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Operation

5591

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1/A1

Winterthur Gas & Diesel Ltd.

Servo Pump Unit with Dynex Servo Oil Pump

1.

General

The servo pump unit (1, Fig. 1) has two built

−

in servo oil pumps. These pumps supply

HP servo oil, which operates the exhaust valves and the injection. The servo oil flows

from the main bearing oil supply, through the automatic filter (10) to the servo oil

pumps.
The gear wheel on the crankshaft moves the intermediate wheel on the drive supply

unit. This movement turns the gear wheels (3, 4) and the pinion (5) on the shaft (6).
For more data about the drive supply unit, see Drive Supply Unit

2.

Function

During operation, the full load range is equally supplied to the servo oil pumps.
The electrically operated pressure control system (the nominal pressure value is

related to the engine load) adjusts the servo oil pressure for the full load range, i.e.

high pressure (approximately 200 bar) at high engine load, and decreased pressures

at low engine load.
Shearable overload protection (OP) on each shaft (6) prevents full damage to the

gear wheel (4) if a pump fully seizes.
If a servo oil pump becomes defective, the engine can use the full load range.
The flow sensors (11) monitor the oil supply in each of the inlet pipes to the servo oil

pumps (2). A possible failure of a servo oil pump shows in the alarm and monitoring

system.

CAUTION

Damage Hazard: If a servo oil pump becomes defective, do not

operate the engine for too long. If the other pump becomes

defective, the engine cannot operate. You must replace the

defective servo oil pump as soon as possible (see the

Maintenance Manual 5552-1).

3.

Lubrication

Oil flows into the oil inlet (OI, Fig. 1) through the oil bore (OB) in the gear wheel (3),

then into the internal bores inside the casing (8) to lubricate the bearings. The oil also

flows to the supply pipes (9). The shaft (6) has an internal bore with holes. The oil that

flows through these holes comes out as a spray and lubricates the teeth of the gear

wheel (3) and pinion (5).

2014

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Summary of Contents for W-X82

Page 1: ...Document ID DBAC753771 Winterthur Gas Diesel Ltd 24hrs Support Sch tzenstrasse 1 3 W rtsil Services Switzerland Ltd CH 8400 Winterthur Z rcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland 41 5...

Page 2: ...ission of the copyright 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 o...

Page 3: ...Document ID DBAC753771 Winterthur Gas Diesel Ltd 24hrs Support Sch tzenstrasse 1 3 W rtsil Services Switzerland Ltd CH 8400 Winterthur Z rcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland 41 5...

Page 4: ...lder Winterthur Gas Diesel Ltd or W rtsil Services Switzerland Ltd make no representation warranty express or implied in this publication and assumes no responsibility for the correct ness errors or o...

Page 5: ...apter for 9 cylinder engines added x Date of publication 2014 09 16 OM_2015 05 2015 05 Cover page Disclaimer and all related pages Data about Winterthur Gas Diesel WinGD and W rtsil Services Switzerla...

Page 6: ...data added Table 1 data FZG gear machine test added Table 2 data FZG gear machine test added paragraph 2 4 Sample point added paragraph 3 1 updated Fig 1 illustration updated paragraph 3 2 new data a...

Page 7: ...n damper damper inlet Min pressure value changed from 1 0 bar to 2 8 bar max pressure 5 0 bar value added Note added x 0250 2 A1 2017 04 Update WinGD Operating Data Sheet Alarms and Safeguards PT2711A...

Page 8: ...text changes only cleaning of compressor x 6606 1 A1 2017 08 Update WinGD Operating Instructions and Cleaning Fig 1 FW line changed x 6735 1 A1 2017 08 Update WinGD Scavenge Air Waste Gate Text correc...

Page 9: ...and Control Elements Crankshaft Connecting Rod and Piston Cylinder Liner and Cylinder Cover Bedplate and Tie Rod Operating Descriptions Supply Unit Servo Oil Pump and Fuel Pump Scavenge Air System Cyl...

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Page 11: ...0 1 A1 Operation during Usual Conditions General Data 0200 1 A1 Safety Precautions and Warnings General Data 0210 1 A1 Slow Turning 0220 1 A1 Engine Start 0230 1 A1 Usual Operation 0240 1 A1 Operating...

Page 12: ...Control 0560 1 A1 Defective Speed Control System 0570 1 A1 Defective Turbocharger 0590 1 A1 Special Procedures Before and After Operation Prepare for Engine Start after a Long Shutdown Period or an O...

Page 13: ...ntenance and operation must be serviceable and in good condition The extent of all supplies and services is set exclusively to the related supply contract 3 Data The specifications and recommendations...

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Page 15: ...er is necessary to order spare parts from Winterthur Gas Diesel Ltd WinGD or the engine supplier The spare parts can only be ordered with the code number from the code book 5 4 External Supplier Docum...

Page 16: ...heir illustrations are divided into the design groups 0peration 1132 1 A1 Title Subtitle Winterthur Gas Diesel Ltd 1 4 2015 2015 05 Year of issue or Modification date Page number Total pages of group...

Page 17: ...re data to help you do a task or give you data about the engine Notes come immediately before or after the related paragraph 7 Technical Documentation Because of the continuous development of the engi...

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Page 19: ...System 0140 1 A1 Operation during Usual Conditions General Data 0200 1 A1 Safety Precautions and Warnings General Data 0210 1 A1 Slow Turning 0220 1 A1 Engine Start 0230 1 A1 Usual Operation 0240 1 A1...

Page 20: ...Operation Prepare for Engine Start after a Long Shutdown Period or an Overhaul 0610 1 A1 Prepare the Engine for a Long Shutdown Period 0620 1 A1 Operation Media Diesel Engine Fuels 0710 1 A1 Fuel Tre...

Page 21: ...l Diagram Designations Description to 4003 1 4003 2 and 4003 3 4003 2 A0 Control Diagram 6 cylinders to 8 cylinders 4003 2 A1 Control Diagram 9 cylinders 4003 2 A2 Control and Auxiliary Systems Detail...

Page 22: ...8 3 A1 Piping Systems Group 8 Lubricating Oil System 6 cylinders to 8 cylinders 8016 1 A1 Lubricating Oil System 9 cylinders 8016 1 A2 Cooling Water System 8017 1 A1 Starting Air Diagram 8018 1 A1 Fue...

Page 23: ...ir control air 0740 1 A1 Control air supply 4605 1 A1 Control diagram designations 4003 2 A0 Control diagram 4003 2 A1 Connecting rod connecting rod bearing 3303 1 A1 Cooling water system 8017 1 A1 Co...

Page 24: ...HP fuel system 0515 1 A1 Faults in servo oil system 0525 1 A1 Feed Rate Adjustment 7218 3 A1 Finding group and page numbers 0040 1 A1 Fires in scavenge air spaces prevention of 0450 1 A1 For your atte...

Page 25: ...g medium air 0740 1 A1 Operating medium oil 0750 1 A1 Operating medium water 0760 1 A1 Operating troubles general 0800 1 A1 Operating with defective turbocharger 0590 1 A1 Operation at low load 0280 1...

Page 26: ...Pressure release servo oil rail 8016 1 A1 Prevention of crankcase explosions 0460 1 A1 Problems during operation 0820 1 A1 Problems when starting and shutting down 0810 1 A1 Problems with engine part...

Page 27: ...Speed control system defective 0570 1 A1 Speed measurement pick up for 4628 1 A1 Starting 0230 1 A1 Starting air system schematic diagram 8018 1 A1 Starting valve 2728 1 A1 Structure of the manuals 0...

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Page 29: ...Controller Area Network Module Bus CAN S Controller Area Network System Bus CCAI Calculated Carbon Aromaticity Index CMCR Contract Maximum Continuous Rating COC Cleveland Open Cup CSR Continuous Servi...

Page 30: ...rgin OMD Oil Mist Detector PCS Propulsion Control System PLM Pulse Lubrication Module PLS Pulse Lubrication System PMCC Pensky Martens Closed Cup method RCS Remote Control System SAC Scavenge Air Cool...

Page 31: ...ted illustrations 3 Where to find data You can find the group titles in the Table of Contents 0020 1 You can also look in The Subject Index 0030 1 In the cross section and longitudinal section illustr...

Page 32: ...ction 6545 1 2728 1 2751 1 6500 1 6420 1 6606 1 8345 1 8017 1 3603 1 8016 1 2722 1 8016 1 8019 1 2138 1 8018 1 4325 1 7218 1 2303 1 3326 1 3303 1 5556 1 5581 1 4104 1 WCH01165 5562 1 2124 1 1903 1 340...

Page 33: ...terthur Gas Diesel Ltd 3 3 5 Longitudinal section 2751 1 1203 1 1903 1 3403 1 2124 1 2138 1 4104 1 2303 1 3326 1 3303 1 3140 1 9223 1 1132 1 018 264 09 7218 1 Fig 2 Longitudinal Section 2014 How to Us...

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Page 35: ...gine control system WECS 9520 controls the exhaust valve operation electronic fuel injection and cylinder lubricating system D The lubrication oil coolant water fuel supply booster pumps and air compr...

Page 36: ...re of the exhaust gas to operate the compressor D The scavenge air from the turbocharger flows through the air cooler and water separator into the air receiver This air then flows through air flaps an...

Page 37: ...r 1 2 Second Stroke Ignition Combustion Expansion Exhaust Scavenging The sequence of piston movements during the second stroke is as follows D When the piston is almost at TDC fuel is injected into th...

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Page 39: ...to be used for the propulsion of vessels with fixed propellers have a load applied on the test bed in accordance with this propeller characteristic However during sea trial of a new ship with a smooth...

Page 40: ...he contract maximum continuous rating CMCR The remaining 10 to 15 of power can be used to catch up with changes in schedules or for the timing of dry dock intervals This margin is usually subtracted f...

Page 41: ...an the specified limits D Line 5 is the permitted torque limit from 95 power and speed to 45 power and 70 speed This shows a curve defined by the equation P2 P1 N2 N1 2 45 When the engine speed and po...

Page 42: ...a that an engine with a CPP must be operated Line 7 shows a typical combinator curve for variable speed mode Maneuvering at maximum speed with low or zero pitch is not permitted Thus installations wit...

Page 43: ...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 opera...

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Page 45: ...ng Numbers 6 5 4 3 2 8 7 Turbocharger 2 9 1 Cylinder Number 10 11 12 1 2 3 4 5 6 7 8 9 FREE END Turbocharger 1 DRIVING END Turbocharger 2 Cylinder Numbering 6 5 4 3 2 8 7 9 1 2 3 4 5 6 7 1 Thrust Bear...

Page 46: ...Pump Unit Fuel Side Clockwise Rotation Servo Pump Unit Fuel Pump Unit Exhaust Side DRAWN FOR 9 CYLINDERS DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS EXHAUST SIDE FUEL SIDE Fuel Pump Unit Clockwise Rotation 0...

Page 47: ...Oil Pump 3 Servo Oil Pump 2 Servo Oil Pump 1 EXHAUST SIDE 016 834 08 Actuator B3 Actuator B2 Actuator B1 DRAWN FOR 9 CYLINDERS DRIVING END Fuel Pump A1 Fuel Pump A2 Fuel Pump A3 Actuator A1 Actuator...

Page 48: ...Operation 0080 1 A1 Winterthur Gas Diesel Ltd 4 4 FUEL SIDE FREE END 013 150 05 Crank Angle Sensors Sensor 2 GT5127C Sensor 1 GT5126C Fig 4 Flex Parts 2014 Engine Numbering and Designations...

