the suction part The silencers have filter mats in them which help to keep the air clean The filter mats must be serviced and or cleaned regularly For this data refer to the turbocharger manual X52 AA00 0000 00AAA 030D A Operation Manual Scavenge air Winterthur Gas Diesel Ltd 472 Issue 002 2018 11 ...

Page 473: ...X52 AA00 0000 00AAA 030D A Operation Manual Scavenge air Page left intentionally blank Winterthur Gas Diesel Ltd 473 Issue 002 2018 11 ...

Page 474: ...ant When bunkering it is possible that the fuel suppliers will report only some of the values given in the Quality Specifications Frequently only the density and maximum viscosity is given This makes the full understanding of the properties of the fuels very difficult thus it is important to get a full certificate of analysis with each bunker The supplier must guarantee the stability of the fuel i...

Page 475: ...he minimum quality of heavy fuel as bunkered ie as supplied to the ship installation Good operation results come from commercially available fuels that are in the ISO 8217 2017 limits But the use of fuel with metal ash and carbon contents and a lower density can have a positive effect on overhaul periods These effects can improve combustion and exhaust gas composition as well as a decrease in wear...

Page 476: ... Maximum 15 mg kg ppm ISO 10478 IP501 IP470 Used lubricating oils ULO must not be present Calcium Ca and zinc Zn ULO shows if Ca 30 and Zn 15 or Ca 30 and P 15 Do no use if Ca 30 and Zn 15 or Ca 30 and P 15 mg kg ppm IP501 or IP470 or IP500 1 For RT flex and X engines the fuel viscosity at the engine inlet must be in the range between 10 mm2 s and 20 mm2 s but WinGD recommends a fuel viscosity at ...

Page 477: ...GD recommends a viscosity range at the engine inlet between 13 mm2 s cSt and 17 mm2 s cSt You get the necessary temperature for a given nominal viscosity from the data in Figure 12 4 The maximum permitted viscosity of the fuel that can be used in an installation is related to the heating and fuel preparation facilities available The flow rate and the temperature of the fuel that flows through the ...

Page 478: ...iagram 00099 Recommended viscosity range for RT flex and W X engines Required viscosity range for RT flex and W X engines X52 AA00 0000 00AAA 030A A Operation Manual Diesel engine fuels Winterthur Gas Diesel Ltd 478 Issue 002 2018 11 ...

Page 479: ...hur content of the fuel in use You use the necessary equipment related to the statutory specifications 12 11 3 5 Flash point The flash point is an important safety and fire hazard parameter for diesel fuels Fuel is always a fire hazard There can be flammable vapors in the air space above the remaining fuel in the tanks Take care if you increase the temperature of the remaining fuel above the flash...

Page 480: ... of the fuel must be adjusted in relation to the viscosity For high viscosity fuels the separation temperature must be increased and the flow rate must be decreased in relation to the nominal capacity of the separator For the recommended data to operate the separator refer to the documentation of the manufacturer 12 11 3 11 Ash and Trace Metals Fuels with a low content of ash vanadium sodium alumi...

Page 481: ... in ISO 8217 2017 and the WinGD specifications make sure that no used lubricating oil is in the fuel Chemical waste eg polymers styrene and other chemical substances must not be added to the fuel These materials can cause the fuel to become too thick to become almost solid and thus can cause blocked filters They can also cause corrosive attacks and damage to the fuel injection system 12 11 4 Disti...

Page 482: ... Water Maximum 0 3 Maximum 0 2 volume ISO 3733 Ash Maximum 0 01 Maximum 0 01 mass ISO 6245 Lubricity corrected wear scar diameter WSD at 60 C 7 Maximum 520 Maximum 520 μm 1 1 mm2 s 1 cSt Centistoke 2 The purchaser must specify the maximum sulphur content in accordance with the usual statutory specifications 3 The hydrogen sulphide limit is applicable from 1 July 2012 4 If the sample is not clear a...

Page 483: ...tic quantity 12 11 5 4 Cetane index The ignition and combustion properties of a distillate fuel in a diesel engine is related to the specific engine design load profile and fuel properties The Cetane Index is a calculated value of the ignition quality of the fuel related to the distillation and density The density and the temperature when 10 50 and 90 of the fuel is distilled gives the Cetane Inde...