Page 49: ...position see Control Air Supply 4605 1 5 Heat the lubrication oil to approximately 35_C through the lube oil separator or heaters in oil drain tank if installed 6 Heat the cylinder coolant water to a...

Page 50: ...has been drained 27 Open the drain and test valve 2 06 to drain possible condensate water 28 Close the drain and test valve 2 06 29 Close the venting valves 2 21 and 2 27 30 Open the shut off valves...

Page 51: ...G button 4618 1 Local Control Panel paragraph 2 1 The engine will slowly turn one time see also Slow Turning 0220 1 40 Make sure that at the location where you want to start the engine the related WEC...

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Page 53: ...Temperature Diagram After a shut down period of more than 24 hours heat the high pressure circuit on the engine for a minimum of four to six hours Do not try to start the engine on heavy fuel before...

Page 54: ...rackets refer to items in 4003 2 Control Diagrams Numbers that do not have parenthesis and square brackets refer to items in 8019 1 Fig 1 The fuel oil system can be vented manually as follows D Make s...

Page 55: ...cosity Temperature Diagram After a shut down period of more than 24 hours heat the high pressure circuit on the engine for a minimum of four to six hours Do not try to start the engine on heavy fuel b...

Page 56: ...theses below refer to items in 0720 1 Fig 1 Configuration of fuel oil system The numbers in the square brackets refer to items in 4003 2 Control Diagrams Numbers that do not have parenthesis and squar...

Page 57: ...the injection control unit 3 02 11 are open 1 2 9 cylinder engines For more data see 8016 1 A2 Fig 3 and Fig 4 and 4003 2 Control Diagram Do the checks that follow 1 Make sure that the stop valve 4 3...

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Page 59: ...r 8 17 is open see Fig 3 5 Make sure that the ball valve 9 downstream of the measurement tube 4 is open see Fig 3 6 Make sure that the shut off valve 6 to the servo oil inlet of the lubricating pumps...

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Page 61: ...des all maneouvers from the first start at cast off until the last maneuver when the vessel is moored The engine is designed to operate with heavy fuel oil HFO from pier to pier i e without a change o...

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Page 63: ...ard When you remove valves from the cylinder cover do not let oil or fuel fall on to the hot piston This can cause an explosion WARNING Injury Hazard If an oil mist detector activates an alarm keep aw...

Page 64: ...hat is soaked with oil or fuel is flammable and must be replaced Make sure that you know the fire fighting instructions Before you do welding work or work that causes sparks make sure that there are n...

Page 65: ...orrosion protection The corrosion protection agent must be easy to remove Examine the the corrosion protection agent at regular intervals and replace if necessary The spare parts must also have protec...

Page 66: ...re you go into the spaces of the crankcase cylinder exhaust pipes and scavenge air receiver make sure that D The starting air to the engine is blocked and the ball valves 30 8605_E0_6 and 30 8605_E0_7...

Page 67: ...in the danger areas crankcase piston underside propeller shaft etc The propeller coupling also turns Note If the engine is stopped for overhaul you must engage the turning gear to prevent engine move...

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Page 69: ...items in 4003 2 Control Diagram 1 Before you start the SLOW TURNING operation do the steps that follow a Make sure that the turning gear is disengaged b Make sure that the WECS 9520 is set on c Make s...

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Page 71: ...CONTROL Remote Control for mode transfer to the remote control 2 At the control room console push the button REMOTE AUTOM CONTROL Remote Control to get control For more procedures to start using the r...

Page 72: ...ary knob to adjust the fuel injection quantity until the engine operates at the necessary speed You can see the related value on the display and speed indicator 6 Read the instructions for speed power...

Page 73: ...rail pressure D Engine speed D Turbocharger speed D Scavenge air pressure D Exhaust gas temperature upstream of the turbine Other important data are the values of the fuel that is used each day and th...

Page 74: ...y used and how to calculate it see 7218 2 Instructions about Measurement of the Cylinder Lubricating Oil Consumption The cooling water pumps must operate at their usual flow capacity i e the supply he...

Page 75: ...ting FQS to change the firing pressures see 4002 3 User Parameters 19 Put the lubricating oil through a centrifuge Get samples at regular intervals and compare these samples with the values given in 0...

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Page 77: ...nstream of pressure retaining valve fuel pump Return 3 0 5 0 Scavenge air Scavenge air cooler after cooler 25 60 Intake from engine room pressure drop Air filter silencer max 10 mbar Intake from outbo...

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Page 79: ...09A ALM H 65_C 0 SLD H 70_C 60 Servo oil Pressure Lubricating pump PT2041 42A ALM L 13 40 bar 3 for cylinder lubrication Inlet FE DE H 70 bar 3 Pressure Lubricating pump PT2046 47A ALM H 10 bar 0 lea...

Page 80: ...ring damper 5 Pressure Damper inlet PT2711A ALM L 2 2 bar 15 0 Axial vibration damper oil Pressure Chamber aft side PT2721A ALM L 1 7 bar 60 Chamber fore side PT2722A ALM L 1 7 bar 60 Cylinder lubrica...

Page 81: ...5 0 bar 0 Fuel pump actuator Failure E98 1 XS5046A ALM F 0 E98 2 XS5047A ALM F 0 WECS 9520 control system Power failure Power supply box E85 XS5056A ALM F 0 Cylinder lubricating system Power failure...

Page 82: ...from TExxxxA to TTxxxxA 11 Alarm has an effect only above 30 engine power 12 Alarm has an effect only above 40 engine power Deviation from the median shows that there is no flow 13 The alarm is not s...

Page 83: ...maneuvering speed for engines that have fixed pitch propellers is related to approximately 70 of the maximum rated engine speed This is approximately 35 of the maximum power This means that when sail...

Page 84: ...ocal Control Panel and 4003 1 Engine Control 3 2 Transfer and Accept Control from ECR Remote to Local For the mode transfer from the remote control REMOTE AUTO CONTROL to the local control LOCAL MANUA...

Page 85: ...and Decrease You must only increase and decrease the engine load during a given time period This time period is usually between 40 minutes to 45 minutes between full maneuvering and service power The...

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Page 87: ...mends the installation and use of an automatic fuel change over system to prevent problems during the change over procedure If an automatic change over system is installed follow the instructions in t...

Page 88: ...cylinder lubricating feed rate 1 Make sure that you know the cylinder lubricant quantity that is between the change over valve and the lubricating quills including the measurement tube 2 Calculate th...

Page 89: ...e a maximum of 2_C each minute 8 If the temperature changes too much wait until the fuel temperature is stable Then you can continue the procedure Try to decrease the temperature as linearly as possib...

Page 90: ...75 CMCR The decrease of the engine power is related to the total quantity of fuel that flows in the system e g the larger the mixing tank the less decrease in load is necessary 8 Set the viscosimeter...

Page 91: ...y automatically adapts to the lower engine load The WECS 9520 controls the lubricating oil quantities related to the engine load 2 WECS 9520 Injection Control At low load the WECS 9520 automatically c...

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Page 93: ...0 1 Operating Data Sheet and the Acceptance Records The coolant temperatures must stay in their usual ranges In usual service the full load position of the load indication fuel injection quantity must...

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Page 95: ...creases the engine speed power then shuts down the engine 2 1 3 Engine Stop from the Local Control Panel See the Control Diagram 4003 2 and Local Control Panel 4618 1 When you push the STOP button on...

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Page 97: ...stopped the coolant water and lubricating oil pumps must operate for a minimum of 20 minutes to let the temperatures become stable Do not let these media cool below their usual inlet temperatures The...

Page 98: ...top the Starting Air System Because of low air pressure after engine stop the venting of the starting air manifold 6 Fig 1 cannot be done correctly Thus dirt and grease stay in the starting air manifo...

Page 99: ...27 2 Handwheel for shut off valve 6 Starting air manifold 3 Drain and test valve 2 06 7 Starting air valve 4 Venting valve 2 21 8 5 2 way solenoid valve 2 Procedures for Service Breaks for a Longer P...

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Page 101: ...the piston running system The procedure includes a temporary higher feed rate refer to Fig 1 WinGD recommends an inspection of the cylinder liners and of the piston rings after 24 operation hours and...

Page 102: ...24 hours 2 Inspect the components for damage 3 If damage occurs find the cause and repair the fault 4 If you have to replace parts of the piston running system do Step 1 and Step 2 again 5 Set the fee...

Page 103: ...he Inj correction factor page set the applicable value 2 Fuel For running in use heavy fuel oil HFO Make sure that the fuel has the correct treatment and viscosity i e heated to the correct temperatur...

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Page 105: ...maximum firing pressure to the compression pressure is in the range of 0 90 to 1 25 at 100 load The engine rating is related to IMO tuning This means that the curves in the diagram can be different i...

Page 106: ...in use 1 Do a check of the injection nozzles 2 In the remote control get the user parameters page see 4002 3 paragraph 1 1 3 In the FQS field enter a negative setting to correct the the ignition press...

Page 107: ...Gas Diesel Ltd 3 3 3 4 Compression Pressure and Maximum Firing Pressure Too High Possible causes D Engine has too much load D VEC timing is incorrect 2014 Indicator Diagrams Example A Example B P F P...

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Page 109: ...r the air cooler and water separator the air flaps in the scavenge air receiver and the scavenge ports have contamination 2 2 Blow by The causes of blow by are as follows D Worn piston rings broken pi...

Page 110: ...receiver The related shut off valve must be fully leak proof 4 If you think there is a fire shut down the engine and fill the scavenge space with CO2 gas Note Make sure that you read 0210 1 Safety Pre...

Page 111: ...th a high cylinder lubrication setting 2 6 Procedures to Prevent Fire Good engine maintenance will help to prevent a fire in the scavenge air spaces The data that follow will also help to prevent fire...

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Page 113: ...crankcase 2 Procedure If an oil mist detector activates an alarm do the procedures given below WARNING Danger If an oil mist alarm is activated keep away from the engine There is a risk of explosion 1...

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Page 115: ...damper becomes defective You can find data about the barred speed range near the telegraph on the bridge and or near the local control panel The exhaust smoke must be monitored because the engine must...

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Page 117: ...G Injury Hazard You must put on gloves and safety goggles when you do work on hot components Oil can come out as a spray and cause injury 2 1 Replace the Defective Injection Control Unit Do the steps...

Page 118: ...e the screw in unions on the ICU fuel leakage pipe to find a defective injection pipe that leaks see 8019 1 Fuel leakage system paragraph 4 3 As a temporary procedure do as follows 1 Disconnect the tw...

Page 119: ...e fuel pump rows at the same output compared with the acceptance report D Unusual noises e g knocks rings and scrapes D The level switch LS3426A 17 shows an alarm see 8019 1 Fuel system paragraph 4 1...

Page 120: ...y regulation is not possible at lower fuel consumption The fuel pressure control valve 3 06 has the fuel pressure regulating function for lower fuel consumption The fuel quantity that flows off goes i...

Page 121: ...Replace the defective actuator as soon as possible see 5801 1 Regulating Linkage in the Maintenance Manual Note Related to the necessary power output you can install the spacer 3 Fig 1 tool 94555 as...

Page 122: ...l unit has a leak D The level switch LS3446A activates an alarm indication because of a leak at the injection pipes see 8019 1 Fuel leakage system 3 2 Causes D The fuel quantity sensor is defective D...

Page 123: ...he electrical connection to the fuel quantity sensor 2 Make sure that the electrical connection is tight 4 3 2 1 015 456 07 5 Fig 2 Injection Control Unit 1 Injection control unit 3 02 4 O ring 2 Fuel...

Page 124: ...ez NSBT 8 to the threads of the four screws 9 8 Put the new rail valve 6 and screws 9 in position on the injection control unit 1 You must make sure that the bores are aligned 9 Torque the four screws...

Page 125: ...data in a 0510 1 Replace the defective injection pipe paragraph 2 2 b 8733 1 Fuel Pressure Piping in the Maintenance Manual 4 Defective Fuel Pressure Control Valve 4 1 Fault Identification Fault iden...

Page 126: ...3 15 and the bearing oil pump 5 Use the hand lever 6 on fuel shut down pilot valve 5 to release the pressure in the fuel rail 6 Clean the filter in the inlet 7 Overhaul or replace the defective fuel...

Page 127: ...e remote control use the parameter Exv A M Cmd to manually close the VCU for the related cylinder see 4002 3 paragraph 1 and paragraph 1 1 3 Disconnect the electrical connections from the rail valve 5...

Page 128: ...related cylinder to Auto see 4002 3 paragraph 1 and paragraph 1 1 10 Connect the electrical connections to the rail valve 5 11 Do a visual check for leaks DRIVING END 8 1 2 018 104 09 Fig 1 Servo Oil...

Page 129: ...signal connection 5 from the starting air valve 11 After the procedure above is completed the engine can be put back into service Note The same conditions are applicable for the engine load as those...

Page 130: ...4 4 WCH00699 VS 1 2 5 WCH00700 4 3 2 Fig 3 Exhaust Valve Pressure Element 1 Damper 4 Pressure element tool 94259a 2 Upper housing 5 Control signal plug 3 Shim VS Maximum exhaust valve stroke Operation...

Page 131: ...nts are clogged D The control or power supply is defective D The system oil parameters are more than the limits given in 0750 1 paragraph 2 2 Alert limits for selected system oil parameters D The lubr...

Page 132: ...p for a long period If the other servo oil pump becomes defective damage can occur and the engine cannot operate 1 Replace the defective servo oil pump as soon as possible see 8016 1 Pressure release...

Page 133: ...in the new rail valve and their surfaces are clean 8 Apply Never Seez NSBT 8 to the threads of the four screws 5 9 Put the rail valve 4 and screws 6 in position on the exhaust valve control unit 3 10...

Page 134: ...e the engine only at decreased load 1 Replace the defective exhaust valve control unit as soon as possible see 0520 1 Start the exhaust valve control unit paragraph 3 2 and the Maintenance Manual 5612...

Page 135: ...aph 1 2 Cut out the exhaust valve control unit see 0520 1 Emergency operation with exhaust valve closed paragraph 2 3 Remove the control air pipe 6 Fig 1 from elbow 5 4 Remove the elbow 5 from the sta...

Page 136: ...from elbow 5 4 Remove the elbow 5 from the starting air pipe 4 5 Install the blank flange 7 tool 94831 6 Disconnect the electrical connection 11 from the from the start air pilot valve on the starting...

Page 137: ...OS Fig 1 Piston Removed 1 Exhaust valve 7 Blank flange tool 94831 2 Crosshead 8 Cover plate tool 94345D 3 Toggle lever 9 Cover and lifting plate tool 94324 4 Starting air pipe 10 Base tool 94324B 5 El...

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Page 139: ...paragraph 1 4 Lock the exhaust valve in the open position see 0520 1 paragraph 3 Note If the cooling flow of the cylinder is stopped there is a risk of that the combustion chamber will overheat becau...

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Page 141: ...e vent and drain valves must stay open Leakage water that goes into the receiver flows away through the drain pipes of the SAC and water separator into the collection pipe During operation in this mod...

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Page 143: ...30 1 Engine Start D 0260 1 Maneuvering D 0310 1 Engine Shutdown D 0320 1 Procedures after Engine Stop D 4003 1 Engine Control paragraph 3 D 4618 1 Local Control Panel CAUTION Damage Hazard You must on...

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Page 145: ...inue to operate The last known fuel command will be used and you will hear an alarm The data are given in the groups that follow D 0230 1 Starting D 0260 1 Maneuvering D 0310 1 Engine Shutdown D 0320...

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Page 147: ...n between Engine Load Output and the Number of Defective TC Number of installed turbochargers Number of defective turbochargers Approximate engine load output related to the CMCR 2 1 50 3 1 66 3 2 33...

Page 148: ...ply pressure of the serviceable turbocharger If the pressure is decreased shut off the oil supply to the defective turbocharger 3 Open all covers 3 on the scavenge air receiver 2 4 Remove the expansio...

Page 149: ...eration period it is recommended that you monitor the parts for unusual heat You monitor the parts as follows 4 Start and stop the engine for short intervals see 0210 1 Temperature paragraph 9 5 Compa...

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Page 151: ...vy Fuel Oil and Back 0270 1 Note The numbers e g 30 8605_E0_7 refer to items shown in the control diagram 4003 2 1 Close the stop valves on the starting air bottles 2 Turn the handwheel 2 10 on the sh...

Page 152: ...y at room temperature Monitor the temperature for a risk of frost 14 Repair all the damage and leaks found during the operation period before and the checks made after shut down 15 Do all scheduled ov...

Page 153: ...he engine two full turns to apply the cylinder lubricating oil to the cylinder liner wall 5 The recommended intervals are a Weekly in dry climates b Daily in damp climates 6 Stop the engine each time...

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Page 155: ...g Oil and Other Contamination 11 6 Bio derived Products and Fatty Acid Methyl Esters 12 7 Fuel Additives 12 1 General Almost all mineral residual and distillate and some renewable fuels can be burned...

Page 156: ...7 and the latest revision is the fourth edition dated 15 June 2010 Viscosity itself is not a quality criterion To make an analysis of the fuel quality to make sure that the fuel is applicable for use...

Page 157: ...hod Necessary Fuel Quality at Engine Inlet Kinematic viscosity at 50_C mm2 s cSt Maximum 700 ISO 3104 13 to 17 2 Density at 15_C kg m3 Maximum 1010 3 ISO 3675 12185 Maximum 1010 CCAI 870 Calculated 87...

Page 158: ...ment plant cannot remove water from high density fuel D 4 ISO 8217 2010 RMK700 Note that lower sulphur limits can apply and are related to statutory specifications and sulphur limits not given in ISO...

Page 159: ...ngine is between 13 mm2 s cSt and 17 mm2 s cSt You get the necessary temperature for a given nominal viscosity from the data in Fig 1 below Example To get the recommended viscosity upstream of the fue...

Page 160: ...as no effect on the combustion properties The CCAI limit is useful to measure fuels with unusual density viscosity relations More tests are available to find ignition and combustion properties and the...

Page 161: ...approximately 5_C to 10_C above the pour point to make sure that the fuel can flow easily 3 10 Water The separator and the correct configuration of drains in the settling and service tanks is used to...

Page 162: ...sediment into the fuel Thus it is better to think that all fuels contain cat fines although it is possible that a fuel analysis can show a different result This makes continuous and satisfactory sepa...

Page 163: ...m 25 ISO 12205 Maximum 25 Carbon residue micro method on 10 volume distillation residue for grades DMX DMA and DMZ m m Maximum 0 30 ISO 10370 Carbon residue micro method grade DMB m m Maximum 0 30 ISO...

Page 164: ...ary to make sure that the inlet to the fuel pumps has the minimum viscosity 5 2 Density The composition of the fuel gives the distillate density and a high density indicates a high aromatic quantity 5...

Page 165: ...l is pumped easily It is possible that in extremely cold conditions there could be problems for distillate fuel 5 10 Water The quantity of water in distillate fuel can be decreased as follows D Let th...

Page 166: ...ses fuel and water to combine D Microbial growth can appear in the fuel D Unsatisfactory low temperature properties D FAME material particles can appear on exposed surfaces and filter elements Where F...

Page 167: ...d from the fuel Settling tanks are used for the first steps of treatment but their effect is only a coarse separation to release water from the HFO The settling tanks must have the sludge and water th...

Page 168: ...e g increased wear of piston ring cylinder liner and fuel injection equipment The HFO must be heated before it goes into the centrifuge to keep the temperature constant to a tolerance of 2 C The separ...

Page 169: ...ou can use the clean fuel oil leakage tank 33 to isolate marine diesel oil MDO or marine gas oil MGO leakage from HFO leakage The pressure regulating valve 17 sets the applicable system pressure The p...

Page 170: ...alve 11 HFO LSHFO preheater 28 Supply unit fuel pump 12 HFO LSHFO separator supply pump 29 Fuel leakage pipe injection valve 13 Suction filter 30 Main engine 14 Self cleaning HFO LSHFO separator 31 Sl...

Page 171: ...interthur Gas Diesel Ltd 5 5 WCH03254 6 5 4 3 2 1 8 9 12 13 12 13 11 11 14 14 10 18 19 16 17 18 19 20 15 29 22 22 21 23 23 24 30 28 27 7 25 26 31 32 33 Fig 1 Schematic Diagram Fuel System Fuel Treatme...

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Page 173: ...must be serviced and or cleaned regularly see the turbocharger manual 2 Starting Air Control Air 2 1 Starting Air Compressors pressurize the air in the starting air bottles to a maximum of 30 bar The...

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Page 175: ...s for system oil and cylinder lubrication 2 System Oil System oil lubricates the bearings the running parts of the engine and the crosshead assembly System oil is also used as hydraulic fluid in the s...

Page 176: ...by mass during a long period If higher water contamination is seen special procedures such as treatment in the centrifugal separator or in a renovating tank must be done 2 1 2 Servo Oil To increase th...

Page 177: ...condition The oil condemnation limits are given in Table 2 If the oil condition has so much deterioration that the purifier and filters cannot make the condition better some of the oil charge must be...

Page 178: ...hed This gives protection against scuffing during the running in of the gears If the system oil is in use for more than one year the FZG performance of the oil must be done to make sure that the perfo...

Page 179: ...6 mm maximum 500 000 1 000 000 20 250 000 500 000 19 130 000 250 000 18 More than 14 mm maximum 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...

Page 180: ...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 1...

Page 181: ...iness Classes Particle size mm or microns 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 Cleanline...

Page 182: ...t a sample of system oil as follows 1 Make sure that the oil pump operates and the engine oil is at the correct temperature for operation 2 Put an applicable container below a ball valve in the lubric...

Page 183: ...lphur content the higher the BN of the cylinder lubricating oil must be For a list of validated cylinder lubricating oils see paragraph 8 2 Cylinder Lubricating Oils When the analysis of the piston un...

Page 184: ...inder lubricating oil adjust the cylinder lubricating oil feed rate to the guide feed rate see 7218 1 Cylinder Lubrication This prevents too much piston crown and top land deposits Note Permitted for...

Page 185: ...te The BN 40 products can also be used safely with HFO that has a sulphur content in the range 0 5 m m to 1 5 m m It is possible that the feed rate must be increased in relation to the remaining BN me...

Page 186: ...gland box condition It is important to monitor trends and not full values and to think about the actual quantity of drained oil relative to the analysis results For data about the procedure to get an...

Page 187: ...ith chrome ceramic piston rings and fully honed cylinder liners installed It shows the relation between the piston underside total oil iron content and the residual BN If necessary the cylinder lubric...