Page 484: ...rature of the fuel must be kept between approximately 5 C and 10 C above the pour point to make sure that the fuel flows easily It is possible that in very cold conditions there could be problems for distillate fuel 12 11 5 11 Water The quantity of water in distillate fuel can be decreased as follows Let the fuel settle in the service tanks Use a separator to remove water from the fuel 12 11 5 12 ...

Page 485: ... 14214 and ASTM D 6751 FAME has good ignition properties and very good lubrication and environmental properties but FAME has also known negative properties as follows Possible oxidation and thus long term storage problems A chemical attraction to water and nutrient for microbial growth Unsatisfactory low temperature properties FAME material particles can appear on exposed surfaces and filter eleme...

Page 486: ...bjection Letters done by Wärtsilä Switzerland Ltd are no longer applicable and have no more support by WinGD NOTE WinGD does not accept liability or responsibility for the performance or potential damage caused by the use of such additives 12 11 9 Non standard fuels If it is necessary to use non standard fuels fuels that are not in the related list from WinGD speak to or send a message to WinGD be...

Page 487: ...13 Schematic diagrams 13 1 Schematic diagrams general 488 13 2 List of diagrams 494 487 ...

Page 488: ...1 2 Line codes in the engine control diagram The line codes in the engine control diagram are shown in Figure 13 1 Fig 13 1 Line codes 001 002 003 004 005 006 007 00208 Legend 001 Low pressure oil circuits 005 Heating 002 High pressure oil circuits 006 Control air circuits 003 Low pressure fuel circuits 007 Starting air circuits 004 High pressure fuel circuits 13 1 1 3 System codes in the engine c...

Page 489: ...ram The component codes in the engine control diagram are shown as example in Figure 13 2 Fig 13 2 Process codes 10 5553_E0_1 001 002 003 004 005 00206 Legend 001 System code 004 CX Cylinder eg C5 for cylinder 5 002 Design group 005 Running number 003 E0 for engine 13 1 1 5 Signal codes identification The signal codes in the engine control diagram are shown as example in Figure 13 3 X52 AA00 0000 ...

Page 490: ... position A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Temperature Transmitter V n a Valve X Unclassified Unclassified Y Vibration Relay Z Position binary n a X52 AA00 0000 00AAA 043I A Operation Manual Schematic diagrams general Winterthur Gas Diesel Ltd 490 Issue 002 2018 11 ...

Page 491: ...haust gas 40 to 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals to the engine Miscellaneous Tab 13 3 Applied system Code Description A Alarm and monitoring system C Control system L Local M Measured indication Local control panel S Safety system W Wrong way ala...

Page 492: ...13 4 Color codes and symbols electric connection diagram 00221 ECR component Color codes Power Option Diesel Speed Bus CCM 20 A1 Cylinder 1 13 1 3 Piping and instrumentation diagram The piping and instrumentation diagrams show data about the piping and instrumentation of the auxiliary systems of the engine X52 AA00 0000 00AAA 043I A Operation Manual Schematic diagrams general Winterthur Gas Diesel...

Page 493: ...X52 AA00 0000 00AAA 043I A Operation Manual Schematic diagrams general Page left intentionally blank Winterthur Gas Diesel Ltd 493 Issue 002 2018 11 ...

Page 494: ...on the pages that follow Tab 13 4 List of diagrams Item Title 1 Engine control diagram 2 Electric connection diagram 3 Piping and instrumentation diagram 5 cylinder 4 Piping and instrumentation diagram 6 cylinder X52 AA00 0000 00AAA 050A A Operation Manual List of diagrams Winterthur Gas Diesel Ltd 494 Issue 002 2018 11 ...

Page 495: ...ETY VALVE PRESSURE RETAINING VALVE CONNECTION PIECE NON RETURN VALVE BALL VALVE 3 3 WAY VALVE FILTER FILTER 3 2 WAY VALVE SHUT OFF VALVE STARTING AIR BALL VALVE BALL VALVE PRESSURE SAFETY VALVE FLAME ARRESTER DOUBLE CHECK VALVE PRESSURE REDUCING VALVE PRESSURE REDUCING VALVE PRESSURE SAVETY VALVE PRESSURE SAVETY VALVE NON RETURN VAVLE RESTRICTOR CONTROL AIR BOTTLE 3 2 WAY VALVE NON RETURN VALVE NO...