Page 188: ...message to WinGD It is necessary to monitor the residual BN at regular intervals see paragraph 3 1 and paragraph 3 2 WinGD recommends the use of an on board monitoring programme that at a minimum give...

Page 189: ...ine manufacturer The lubricant suppliers are given in paragraph 8 4 7 Environmentally Acceptable Lubricants Environmentally Acceptable Lubricants EAL are necessary for ships that operate in USA waters...

Page 190: ...6 Cyltech 40 SX Cyltech 70 Cyltech 100 Chevron Taro Special HT LF BN 25 Taro Special HT LS 40 Taro Special HT 55 BN 55 Taro Special HT 70 Taro Special 70 Taro Special HT 70X Taro Special HT 100 Taro S...

Page 191: ...tar Marine 570 Notes to Table 6 1 This product is under testing and is not validated at this time 2 Multiple formulations of this product are available Not all of them are validated Speak to the suppl...

Page 192: ...un DCC3005H 1 8 5 Premier Six Opt Max Shieldguard 3008 8 Shell Melina S30 5 SINOPEC Marine System Oil 3005 Marine System Oil 3006 Marine System Oil 3008 5 6 8 SK Supermar AS 2 5 Total Atlanta Marine D...

Page 193: ...rse osmosis technologies the minimum pH value is 6 0 If you think there is a problem do an analysis of the water Send the results of the analysis to Winterthur Gas Diesel Ltd to get advice Corrosion p...

Page 194: ...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 o...

Page 195: ...tart D Engine cannot be stopped For more data see 0810 1 1 2 Irregular Functions during Operation At the same load indication compared to results or with data in the shop trial documents D Scavenge ai...

Page 196: ...ston D Hot running of the running gear For more data see 0840 1 1 4 Failures and Defects of WECS Components D WECS passive fault D WECS common fault D WECS cylinder fault D WECS pressure fault D WECS...

Page 197: ...ol stand has no effect Push the related button for mode transfer or to get control The remote control system RCS and or telegraph system has a fault Do a check of the RCS or speak to the RCS supplier...

Page 198: ...s ZV7241 to ZV7248C cannot move The cable to the FCM 20 is broken Do a check of the starting air pipe flame arrestor and remove the blockage Clean or replace the related solenoid valve s do a check of...

Page 199: ...repair the leak with the servo oil service pump in operation Connect the pipe tool 94583 between the fuel rail and servo oil rail A cylinder does not fire or does not fire correctly when starting The...

Page 200: ...d wiring Cylinders were lubricated too much before starting Unwanted quantity of cylinder oil in the combustion spaces Decrease the speed setting fuel injection quantity until the unwanted oil has bur...

Page 201: ...e nozzle ring of turbocharger is damaged The exhaust gas boiler plant side is clogged There is increased resistance or back pressure downstream of turbine Clean as soon as possible The scavenge air pr...

Page 202: ...ure pipes or injection valves Grind the sealing faces or replace defective parts see the Maintenance Manual The exhaust valve does not open The exhaust valve control unit or its hydraulic pipe is defe...

Page 203: ...il leakage Do a check of the oil flow Find and repair the leaks An auxiliary blower operates at part load or the two auxiliary blowers do no operate Set the auxiliary blowers to on Engine operates irr...

Page 204: ...oo hot See 0840 1 Problems and Damage with Engine Parts The exhaust gases go into the cooling water because of a crack cylinder liner cylinder cover valve cage See 0545 1 Operation with Water Leakage...

Page 205: ...ter or pump body is defective Replace defective parts see the documentation of lubricating pump manufacturer 3 Exhaust Valve Problem Possible Causes Procedure Exhaust valve The inside and or outside p...

Page 206: ...operation The cylinder is defective injection exhaust valve control Do a check of the injection and exhaust valve control 5 Oil Mist Detector WARNING Injury hazard If an oil mist detector activates an...

Page 207: ...al operation on the solenoid valve ZV7076C see 8135 1 Fig 1 Do an overhaul and replace the butterfly valve As a temporary solution install a blind flange in the exhaust bypass and operate the engine o...

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Page 209: ...l use an oil stone to repair these areas If there is much damage replace the piston piston skirt and cylinder liner see the Maintenance Manual If a replacement of these parts is not possible remove th...

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Page 211: ...Pressure Failure 34 4 9 WECS Critical Failure WECS Engine Failure 36 4 10 Malfunction of Cylinder Lubrication 37 1 General Failures and defects of WECS components cause failure messages which are tran...

Page 212: ...nject 1 2 3 Exhaust Start Vlv PWM Power IN Fail SW CA2 CA1 CA PF xx ID In Out InjQ ExD ExF AI1 AI2 AI3 CA1 SSI CA2 S1 CAN S2 M BI1 In Out AQ PF Modul Bin Out Modbus 2 1 1 1 Fig 1 Failure ID and LED In...

Page 213: ...el Ltd 3 39 3 LED Indication on ALM 20 4 4 1 014 537 06 014 538 06 PART NO SER NO HW REV PROD DATE 1 4 3 2 Fig 2 LED Indications on ALM 20 1 Connector COMBICON 3 Screw 2 Control box 41 nn 4 LEDs 2014...

Page 214: ...has an effect on the engine stop Must be repaired immediately to start the engine 4 2 Failure of Pulse Lubrication Type of Failure Failure Effects Procedures WECS lubrication passive failures Failures...

Page 215: ...re ID 213 is shown as 1 3 4 3 3 Failure The Fail LED flashes three times before the first failure ID is shown Each failure ID is shown for 2 7 seconds then there is a pause of 1 3 seconds before the f...

Page 216: ...SSI CA1 CA2 and CAN S1 S2 and M LEDs show red for approximately four seconds The Fail LED shows red for approximately two seconds The yellow LEDs In Out from InjQ to AI3 CAN S1 S2 and M and the green...

Page 217: ...ommon 20 20 ME servo oil pressure low WECS common 21 21 ME servo oil pressure very low WECS pressure 26 26 ME servo oil pump 1 fail WECS common 26 26 ME servo oil pump 2 fail WECS common 27 27 ME fuel...

Page 218: ...94 WECS module FCM 20 00 fail WECS passive 95 to 108 95 to 0 8 WECS module FCM 20 nn fail WECS cylinder 110 1 0 ME crank angle 1 fail WECS passive 111 1 1 ME crank angle 2 fail WECS passive 112 1 2 WE...

Page 219: ...e transmitter if necessary If failure ID 8 stays on when the plug X27 is disconnected replace FCM 20 03 Failure Text ME scavenge air pressure sensor 2 meas fail ID 8 FCM 20 No LED Failure ID Display I...

Page 220: ...transmitter if necessary If failure ID 16 stays on when the plug X27 is disconnected replace FCM 20 01 Failure text ME servo oil pressure sensor 2 meas fail ID 16 FCM 20 No LED Failure ID Display Ind...

Page 221: ...comes on Use a multimeter to do a check between each of the cables on plug X25 terminals 79 and 80 and ground for a short circuit or ground fault Replace damaged cables or temporarily repair with ins...

Page 222: ...f or an FCM 20 starts again with this failure and continues to have this failure then the FCM 20 in operation will not start its function again The related cylinder is cut out Failure Text WECS CAN M...

Page 223: ...FCM 20 nn ID 42 FCM 20 No LED Failure ID Display Indication 00 E90 S1 or S2 42 42 Cause Missing bus connection on CAN S bus 1 or CAN S bus 2 on FCM 20 00 Procedure Make sure that each of the two CAN S...

Page 224: ...age and are connected correctly Make sure that the cables and connections in the related FCM 20 and in the terminal box have no damage and are correctly connected If necessary replace the related sens...

Page 225: ...are connected correctly Repair the cables in the related FCM 20 If necessary replace the related FCM 20 Failure Text ME crank angle 2 fail ID 1 1 FCM 20 No LED Failure ID Display Indication 01 to 09 S...

Page 226: ...conds Procedure On the related FCM 20 plug X23 terminals 57 58 make sure that the cable connections have no damage and are connected correctly Make sure that the S2 bus with 120 ohm resistors on first...

Page 227: ...lated resistors see 7218 1 Resistor in plug X1 paragraph 5 2 Repair the cables and connections in the related ALM 20 If necessary replace the defective ALM 20 Failure Text ME waste heat recovery valve...

Page 228: ...ition switch ZS5373C 4 6 WECS Common Failure Failure Text ME scavenge air pressure sensor 1 2 meas fail ID 9 FCM 20 No LED Failure ID Display Indication 03 and 04 AI2 9 9 Cause The two sensor signals...

Page 229: ...essure transmitter immediately FCM 20 No LED Failure ID Display Indication 01 and 02 AI2 17 17 Cause The sensor power supply has a short circuit red LED Procedure Disconnect the pressure transmitters...

Page 230: ...als and cables to the servo oil pumps for correct connections and or damage Repair or replace damaged cables Make sure that the safety valve 4 23 open The pump drive shaft 4 50 is broken pump temperat...

Page 231: ...3461C and PT3462C for damage Use a multimeter to do a check of the 24 VDC supply on the plugs X25 terminal 79 and ground and the cables to E95 03 and E95 04 and on the transmitter plugs 2 1 If there i...

Page 232: ...e different signal If necessary replace the applicable pressure transmitter Failure Text ME fuel rail pressure high ID 30 FCM 20 No LED Failure ID Display Indication 03 and 04 AI1 30 30 Cause The meas...

Page 233: ...0 bar and the pressure down stream from the pressure retaining valve is 3 bar to 5 bar Do a check for leakage alarms Make sure that there is an oil supply to the fuel pressure control valve 3 06 Make...

Page 234: ...5 BI1 62 62 Cause No TDC signal from pick up ZS5123C failure signal is released after 10 seconds Procedure Do a check of the cables between the pick up ZS5123C and E95 05 Make sure that the distance b...

Page 235: ...gle measurement system 1 is 4 0_ CA The crank angle sensor or toothed belt has moved Procedure Do a check for an incorrect TDC offset adjustment in flexView Adjust to get the correct distance between...

Page 236: ...check for an incorrect TDC offset adjustment in flexView Adjust to get the correct distance between the pick up and the flywheel tooth 4 mm Do a check of the crank angle sensor drive Make sure that th...

Page 237: ...emark No failure shown at shut down Procedure Do a check for an incorrect TDC offset adjustment in flexView Do a check of the crank angle sensor offset adjustment in flexView Adjust to get the correct...

Page 238: ...Make sure that the rail valve is serviceable If the rail valve is serviceable do a check of the opening pressure of the injector valve If the opening pressure is correct make sure that the injection n...

Page 239: ...20 seconds Procedure Decrease engine power Between FCM 20 05 plug X15 terminals 39 40 and the solenoid valve ZV7076C make sure that the cables have no damage and are connected correctly If necessary r...

Page 240: ...of the belt condition Do a check of the crank angle sensor offset adjustment in flexView Do a CAS trend in flexView If each of the two CAS are defective replace a minimum of one CAS Adjust the offset...

Page 241: ...piston in the exhaust valve drive 4 03 moves freely Do a check of the related FCM 20 Repair or replace damaged cables between the rail valve and the related FCM 20 If necessary replace the related FCM...

Page 242: ...Failure Text ME Inj Quantity Piston Late No Return ID 90 FCM 20 No LED Failure ID Display Indication 01 to 09 ExD 90 90 Cause The fuel quantity piston does not go back to its initial position after th...

Page 243: ...uel viscosity is in the permitted range Examine the fuel injectors and pipes for leaks Failure Text ME injection quantity piston fail cylinder nn ID 93 FCM 20 No LED Failure ID Display Indication 01 t...

Page 244: ...Cause The servo oil pressure is 50 bar less than the setpoint The engine speed is more than 8 of the nominal speed failure signal is released after 5 seconds Remark No failure is shown during the cond...

Page 245: ...tween 3 bar and 5 bar Do a check for leakage alarms Make sure that there is oil supply to fuel pressure control valve 3 06 Make sure that the valve seat can move Examine the fuel pressure control valv...

Page 246: ...m of one two crank angle sensor immediately Failure Text ME both CA TDC high shift ID 65 FCM 20 No LED Failure ID Display Indication 05 BI1 65 65 Cause The difference between the TDC pick up measured...

Page 247: ...les to the pressure transmitter 4 2 way solenoid valve and WECS 9520 are correctly connected and have no damage If necessary repair or replace damaged cables If necessary replace he related ALM 20 or...

Page 248: ...ed and has no damage If necessary repair or replace damaged cables If necessary replace the related 4 2 way solenoid valve see 0820 1 paragraph 2 Cylinder lubrication ALM 20 No LED On Off Code Indicat...

Page 249: ...ecessary replace the related pressure transmitter PT3131C to PT3139C if necessary see 0820 1 Cylinder lubrication ALM 20 No LED On Off Code Indication 01 to 09 Power Off None Cause No power supply to...

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Page 251: ...Operation Group1 Winterthur Gas Diesel Ltd 1 1 Bedplate and Tie Rod Group 1 Main Bearing 1132 1 A1 Thrust Bearing 1203 1 A1 Tie Rod 1903 1 A1 X82 OM 2014 Winterthur Gas Diesel Ltd...

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Page 253: ...The elastic studs 2 have a non hardening locking compound applied to the threads Hydraulic tension is applied to the the elastic studs 2 during the install procedure The round nuts 3 keep the bearing...

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Page 255: ...rough the thrust pads 5 13 into the bedplate The arbor supports 6 Fig 1 prevent circular movement of the thrust pads 5 13 see Fig 2 There are seven thrust pads 5 13 on each side of the thrust bearing...

Page 256: ...9 8 7 6 1 2 3 4 018 087 09 OI 5 Fig 1 Cross Section 1 Column 6 Arbor support 2 Oil pipe 7 Bearing cover 3 Nozzle 8 Intermediate wheel pump unit 4 Bedplate 9 Intermediate wheel supply unit 5 Thrust pad...

Page 257: ...flange 17 and the thrust pads 5 13 20 19 18 16 5 4 10 11 2 3 7 12 13 14 15 1 17 018 088 09 I I Fig 2 Longitudinal Section 1 Column 13 Thrust pad driving end 2 Oil pipe 14 2 part oil baffle 3 Nozzle 15...

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Page 259: ...The tie rods 1 Fig 1 keep the cylinder block 2 column 3 and bedplate 4 together at four locations around the cylinders FOR 7 CYLINDER ENGINES 1 1 2 3 4 WCH01187 WCH01187 Fig 1 Tie Rod Configuration a...

Page 260: ...The oil enters through a bore from the crosshead guide plate The bottom of the intermediate ring 4 has a drain groove DG through which some of the oil can drain Possible condensation can also drain t...

Page 261: ...Liner and Cylinder Cover Group 2 Cylinder Liner 2124 1 A1 Lubricating Quills on Cylinder Liner 2138 1 A1 Piston Rod Gland 2303 1 A1 Injection Valve FAST Nozzle 2722 1 A1 Starting Valve 2728 1 A1 Exhau...

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Page 263: ...ections 7 and the connection pieces 8 into the annular space AS Then the water flows through the bores CB and cools the cylinder cover 9 The cooling water then flows through the exhaust valve cage Not...

Page 264: ...Bottom water guide jacket 4 Cylinder jacket AS Annular space in upper water guide jacket 5 Lubricating quill CB Cooling bores in cylinder cover 6 Holder CI Cooling water inlet 7 Pipe connection LG Lu...

Page 265: ...ht lubricating quills 1 Fig 1 are are installed around the circumference of the cylinder liner 2 The lubricating pump 3 supplies lubricating oil through pipes to each lubricating quill 1 2 1 3 WCH0112...

Page 266: ...LP as a spray The lubricating oil flows equally on to the cylinder liner wall see also 2124 1 Cylinder Liner and 7218 1 Cylinder Lubrication After a lubrication pulse the oil pressure decreases and th...

Page 267: ...LD Leakage oil drain 2 Crankcase LP Leakage oil pipe 3 Piston rod SP Sample port 4 Cylinder block SS Scavenge space 2 Function During operation the three scraper rings 3 Fig 2 and 5 remove dirty oil...

Page 268: ...2 Piston Rod Gland 1 Housing 2 part 10 Cylinder jacket 2 Support 11 Piston rod 3 Scraper ring 4 part 4 Ring support 3 part BD Bearing oil drain 5 Scraper ring 3 part LD Leakage oil drain 6 Gasket 4 pa...

Page 269: ...If exhaust gas goes out of the injection valve at the leakage fuel outlet LO the sealing face SF is damaged Do an overhaul of the sealing face see the Maintenance Manual 2708 3 WARNING Injury Hazard F...

Page 270: ...4 5 6 016 921 08 Fig 1 Location of Injection Valves 1 Cylinder cover 5 Collector block 2 Fuel leakage pipe 6 Fuel leakage pipe 3 49 3 Injection valve 3 01 7 Injection control unit 3 02 4 Injection pi...

Page 271: ...I II II I I Fig 2 Injection Valve 9 Nozzle holder FS Fuel supply high pressure 10 Tappet carrier LO Leakage fuel outlet 11 Nozzle body FB Fuel bore 12 Nozzle tip SF Sealing face 13 Clamping nut LD Lea...

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Page 273: ...t The FCM 20 activates the 3 2 way solenoid valve 7 The space S1 is pressurized the valve opens and starting air flows into the combustion chamber The piston 2 moves down starting air flows into the c...

Page 274: ...3 4 S1 6 RB 5 016 856 08 016 856 08 SA Fig 1 Starting Valve 1 Cover SA Starting air 2 Piston RB Relief bore 3 Housing S1 Air space 4 Compression spring S2 Air space 5 Cylinder cover CA Control air fro...

Page 275: ...bustion Control 6 1 General The exhaust valve 2 Fig 1 is installed in the centre of cylinder cover 1 and has the parts that follow D Upper housing D Lower housing D Valve cage D Valve spindle D Valve...

Page 276: ...e pressure in the air spring AS damage can occur to the exhaust valve Thus for safety the cup springs 15 are installed to absorb vibration and shock The thrust piece 12 prevents damage to the inside p...

Page 277: ...Operation 2751 1 A1 Winterthur Gas Diesel Ltd 3 6 3 1 I I 13 12 4 5 8 11 10 2 15 9 19 20 AS 6 14 16 IV IV HO 18 016 874 08 WCH00851 7 Fig 2 Exhaust Valve and Leakage Oil Drain Exhaust Valve 2014...

Page 278: ...he exhaust valve control unit opens the related relief bores the pressure in the air spring AS pushes the air spring piston 10 up The valve spindle 6 then pushes the inside piston 5 and the outside pi...

Page 279: ...air spring pipe to an accumulator The oil in the accumulator automatically drains through the leakage oil pipe at the driving end of the exhaust valves into the crankcase Oil from the oil bath OB lubr...

Page 280: ...4 one for each cylinder is installed on the cylinder cover 3 A relief valve 1 is installed on each pressure transducer 2 For more data see 9308 1 Intelligent Combustion Control I I I I 1 WCH00830 2 3...

Page 281: ...aft Connecting Rod and Piston Group 3 Axial Damper 3140 1 A1 Connecting Rod and Connecting Rod Bearing 3303 1 A1 Crosshead and Guide Shoe 3326 1 A1 Piston 3403 1 A1 Crosshead Lubrication and Piston Co...

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Page 283: ...measurement The setting value of the spindle must be engraved on a nameplate near the housing 3 An opening in the top of the casing lets you get indications at different positions of the spindle 4 dur...

Page 284: ...l Damper 1 Top cylinder half 9 Bearing cover 2 Bottom cylinder half 10 Crankshaft 3 Housing 11 Bearing girder part of bedplate 4 Spindle 12 Oil pipe 5 Locking device 13 Flange on crankshaft 6 Small ga...

Page 285: ...bricating oil flow to the guide shoes Crosshead lubricating oil flows through the oil bore OB in the connecting rod 1 to the bottom end bearing Bearing oil flows through the connection PC for piston c...

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Page 287: ...through the oil pipe 1 and returns to the crankcase through the drain OD The guide shoes 3 are attached to the crosshead pin 6 and move up and down in the guide ways of the column 10 The guide rails...

Page 288: ...PC CO 11 3 6 10 4 9 12 12 016 783 08 9 Fig 2 Crosshead and Guide Shoe Top View 3 Guide shoe 11 Groove 4 Connecting rod 12 Guide rail 6 Crosshead pin 9 Holding plate CO Crosshead lubricating oil inlet...

Page 289: ...4 and crosshead pin 7 The thickness of the compression shim 6 is related to the compression ratio Note The mark TOP on all piston rings must point up For more data about the piston rings see the Maint...

Page 290: ...9 016 784 08 CO OR Fig 1 Piston 1 Piston crown 9 Elastic bolt 2 Piston rings 10 Spray plate 3 Piston skirt 4 Piston rod 5 Oil pipe to spray plate OI Oil inlet 6 Compression shim OR Oil return from pis...

Page 291: ...crosshead lubricating oil flows from the oil inlet OI through the support 4 Fig 1 the bottom lever 6 and the top lever 7 to the connecting piece 8 The connecting piece 8 is attached to the connecting...

Page 292: ...the crosshead pin 11 through bores in the top end bearing shell 9 and the bores 14 The oil flows outside the oil pipe 3 through the piston rod 1 to the piston The oil then flows inside the oil pipe 3...

Page 293: ...1 A1 Control Diagram Designations Description to 4003 1 4003 2 and 4003 3 4003 2 A0 Control Diagram 6 cylinders to 8 cylinders 4003 2 A1 Control Diagram 9 cylinders 4003 2 A2 Control and Auxiliary Sys...

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Page 295: ...e W rtsil Engine Control System WECS 9520 is specially designed for two stroke engines with Common Rail technology This includes all engine related control functions paragraph 3 and cylinder related c...

Page 296: ...E90 has communication to the external systems The SIB also contains an FCM 20 as an online spare D Each cylinder has a control box E95 xx which contains an FCM 20 for engine and cylinder related contr...

Page 297: ...Control Room Rail Unit E85 1 2 System Bus E25 E95 01 E95 02 E95 03 E95 04 E95 05 E95 06 FCM 20 Cyl 6 FCM 20 Cyl 5 FCM 20 Cyl 4 FCM 20 Cyl 3 FCM 20 Cyl 2 FCM 20 Cyl 1 FCM 20 Online Spare Remote Contro...

Page 298: ...ee Fig 2 A defective FCM 20 must only be replaced with the online spare If the online spare is installed a new FCM 20 must be installed in the control box E90 This FCM 20 will receive an application d...