Page 496: ...ber of cylindersand or number ofTC Inj Lub Shut offVlv CV7003C To AMS Power Torque JT5156C Rail Unit Ethernet Modbus Modbus CY7036 37C AuxBlow 1 2 Speed Setp Note Only with E21 with FrequencyConverter HFO Supply XS3411C HFO Supply XS3411C Starting Air Press 1 Before ShutoffVlv PT4301C Starting Air Press 1 Before ShutoffVlv PT4301C MainStartVlvMan Closed ZS5018C MainStartVlvMan Closed ZS5018C Turn ...

Page 497: ...16 06 16 EAAD087062 19 08 16 EAAD088576 22 09 17 24VDC AC 24VDC AC U2 24VDC AC 24VDC AC U2 24VDC AC 24VDC AC 24VDC AC 24VDC AC U1 U2 24VDC AC 24VDC AC U1 E85 3 24VDC AC 24VDC AC 24VDC AC 24VDC AC U2 U1 E85 5 24VDC AC 24VDC AC E85 0 Mains 1 24VDC AC 24VDC AC Batt 24VDC DC 24VDC DC 24VDC DC 24VDC DC U1 E85 2 To E85 1 2x4mm 2 2x4mm 2 Engine Engine Control Room E g PULS CD5 241 Mains 2 24VDC AC 24VDC ...

Page 498: ...may be used in any way for construction fabrication or marketing or any other purpose nor copied in any way nor made accessible to third partieswithout the previous written consent of Winterthur Gas Diesel Ltd In case of violation the recipient will be liable to damages Mod 0 1 2 3 4 5 6 7 8 9 3 4 EAAD086428 05 02 16 EAAD086753 16 06 16 EAAD087062 19 08 16 EAAD088576 22 09 17 24VDC 230VAC 24VDC 23...

Page 499: ...2 3 4 5 6 7 8 X25 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 X12 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 PSS_2 PSS_2 CAN_2_H CAN_2_L Speed_2 Speed_2 Phase_2 Phase_2 Controller Supply B System Bus 2 Gear Wheel Sens B D Engine BDC signal Controller Supply A System Bus 1 Gear Wheel sens A C Engine TDC signal PSS_1 PSS_1 CAN_1_H CAN_1_L Speed_1 Speed_1 Phase_1 Phase_1 HSD_1 HSD_1 HSD_2 HSD_2 LSD_1 LSD_2 DR_GND DR_GND Dr...

Page 500: ...y flow auxiliary system and energy carrier lines heating 0 5mm Control data transmission and other auxiliary lines 0 25mm Symbol definitions Ball valve Butterfly valve Flange pair Flange pair Funnel Pressure indicator Pressure relief valve Orifice Adjustable orifice Air filter Pressure vessel Reducer Connection with a plug Non return valve Adjustable pressure retaining valve Rupture disc Filter st...

Page 501: ...0 8305 E0_1 DN125 8305 C1_1 DN40 8305 C2_1 DN40 8305 C3_1 DN40 8305 C4_1 DN40 8611 E0_1 DN40 8611 C1_1 DN20 8611 C2_1 DN20 8611 C3_1 DN20 8611 C4_1 DN20 8310 E0_1 DN125 Cylinder Cylinder Cylinder Cylinder 8313_C1_1 8313_C2_1 8313_C3_1 8313_C4_1 8310_C1_2 8310_C2_2 8310_C3_2 8310_C4_2 8310_C1_1 8310_C2_1 8310_C3_1 8310_C4_1 TI 1121L TE 1121A TE 1122A TE 1123A TE 1124A TI 1124L TI 1123L TI 1122L 830...

Page 502: ...1_1a DN20 8347 E0_3a DN20 8338 E0_2a DN20 8357 E0_2a DN40 8338 E0_1a DN20 8338 T1_1a DN15 8314 T1_1a DN15 8352 E0_9a DN50 8352 E0_3a DN25 8352 T1_1a DN25 8335 T1_3a DN15 8357 T1_2a DN40 8357 T1_1a DN40 8352 E0_2a DN12 8352 E0_5a DN25 8352 E0_1a DN12 8357 E0_1a DN50 Scavenge Air Cooler 8314_T1_2a Aux Blower 8347_E0_3a 8347_E0_1a 8347_E0_2a 8347_T1_1a 8338_E0_2a 8338_E0_1a p 8347_E0_4a 8335_T1_1a 83...