Page 299: ...s given as follows D The WECS 9520 generates a control signal which is related to the engine speed and the fuel command D The signals from the FCM 20 control the three fuel pump actuators Each actuato...

Page 300: ...Safety Valve Servo Oil Rail one or two part design related to number of cylinders Fig 4 Servo Oil Pressure Setpoint 3 3 1 Pressure Setpoint Each servo oil pump has an internal mechanical pressure cont...

Page 301: ...yl 6 CAN L Bus ALM 20 Cyl 7 to next Pump Lubricating Oil Servo Oil Rail Filter Measurement Tube Pressure Reducing Valve Lubricating Pump 4 2 way Solenoid Valve Fig 5 Cylinder Lubricating System 3 4 1...

Page 302: ...the cylinder related control functions are as follows D Volumetric injection control with VIT D Exhaust valve control with VEO VEC D Starting valve control FCM 20 System Bus CANopen 2 x SSI Exhaust R...

Page 303: ...on modes enable the injection with only one or two injection valves or with spray intervals multi shot patterns see also 0280 1 WECS 9520 Injection control To improve the fuel spray at low load one or...

Page 304: ...tion of the injection system is monitored at each cycle 4 3 5 Reverse For operation of the the engine in ASTERN the crank angle is mirrored 4 3 6 Emergency Mode If the fuel quantity sensor is defectiv...

Page 305: ...e in ASTERN the crank angle is mirrored 4 4 6 Emergency Mode If the valve stroke sensor becomes defective the exhaust valve control continues with time control for the related cylinder 4 5 Starting Va...

Page 306: ...ications between the systems can be different and is related to the approved system manufacturers see the related documentation 5 1 Propulsion control system The propulsion control system is divided i...

Page 307: ...ing commissioning A typical expert parameter is the firing order of the engine which is set only once There is a connector for service access in the engine control room 5 3 BACKUP Control Box The BACK...

Page 308: ...Automatic shut down D Automatic slow down The WECS 9520 will transmit a signal to the safety system for each malfunction For more data see 0850 1 Failures and Defects of WECS Components 5 6 Telegraph...

Page 309: ...ENIS 9520 Remote Control Specification Independent Subsystems Command Orders from RCS Speed Control Feedback Signals from WECS CANopen to ECR Manual Control CAN open for Service Access Alarm Sensors I...

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Page 311: ...to stop fuel injection to a cylinder if necessary e g for liner piston ring problems or damaged injection system The exhaust valve stays open in usual operation Inj venting Injection venting Injection...

Page 312: ...ion pressure Inj begin offset Injection begin offset Cylinder pressure fine tuning in service Lets you adjust the compression pressure Inj correction factor Injection correction factor The injected fu...

Page 313: ...tion 5 Install the terminal cover to the sensor 3 2 Power Supply to FCM 20 ALM 20 and Fuel Pump Actuators Do the procedure that follows 1 In the power supply box E85 make sure that all related circuit...

Page 314: ...cylinder No 4 the RCS or the ECR Manual Control panel has control of the engine This will prevent an unwanted short engine stop start Replace the FCM 20 as follows 1 Disconnect the power supply to the...

Page 315: ...System WECS 9520 are designed so that different remote controls can be used All nodes are fully specified Terminal boxes are installed on the engine to which the cable ends from the control room or f...

Page 316: ...source pressure 7 bar to 9 bar to 6 5 bar 2 The pressure reducing valve 19HA is used to decrease the source pressure 25 to 30 bar to 6 bar 3 Engine Local Control The engine can be operated at the loc...

Page 317: ...neral operational check must be made before commissioning The paragraphs that follow give instructions about the procedures The item numbers of the valves and the designations that follow relate to th...

Page 318: ...e set to on 2 On the control room console push the EMERGENCY STOP button Make sure that the fuel pressure control valve 3 06 and the fuel shut down pilot valve 3 08 operate 3 Do the procedure above fr...

Page 319: ...manual 4 4 3 Speed Pick ups WARNING Injury Hazard Before you operate the turning gear make sure that no personnel are near the flywheel 1 Do a check of the pick ups for speed measurement as follows a...

Page 320: ...n be adjusted 6 To adjust the settings to those given in Table 4 and for other parameter settings refer to the instructions given in the documentation of the control box E92 Boll Kirch electronic cont...

Page 321: ...related to the simulated pressure 0 bar to 4 bar TIER I or 0 bar to 6 bar TIER II If necessary adjust or replace the transmitter Note You can see the value in the operator interface flexView 9 Disconn...

Page 322: ...11 make sure that the stop valves 4 26 3 4 26 4 4 26 5 and 4 26 6 are open 3 Start the servo oil service pump 4 88 4 Make sure that the pressure in the servo oil rail 4 11 is approximately 100 bar You...

Page 323: ...is open see 7218 1 paragraph 7 Lubrication of exhaust valve spindle 8 Bleed the duplex filter 8 17 measurement tube 8 19 and all lubricating pumps 8 06 see 7218 1 Cylinder Lubrication paragraphs 4 3 a...

Page 324: ...r to 100 bar 10 In the flexView select Inj venting to bleed the injection system see 4002 3 paragraphs 1 and 1 1 11 Push all EMERGENCY STOP buttons to activate a shut down The fuel pressure control va...

Page 325: ...ased 11 Select AUX BLOWER PRESEL 12 Do the tests for START AHEAD and START ASTERN as given above The auxiliary blowers start and control air comes out of each pipe from the solenoid valves ZV7013C and...

Page 326: ...sure in fuel rail 3 05 decreases immediately You can see the pressure decrease on the WECS 9520 manual control panel At the same time the fuel pump actuators move the regulating linkages to the positi...

Page 327: ...Code Numbers Table 1 List of Part Code Numbers A Control air supply unit B Fuel supply C Fuel injection D Servo oil supply E Valve unit for start F Exhaust valve drive H Instrument panel I Pressure sw...

Page 328: ...el leakage pipe 21 Venting valve 47 Injection pipe 27 Venting valve 48 Fuel leakage pipe pressurized 49 Fuel leakage pipe injector 3 Fuel system 52 Fuel overpressure safety valve 01 Fuel injection val...

Page 329: ...alve 88 Servo oil service pump 24 1 Non return valve 7 Monitoring 24 2 Non return valve 18 Collector for leakage oil from air spring 24 3 Non return valve 26 3 Stop valve 9 cylinders 8 Cylinder lubric...

Page 330: ...Fuel Shd pilot valve LS3427A Fuel supply unit leak exhaust side ZV7013C Common start valve 1 LS3444A Rail unit general leak DE ZV7014C Common start valve 2 LS3445A Rail unit general leak FE LS3446A I...

Page 331: ...Operation 4003 2 A1 W X82 Winterthur Gas Diesel Ltd 1 1 Note Systems are drawn for engine in the STOP position with unpressurized circuits WCH03263 Control Diagram 6 cylinders to 8 cylinders 2015 07...

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Page 333: ...Operation 4003 2 A2 W X82 Winterthur Gas Diesel Ltd 1 1 Note Systems are drawn for engine in the STOP position with unpressurized circuits WCH03264 Control Diagram 9 cylinders 2015 07...

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Page 335: ...60 8 Starting system 110 9 Speed control 150 10 Cylinder lubrication pulse 6 to 8 cylinders See Note 170 11 Cylinder lubrication pulse 9 cylinders See Note 170 12 Exhaust gas turbocharger type TPL and...

Page 336: ...or example on page 3 there are the numbers 38 and 38A The number 38 is Control Air and the number 38A is Air Spring Air 1 2 Example 38 39 38 119 119 118 Page 3 Page 9 38 CONTROL AIR CONTROL AIR Path N...

Page 337: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 3 21 WCH00345 2014 Air Supply...

Page 338: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 4 21 018 071 09 2014 Bearing and Cooling Oil Supply...

Page 339: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 5 21 WCH01167 2014 Servo Oil Supply 6 cylinders to 8 cylinders...

Page 340: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 6 21 WCH01167 2014 Servo Oil Supply 9 cylinders...

Page 341: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 7 21 WCH01167 2014 Fuel Supply 6 cylinders to 8 cylinders...

Page 342: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 8 21 WCH01123 2014 Fuel Supply 9 cylinders...

Page 343: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 9 21 016 805 08 2014 Starting System...

Page 344: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 10 21 016 335 07 2014 Speed Control...

Page 345: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 11 21 WCH03265 2015 07 Cylinder Lubrication Pulse Jet 6 cylinders to 8 cylinders...

Page 346: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 12 21 WCH03265 2015 07 Cylinder Lubrication Pulse Jet 9 cylinders...

Page 347: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 13 21 WCH03265 2015 07 Exhaust Gas TC Type TPL and MET Scavenge Air Auxiliary Blower 1 stage SAC...

Page 348: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 14 21 WCH03265 2015 07 Exhaust Gas TC Type TPL and MET Scavenge Air Auxiliary Blower 2 stage SAC...

Page 349: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 15 21 WCH03265 2015 07 Exhaust Valve Drive Air Spring 6 cylinders to 8 cylinders 2 pumps...

Page 350: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 16 21 WCH03265 2015 07 Exhaust Valve Drive Air Spring 6 cylinders to 8 cylinders 3 pumps...

Page 351: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 17 21 WCH03265 2015 07 Exhaust Valve Drive Air Spring 9 cylinders 3 pumps...

Page 352: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 18 21 WCH03265 2015 07 Fuel Injection 6 cylinders to 8 cylinders...

Page 353: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 19 21 WCH03265 2015 07 Fuel Injection 9 cylinders...

Page 354: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 20 21 018 138 09 2014 Cooling Water...

Page 355: ...Operation 4003 3 A1 Winterthur Gas Diesel Ltd 21 21 WCH03265 2015 07 Main Bearing Lubrication Piston Cooling OMD...

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Page 357: ...servo pump unit The condition of the tooth profile must have regular checks New gear wheels must have frequent checks after a short running in period see the Maintenance Manual 4103 1 If unusual noise...

Page 358: ...EXHAUST SIDE FUEL SIDE 6 5 4 2 1 3 WCH02837 Fig 2 View of Supply Unit Drive 9 cylinders 1 Drive wheel servo pump unit 4 Crankshaft gear wheel 2 Intermediate wheel 5 Intermediate wheel 3 Column 6 Driv...

Page 359: ...th are supplied with bearing oil through the spray nozzles for more data see Lubricating Oil Diagram 8016 1 WCH02838 1 OI OI 2 5 4 3 8 7 6 6 Fig 3 View of Gear Wheels Longitudinal Section 1 Column 6 B...

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Page 361: ...n the condensate water for more data see 8018 1 Starting Air Diagram 2 Function 2 1 Ready to Start Starting air flows through the air inlet pipe AP into the air inlet chamber AI then through the balan...

Page 362: ...PT4301C 3 Spring BB Balancing bore 4 Spindle AI Air inlet space 5 Handwheel VV To venting valve 2 21 6 Lever AP Air inlet pipe hidden 7 Control valve 2 05 SA To starting air supply pipe 8 Common start...

Page 363: ...ing air system The shut off valves pressure reducing valve filters etc that are necessary to supply air to the different units are shown in the control air supply unit A see Fig 2 and Fig 3 The numeri...

Page 364: ...ur Gas Diesel Ltd 2 3 Fig 2 Schematic Diagram Control Air Supply Unit A1 Control air from board system A3 Connection to air tank 287HA A2 Starting air from starting air system A6 Air supply to air spr...