Page 503: ... DN65 40 8406 E0_1 DN200 23 22 Cylinder 4 Cylinder 3 Cylinder 2 Cylinder 1 8411_E0_1 8411_E0_2 8409_C1_1 8409_C2_1 8409_C3_1 8409_C4_1 8406_E0_1 8488_C1_1 8487_C1_2 8487_C1_1 8488_C2_1 8487_C2_2 8487_C2_1 8488_C3_1 8487_C3_2 8487_C3_1 8488_C4_1 8487_C4_2 8487_C4_1 PS 2002S PT 2002C PT 2001A TE 2011A TI 2011L N02 8406_E0_2 AE 2415A AE 2401A TE 2501A FS 2521S FS 2522S AE 2402A TE 2502A FS 2523S AE 2...

Page 504: ...0 8406 C4_1 DN65 40 8406 E0_1 DN200 23 22 Cylinder 4 Cylinder 3 Cylinder 2 Cylinder 1 8411_E0_1 8411_E0_2 8409_C1_1 8409_C2_1 8409_C3_1 8409_C4_1 8406_E0_1 8488_C1_1 8487_C1_2 8487_C1_1 8488_C2_1 8487_C2_2 8487_C2_1 8488_C3_1 8487_C3_2 8487_C3_1 8488_C4_1 8487_C4_2 8487_C4_1 PS 2002S PT 2002C PT 2001A TE 2011A TI 2011L N02 8406_E0_2 AE 2415A AE 2401A TE 2501A FS 2521S FS 2522S AE 2402A TE 2502A FS...

Page 505: ... C3_7 DN9 5569 C4_7 DN9 5614 E0_2 ø46 5569 E0_2 DN25 5569 E0_3 DN25 5569 C3_6 DN9 5569 C1_6 DN9 5569 E0_4 DN9 8460 C2_1 8460 C4_1 8447 E0_1 8482 E0_1 DN65 8454 E0_1 DN50 8445 E0_6 DN32 8445 E0_5 DN20 8445 E0_4 DN25 5569 C2_6 DN9 5569 C4_6 DN9 8447_E0_4 8447_E0_3 8445_E0_3 VCU VCU 8447_E0_1 8447_E0_2 8445_E0_1 38 34 8445_E0_4 p 8445_E0_2 5610_E0_3 PT 2003A CV 7401C FS 2062A FS 2061A CV 7222C CV 722...

Page 506: ...4 C2_1 ø5 8474 C2_2 ø5 8474 C2_3 ø5 8474 C2_4 ø5 8474 C2_5 ø5 8474 C2_6 ø5 8474 C3_5 ø5 8474 C3_6 ø5 DOC 006 015 4 C 5614 C1_1 DOC 006 015 5 C 5614 C2_1 DOC 006 015 6 C 5614 C3_1 DOC 006 015 7 C 5614 C4_1 8474 C4_6 ø5 8474 C4_5 ø5 5614 C1_2 DN15 5614 C2_2 DN15 5614 C3_2 DN15 5614 C4_2 DN15 5614 E0_4 DN50 CV 7132C PT 3132C CV 7131C PT 3131C CV 7133C PT 3133C CV 7134C PT 3134C PT 3124A flexLube DG 7...

Page 507: ...53 E0_1 DN7 8605 E0_1 DN100 Cyl 8353_E0_2 40 Cyl Cyl Cyl 8605_E0_6 8605_C1_1 8605_C2_1 8605_C3_1 8605_C4_1 p 35 274HD 8606_E0_4 CV 7013C CV 7014C PT 5017C PT 4302C ZS 5018C PT 4301C PT 4341C LS 4351A ZS 5016C ZS 5123C ZS 5124C ST 5101C ST 5102C ST 5103C ST 5104C ST 5111S ST 5112S ST 5131C ST 5132C ST 5133C ST 5134C CV 7241C CV 7242C CV 7243C CV 7244C TE 4081A TE 4082A TE 4083A TE 4084A 8353_E0_1 1...

Page 508: ...T 3603C PT 3604C 1 2 3 4 Cyl TE 3705A TI 3705L PT 3605C 5 8631 E0_1 DN7 Aux Blower Turbocharger PI 4001L PI 4021L TE 4031A TI 4031L PT 4044C JS 5031C JS 5032C CY 7031C CY 7032C 43 TI 3721L Scavenge Air Cooler ST 5201C TE 3721A TI 3731L TE 3731A 8615_E0_1 8631_E0_1 CV 7077C XI 7077C DG 6547 Starter Unit for Auxilliary Blower PLANT ENGINE 8135_E0_2 Cooling Air System for MHI Turbo chargers only Appl...

Page 509: ...V 7231C 8702_E0_1 8704_E0_3 PI 3431L LS 3426A 5556_E0_1 5556_E0_2 CV 7232C 8744_E0_7 8744_E0_6 52 60 9210_E0_4 9210_E0_2 9210_E0_3 9210_E0_1 8752_E0_1 8752_E0_2 8752_E0_5 8752_E0_4 8752_E0_7 8752_E0_8 TE 3411C Fuel Pump 1 Fuel Pump 2 8746 E0_1 DN32 8746 E0_13 DN32 8746 E0_9 DN15 8746 E0_11 DN15 8746 E0_12 DN32 8830 E0_1 DN32 8830 C1_1 DN15 8830 C2_1 DN15 8830 C3_1 DN15 8830 C4_1 DN15 8744 E0_1 DN2...

Page 510: ... flow auxiliary system and energy carrier lines heating 0 5mm Control data transmission and other auxiliary lines 0 25mm Symbol definitions Ball valve Butterfly valve Flange pair Flange pair Funnel Pressure indicator Pressure relief valve Orifice Adjustable orifice Air filter Pressure vessel Reducer Connection with a plug Non return valve Adjustable pressure retaining valve Rupture disc Filter str...

Page 511: ...1 DN40 8611 E0_1 DN40 8611 C1_1 DN20 8611 C2_1 DN20 8611 C3_1 DN20 8611 C4_1 DN20 8310 E0_1 DN125 Cylinder Cylinder Cylinder Cylinder 8313_C1_1 8313_C2_1 8313_C3_1 8313_C4_1 8310_C1_2 8310_C2_2 8310_C3_2 8310_C4_2 8310_C1_1 8310_C2_1 8310_C3_1 8310_C4_1 TI 1121L TE 1121A TE 1122A TE 1123A TE 1124A TI 1124L TI 1123L TI 1122L 8305_C1_1 8305_C2_1 8305_C3_1 8305_C4_1 8611_C1_1 8611_C2_1 8611_C3_1 8611...

Page 512: ...1_1a DN20 8347 E0_3a DN20 8338 E0_2a DN20 8357 E0_2a DN40 8338 E0_1a DN20 8338 T1_1a DN15 8314 T1_1a DN15 8352 E0_9a DN50 8352 E0_3a DN25 8352 T1_1a DN25 8335 T1_3a DN15 8357 T1_2a DN40 8357 T1_1a DN40 8352 E0_2a DN12 8352 E0_5a DN25 8352 E0_1a DN12 8357 E0_1a DN50 Scavenge Air Cooler 8314_T1_2a Aux Blower 8347_E0_3a 8347_E0_1a 8347_E0_2a 8347_T1_1a 8338_E0_2a 8338_E0_1a p 8347_E0_4a 8335_T1_1a 83...

Page 513: ... 8409_C1_1 8409_C2_1 8409_C3_1 8409_C4_1 8406_E0_1 8488_C1_1 8487_C1_2 8487_C1_1 8488_C2_1 8487_C2_2 8487_C2_1 8488_C3_1 8487_C3_2 8487_C3_1 8488_C4_1 8487_C4_2 8487_C4_1 PS 2002S PT 2002C PT 2001A TE 2011A TI 2011L N02 8406_E0_2 AE 2415A AE 2401A TE 2501A FS 2521S FS 2522S AE 2402A TE 2502A FS 2523S AE 2403A TE 2503A FS 2524S AE 2404A TE 2504A TE 2101A TE 2102A TE 2103A TE 2104A TE 2105A TE 2106A...