Page 365: ...g valve 19HA 2 Pressure transmitter PT4401A 9 Non return valve 342HB 3 Shut off venting cock 36HB for control air 10 Filter 351HA 4 Shut off venting cock 36HC for starting air 11 Pressure gauge PI4411...

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Page 367: ...ed in the local control panel 1 Fig 1 The other manual control panel is installed in a console in the engine control room ECR Note You can only use the function buttons on the manual control panel tha...

Page 368: ...X 2 AST AHD RPM 3 4 5 6 1 013 781 06 FREE END 8 7 1 Fig 1 Location of Control Air Supply 1 Local control panel 5 Telegraph 2 ME tachometer 6 Emergency stop button 3 WECS 9520 manual control panel 7 N...

Page 369: ...NG AUX BLOWER STOP FUEL CONTROL MODE LOCAL MANUAL CONTROL SOUND OFF ALM ACKN WECS 9520 MANUAL CONTROL xx xx xx xx xx xx xx Fig 2 WECS 9520 Manual Control Panel 1 LCD display 3 Function buttons 2 LED A...

Page 370: ...s AUX BLOWER PRESEL or START AHEAD START ASTERN to activate SPEED CONTROL MODE GREY GREEN Setting of speed nominal value to electronic speed control system adjustable by rotary knob speed fuel LED com...

Page 371: ...er to LOCAL MANUAL CONTROL must be accepted at the control room console SAFETY SYSTEM RESET GREY GREEN Resets the blocked shut down conditions LED comes on if all shut down conditions are the same as...

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Page 373: ...Overspeed safety system D Speed control system 2 Function The proximity sensors 8 Fig 2 measure the speed of the flywheel 4 Each time a tooth passes a proximity sensor a signal is sent through the DEN...

Page 374: ...IVING END CRANKSHAFT WCH01174 4 3 Fig 1 Location of Proximity Sensors and Speed Pickup Unit 1 Speed pick up unit 6 Bedplate 2 Pick up holder 7 Terminal box 3 Proximity sensor crank angle 8 Proximity s...

Page 375: ...el Pump 5556 1 A1 Fuel Pump Cutting Out and Cutting In 5556 2 A1 Fuel Pressure Control Valve 5562 1 A1 Fuel Pump Unit 5581 1 A1 Fuel Pump Actuator 5583 1 A1 Servo Pump Unit with Dynex Servo Oil Pump 5...

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Page 377: ...carrier 10 against the guide piston 9 which in turn keeps the roller 11 against the cam 13 When the cam 13 moves the roller 11 up the guide piston 9 moves up and the lower spring carrier 10 compresses...

Page 378: ...hed rack 4 Non return valve 5 Regulating sleeve 6 Toothed rack AS Accumulation space 7 Upper spring carrier DB Drain Bore 8 Compression spring FI Fuel inlet 9 Guide piston FO Fuel outlet 10 Lower spri...

Page 379: ...g of the fuel pump unit Some of the engine lube oil lubricates the guide piston 9 roller pin 12 and roller 11 through the spot faces annular groove and bores in the guide piston 9 Engine lube oil that...

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Page 381: ...cause the engine must operate it is possible to cut out the unserviceable fuel pump WARNING Injury Hazard Cutting out and cutting in of unserviceable fuel pumps must only be done when the engine has s...

Page 382: ...the fuel pump 7 4 Attach the blank flange 1 tool 94569a to the intermediate piece 6 5 Remove the applicable inspection cover 5 6 Find the position of the related cam 1 6 3 018 103 09 5 4 3 1 2 2 for...

Page 383: ...k 8 Fully turn the elastic bolt 3 together with the pad 4 9 Put the tool 94430 in position 10 Turn the round nut 5 until it touches the pad 4 Make sure that the pad 4 touches the guide piston 2 8 7 3...

Page 384: ...sure that the roller 10 stays approximately 3 0 mm above the cam 9 15 Install the inspection cover 6 Fig 2 Note For the torque values and lubrication of the applicable screws see the Maintenance Manua...

Page 385: ...oner 6 on to the elastic bolt 3 The pre tensioner must touch the pad 4 6 Use the pre tensioner 6 for loosening the elastic bolt 3 see the procedure in the Maintenance Manual 9403 4 7 Remove the pre te...

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Page 387: ...e also 4002 1 paragraph 3 2 Pressure control If the fuel pressure is more than approximately 950 bar the fuel pressure control valve 1 opens and the pressure is released The knurled screw 10 sets the...

Page 388: ...trol function when D There are missing or incorrect control signals D The fuel pump actuator s is are out of service D A toothed rack is blocked The toothed rack of the fuel pump is locked in the midd...

Page 389: ...Function Check During operation carefully turn the knurled screw 1 counterclockwise until the axial slide valve 5 starts to open When the axial slide valve functions correctly fuel pressure is release...

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Page 391: ...ump unit 1 1 Camshaft Connection The screws 5 Fig 1 attach the camshaft 4 to the gear wheel 8 The bearing halves 3 and the thrust bearing ring halves 7 keep the camshaft in position The crankshaft gea...

Page 392: ...5 4 3 OB 8 7 6 1 9 OI DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS Fig 1 Fuel Pump Unit 1 Fuel pump 3 14 7 Thrust bearing ring half 2 Housing 8 Gear wheel 4 42 3 Bearing half 9 Fuel pump actuator 3 21 4 Cams...

Page 393: ...me time i e the control positions and the fuel quantity that flows through the fuel pumps are the same If a pump plunger does not move which blocks the toothed rack 4 electrical power to the related a...

Page 394: ...Diesel Ltd 2 2 1 2 3 WCH01162 1 6 2 4 5 DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS Fig 1 Fuel Pump Actuator 1 Fuel pump 3 14 4 Toothed rack 2 Fuel pump actuator 3 21 5 Connecting element 3 Fuel pump unit 6...

Page 395: ...bar at high engine load and decreased pressures at low engine load Shearable overload protection OP on each shaft 6 prevents full damage to the gear wheel 4 if a pump fully seizes If a servo oil pump...

Page 396: ...54 2 Servo oil pump 4 15 12 Stop valve 4 37 3 Driving gear wheel 4 43 13 Oil inlet pipe on exhaust side 4 Gear wheel 4 44 14 Stop valve 4 80 5 Pinion 4 45 15 Supply pipe 4 51 6 Shaft 4 50 16 Servo oi...

Page 397: ...gh pressure approximately 200 bar at high engine load and decreased pressures at low engine load Shearable overload protection OP on each shaft 6 prevents full damage to the gear wheel 4 if a pump ful...

Page 398: ...pump 4 15 12 Stop valve 4 37 3 Driving gear wheel 4 43 13 Oil inlet pipe on exhaust side 4 Gear wheel 4 44 14 Stop valve 4 80 5 Pinion 4 45 15 Supply pipe 4 51 6 Shaft 4 50 16 Servo oil service pump 4...

Page 399: ...ir Receiver 6420 1 A1 Turbocharging 6500 1 A1 Cleaning the Turbocharger in Operation All Types 6510 1 A1 Auxiliary Blower and Switch Box 6545 1 A1 Scavenge Air Cooler Operation Instructions and Cleani...

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Page 401: ...ceiver space RS and through openings in the cylinder jacket 19 to the piston underside PU The scavenge air flows through the scavenge ports when the piston is near BDC The air flaps 15 prevent back fl...

Page 402: ...3 2 6 1 II 4 3 5 WCH01159 For view II see Fig 2 4 4 8 7 I I Fig 1 Scavenge Air Receiver 1 Auxiliary blower 5 Scavenge air receiver 2 Electric motor 6 Cover 3 Hinged cover 7 Cup springs 4 Relief valve...

Page 403: ...fixed support 19 Cylinder jacket for exhaust gas manifold 9 Scavenge air cooler PU Piston underside 10 Charging unit RS Receiver space 11 Water separator SA Scavenge air from turbocharger 12 Cover AS...

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Page 405: ...ached to the same shaft The compressor pulls fresh air FA from the engine room through a filter silencer The compressor compresses and heats the scavenge air SA This hot compressed air flows through a...

Page 406: ...er 18 Air flaps upstream of auxiliary blower 4 Cylinder jacket 5 Inlet ports 6 Piston EG Exhaust gas 7 Auxiliary blower OW Oily water drain 8 Air inlet casing EO Exhaust gas outlet 9 Expansion piece F...

Page 407: ...re decrease To keep the silencer in a clean and serviceable condition regular visual checks and procedures are necessary Clean the silencer and filter only when the engine is stopped and in accordance...

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Page 409: ...rs supply air from the air space through the suction casing into the receiver space during the start and operation at low load Air flaps prevent the back flow of air into the receiver see 6420 1 Scave...

Page 410: ...ower starts When the turbocharger produces sufficient pressure in the scavenge air receiver the auxiliary blowers stop If the scavenge air pressure decreases below the minimum pressure necessary the a...

Page 411: ...g maneuvering CAUTION Damage Hazard Do not use the butterfly valves at the cooling water inlet and outlet pipes to control the flow rate The water separators which are plastic could be damaged because...

Page 412: ...eiver 19 3 way ball valve 5 Fresh water supply pipe 20 Cleaning fluid and wash water drain 6 Compressed air supply pipe 21 SAC drain 7 Ball valve 22 Vent unit 8 Ball valve 9 Shut off valve 10 Shut off...

Page 413: ...tion filter on the turbocharger Note It is recommended that you do not clean the SAC in tropical conditions because of increased condensation 3 2 Cleaning Agents Use cleaning agents only from recommen...

Page 414: ...out of the nozzles 9 as a spray into the SAC for approximately one minute 8 Move the 3 way ball valve 8 to the SAC Cleaning Position to drain the wash water 9 Close the shut off valve 4 and the ball...

Page 415: ...ou can get these Instruction Leaflets directly from the manufacturers It is also possible to send an order for Instruction Leaflets from the engine manufacturer or supplier When you send an order for...

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Page 417: ...arctic conditions when the outside air temperature is below the related value The waste gate valve operates as a safety valve i e the overpressure is blown off into the engine room The waste gate val...

Page 418: ...0839 SP 19 Fig 2 Waste Gate Valve and Control Diagram 1 Scavenge air receiver 14 Test connection SA 2 Silencer 15 Non return valve 3 Valve housing 16 Non return valve 4 Piston 17 Temperature sensor TE...

Page 419: ...5 and the waste gate valve opens Scavenge air then flows through the silencer into the engine room The temperature sensor 17 TE3991C measures the outside air temperature to energize de energize the so...

Page 420: ...e pressure gage shows a pressure difference do as follows a Loosen the locknut 19 b Turn the adjustment screw 12 to adjust the pressure that opens the waste gate valve c Tighten the locknut 19 4 Funct...

Page 421: ...interthur Gas Diesel Ltd 1 19 Cylinder Lubrication Group 7 Cylinder Lubrication 7218 1 A1 Cylinder Lubrication Oil Consumption Measurement 7218 2 A1 Feed Rate Adjustment 7218 3 A1 Winterthur Gas Diese...

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Page 423: ...alve Spindle 16 8 Cylinder Lubricating System Control 17 8 1 Control System 17 8 2 Radial Oil Supply 18 8 3 Vertical Oil Supply 18 8 4 Lubricating Oil Feed Rate Adjustment 19 1 General The cylinder lu...

Page 424: ...cating quills 8 12 eight for each cylinder with non return valves D Pressure reducing valve 8 11 1 one and pressure reducing valve 8 11 2 one only for 9 cylinder engines D System control from the WECS...