Page 514: ... 8411_E0_2 8409_C1_1 8409_C2_1 8409_C3_1 8409_C4_1 8406_E0_1 8488_C1_1 8487_C1_2 8487_C1_1 8488_C2_1 8487_C2_2 8487_C2_1 8488_C3_1 8487_C3_2 8487_C3_1 8488_C4_1 8487_C4_2 8487_C4_1 PS 2002S PT 2002C PT 2001A TE 2011A TI 2011L N02 8406_E0_2 AE 2415A AE 2401A TE 2501A FS 2521S FS 2522S AE 2402A TE 2502A FS 2523S AE 2403A TE 2503A FS 2524S AE 2404A TE 2504A TE 2101A TE 2102A TE 2103A TE 2104A TE 2105...

Page 515: ...9 5569 C1_6 DN9 5569 E0_4 DN9 8460 C2_1 8460 C4_1 8447 E0_1 8482 E0_1 DN65 8454 E0_1 DN50 8445 E0_6 DN32 8445 E0_5 DN20 8445 E0_4 DN25 5569 C2_6 DN9 5569 C4_6 DN9 8447_E0_4 8447_E0_3 8445_E0_3 VCU VCU 8447_E0_1 8447_E0_2 8445_E0_1 38 34 8445_E0_4 p 8445_E0_2 5610_E0_3 PT 2003A CV 7401C FS 2062A FS 2061A CV 7222C CV 7221C LS 2055A ZT 5421C ZT 5422C ZT 5423C ZT 5424C CV 7404C CV 7403C CV 7402C PI 20...

Page 516: ...ø5 DOC 006 015 3 C 5614 C1_1 DOC 006 015 4 C 5614 C2_1 DOC 006 015 5 C 5614 C3_1 DOC 006 015 6 C 5614 C4_1 8474 C4_6 ø5 8474 C4_5 ø5 5614 C1_2 DN15 5614 C2_2 DN15 5614 C3_2 DN15 5614 C4_2 DN15 5614 E0_4 DN50 CV 7132C PT 3132C CV 7131C PT 3131C CV 7133C PT 3133C CV 7134C PT 3134C PT 3124A flexLube DG 7230 flexLube DG 7230 flexLube DG 7230 flexLube DG 7230 Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4...

Page 517: ...8353_E0_2 40 Cyl Cyl Cyl 8605_E0_6 8605_C1_1 8605_C2_1 8605_C3_1 8605_C4_1 p 35 274HD 8606_E0_4 CV 7013C CV 7014C PT 5017C PT 4302C ZS 5018C PT 4301C PT 4341C LS 4351A ZS 5016C ZS 5123C ZS 5124C ST 5101C ST 5102C ST 5103C ST 5104C ST 5111S ST 5112S ST 5131C ST 5132C ST 5133C ST 5134C CV 7241C CV 7242C CV 7243C CV 7244C TE 4081A TE 4082A TE 4083A TE 4084A 8353_E0_1 1 DG 3225 Disengaging Device Turn...

Page 518: ... Air Cooler ST 5201C TE 3721A TI 3731L TE 3731A 8615_E0_1 8631_E0_1 CV 7077C XI 7077C DG 6547 Starter Unit for Auxilliary Blower PLANT ENGINE 8135_E0_2 Cooling Air System for MHI Turbo chargers only Application depending on Scavenge Air pressure 2 1 4002 03C PT 4041 42C TE 4045 46C TE 8631 E0_1 Page 8 Cyl Cyl Cyl Cyl TE 3701A TE 3702A TE 3703A TE 3704A TI 3701L TI 3702L TI 3703L TI 3704L PT 3601C ...

Page 519: ...I 3421L CV 7231C 8702_E0_1 8704_E0_3 PI 3431L LS 3426A 5556_E0_1 5556_E0_2 CV 7232C 8744_E0_7 8744_E0_6 52 60 9210_E0_4 9210_E0_2 9210_E0_3 9210_E0_1 8752_E0_1 8752_E0_2 8752_E0_5 8752_E0_4 8752_E0_7 8752_E0_8 TE 3411C Fuel Pump 1 Fuel Pump 2 8752 E0_3 ø18 8702 E0_4 DN20 5556_E0_3 CV 7233C 8752_E0_9 8752_E0_6 8752_E0_3 Fuel Pump 3 8746 E0_1 DN32 8746 E0_13 DN32 8746 E0_9 DN15 8746 E0_11 DN15 8746 ...