Page 425: ...ration 7218 1 A1 Winterthur Gas Diesel Ltd 3 19 WCH01117 DATA FOR 6 CYLINDERS TO 8 CYLINDERS DATA FOR 9 CYLINDERS WCH01117 Fig 1 Schematic Diagram Cylinder Lubrication System 2014 09 Cylinder Lubricat...

Page 426: ...pressure reducing valve 2 decreases the servo oil pressure to 60 bar For safety all high pressure servo oil pipes have double walls The pressure transmitter 3 monitors the servo oil pipes If the pres...

Page 427: ...that the ball valve 8 is opened during operation 3 1 Duplex Filter It is necessary to bleed the duplex filter D At the first operation D After you replaced a filter element 3 2 Filter Element It is p...

Page 428: ...he measurement tube 4 Do the steps that follow 1 Close the ball valve 5 2 Open the ball valve 8 3 When you can see the oil level on the scale 7 mark the oil level and start the time measurement 4 Afte...

Page 429: ...entation of the lubricating pump supplier 4 1 2 Pump Body The function of the pump body 1 is to increase the oil pressure and to supply the servo oil To release the air in the lubricating pump the ven...

Page 430: ...t and fill connection 3 4 2 way solenoid valve ZV7131 39C 12 Control box E41 01 09 4 Accumulator 5 Pressure transmitter PT3131 39C 6 Shut off valve servo oil OQ Oil to lubricating quill 7 Lubricating...

Page 431: ...flows at high pressure through the non return valve into the outlet ports The lubricating quills inject the lubricating oil on to the cylinder liner wall The maximum stroke of the central piston is ad...

Page 432: ...oil can come out as a spray 1 Put an oil tray below the lubricating pump 2 On the operator interface select the related cylinder number in the menu MANUAL LUBRICATION ON CYL As an alternative set the...

Page 433: ...5 8 I I I I Fig 5 Last Lubricating Pump 1 Pump body 7 Screw plug 2 Baseplate 8 Screw plug 3 4 2 way solenoid valve ZV7131 39C 9 Vent screw servo oil 4 Accumulator 10 Vent screw lubricating oil 5 Blind...

Page 434: ...uts After all the oil pipes of a cylinder are bled you can visually examine the cylinder oil supply as follows 5 Make sure that the piston is in the TDC position Look through the scavenge air ports in...

Page 435: ...to lubricating pump 13 Plug X1 X2 7 Cable connections to control 14 Nameplate 5 1 LED Indications The LEDs 4 and 5 see Fig 6 show the status of the lubricating pump and the control system The LEDs are...

Page 436: ...ws red and LED 11 FAIL flashes red one time Indicates a defective cable at the 4 2 way solenoid valve LED 11 FAIL None Electrical circuit of the injection system ready for operation Shows red and LED...

Page 437: ...is related to the cylinder number Note Before you install a new resistor make sure that the replacement has the correct resistance See the table that follows Table 3 Resistors in Plug X1 Cylinder No...

Page 438: ...ing oil flows through the non return valve 5 orifice 6 and ball valve 7 into the exhaust valve Note The cylinder lubricating oil supply to the valve guide bush is open for all load ranges see also 275...

Page 439: ...ressure transmitter to monitor the metering pressure E85 E90 Power supply DATA FOR 9 CYLINDERS Crank angle sensor unit CAN Bus SSI Bus GT5126C Sensor Valve ALM 20 Cyl 1 ALM 20 Cyl 2 ALM 20 Cyl 9 PT313...

Page 440: ...o 2138 1 Lubricating Quills on Cylinder Liner Fig 9 Radial Oil Supply 8 3 Vertical Oil Supply The WECS 9520 controls the injection timing of the vertical oil supply see 4002 1 paragraph 4 4 The parame...

Page 441: ...in the columns Supply Rate and Adjustment for one cylinder or for all cylinders see 4002 3 paragraph 1 1 For more data about the adjustment of the lubricating oil feed rate see 7218 3 For data about t...

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Page 443: ...on quantity x engine speed FQ x rpm Make sure that the curve refers to the fuel that is used see the acceptance protocol 2 From the field Est Power shown in the operator interface fuel injection quant...

Page 444: ...n g kWh R 3600 h x k f x t x P R Specific cylinder lubricating oil consumption g kWh h Measurement height cm k Conversion factor l cm Oil density g l typical value 920 g l f Correction factor see tabl...

Page 445: ...xamine the PU D Make an analysis of the fuel quality If possible send a sample of the fuel to a laboratory to make an analysis of the effective sulfur content Do the analysis before you use the fuel f...

Page 446: ...ual base number BN and iron content of the PU drain oil D The sulfur content m m of the used heavy fuel oil HFO D The BN mg KOH g of the used cylinder lubricating oil 2 1 Empirical Data Collection To...

Page 447: ...future operation with the same cylinder lubricating oil and fuel with the same sulphur content 0 125 m m When you use your empirical data WinGD recommends that you do a PU oil sample This makes sure...

Page 448: ...Drain Oil Analysis Tool Iron Content in Relation to the Engine Load Note If the engine operates with fuel that has a sulphur content less than 0 1 m m and a cylinder lubricating oil with a base number...

Page 449: ...te in steps of 0 05 g kWh to get the iron content value to approximately 200 mg kg You must get PU drain oil samples regularly to make sure that the feed rate used is applicable WinGD recommends that...

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Page 451: ...A1 Lubricating Oil System 9 cylinders 8016 1 A2 Cooling Water System 8017 1 A1 Starting Air Diagram 8018 1 A1 Fuel System 6 cylinders to 8 cylinders 8019 1 A1 Fuel System 9 cylinders 8019 1 A2 Exhaust...

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Page 453: ...edure 11 6 Servo Oil Rail Fill and Drain 12 6 1 Fill and Vent 12 6 2 Drain 12 1 General The oil pump 1 Fig 1 supplies oil at the necessary pressure for engine control lubrication and crosshead lubrica...

Page 454: ...the drive supply unit are supplied and cooled with bearing oil There is an oil supply through the supply pipe 16 for the bearings nozzles fuel pumps and internal bores in the fuel pump unit 17 for mor...

Page 455: ...lve 1 5 Open the ball valve 2 to drain the remaining oil from the dirty oil pipe 3 6 Close the ball valve 2 7 Put the sample bottle under the ball valve 1 8 After approximately 10 minutes to 60 minute...

Page 456: ...T ENGINE PLANT OV DT DT OI 2 3 1 2 DT DT OV CV SS 34 39 21 7 27 8 9 35 13 12 11 10 30 31 36 37 38 14 15 31 30 28 30 29 30 24 30 32 30 25 30 33 30 23 30 22 5 30 26 6 30 16 30 16 4 CV SS DT DT 17 19 20...

Page 457: ...l servo pump unit CV to fuel pressure control valve 3 06 21 Axial damper monitor OV Outlet vent 22 Main dirty oil collector piston underside BO Bearing and turbocharger oil 23 Main leakage oil collect...

Page 458: ...Oil supply pipe 21 Servo oil return from cylinder 6 Bottom end bearing lubrication pumps 7 Crosshead pin 22 Flushing oil drain from automatic filter 8 Toggle lever 23 Servo oil return injection contr...

Page 459: ...Oil flows through the automatic filter 1 the supply pipes 5 and the supply pipe 13 to the servo oil pumps 4 CAUTION Damage Hazard Do not operate the engine if there is no oil supply to the servo oil...

Page 460: ...DT DT OI 27 38 16 41 39 40 28 8 11 46 24 21 22 7 31 25 13 15 1 14 47 26 2 10 CL 45 PLANT ENGINE ENGINE PLANT DT 44 30 19 20 30 30 30 36 30 37 30 33 30 9 30 43 30 6 30 42 30 35 30 34 Fig 3 Servo Oil Sy...

Page 461: ...le 4 19 11 Injection control unit 3 02 39 Stop valve 4 30 5 12 Fuel pressure control valve 3 06 40 Pressure reducing valve 8 11 1 13 Supply pipe 41 Leakage oil pipe from hydraulic pipes 4 66 14 Stop v...

Page 462: ...graph 5 2 5 2 Procedure WARNING Injury Hazard Always use gloves and safety goggles when you do work on hot components Oil can come out as a spray when you open the drain screws 1 On the flange 2 Fig 4...

Page 463: ...spray when you open the drain screws 1 On the flange 3 Fig 5 of the hydraulic pipe 1 carefully loosen the drain screw 2 a maximum of one turn 2 Do a check for oil 3 If oil flows from the leakage inspe...

Page 464: ...into the exhaust valve housings Orifices vent the full system For more data see 2751 1 Exhaust Valve Note To do a function check of the exhaust valve movement or a leak test of the servo oil system th...

Page 465: ...cedure 12 6 Servo Oil Rail Fill and Drain 13 6 1 Fill and Vent 13 6 2 Drain 13 1 General The oil pump 1 Fig 1 supplies oil at the necessary pressure for engine control lubrication and crosshead lubric...

Page 466: ...20 and the drive supply unit are supplied and cooled with bearing oil There is an oil supply through the supply pipe 16 for the bearings nozzles fuel pumps and internal bores in the fuel pump unit 17...

Page 467: ...ball valve 1 5 Open the ball valve 2 to drain the remaining oil from the dirty oil pipe 3 6 Close the ball valve 2 7 Put the sample bottle under the ball valve 1 8 After approximately 10 minutes to 60...

Page 468: ...LANT ENGINE PLANT OV DT DT OI 2 3 1 2 DT DT OV CV SS 34 39 21 7 27 8 9 35 13 12 11 10 30 31 36 37 38 14 16 15 31 30 33 30 32 30 24 30 25 30 23 30 22 4 5 30 26 30 28 30 29 6 30 CV DT DT 17 19 30 16 30...

Page 469: ...e wheel servo pump unit CV to fuel pressure control valve 3 06 21 Axial damper monitor OV Outlet vent 22 Main dirty oil collector piston underside BO Bearing and turbocharger oil 23 Main leakage oil c...

Page 470: ...o oil service pump 4 88 5 Oil supply pipe 21 Servo oil return from cylinder 6 Bottom end bearing lubrication pumps 7 Crosshead pin 22 Flushing oil drain from automatic filter 8 Toggle lever 23 Servo o...

Page 471: ...through the automatic filter 1 the supply pipes 5 and the supply pipe 13 to the servo oil pumps 4 CAUTION Damage Hazard Do not operate the engine if there is no oil supply to the servo oil pumps Duri...

Page 472: ...16 1 15 39 54 32 2 CL PLANT ENGINE ENGINE PLANT DT DT 6 41 50 40 43 52 30 51 49 27 25 24 36 7 36 7 21 20 8 33 51 19 18 12 53 44 44 11 10 26 9 26 9 12 27 24 25 11 10 34 46 45 53 49 29 52 31 8 37 48 47...

Page 473: ...akage oil pipe exhaust valve DE 13 Fuel pressure control valve 3 06 44 Throttle 4 19 14 Supply pipe 45 Stop valve 4 30 5 15 Stop valve 4 37 46 Pressure reducing valve 8 11 1 16 Stop valve 4 80 47 Stop...

Page 474: ...pes Leakage If the level switch 7 Fig 4 LS2055A activates an alarm the leakage inspection point on the HP servo oil pipes 1 lets you find the location of the leakage You can then do the applicable pro...

Page 475: ...Note Do the procedure in paragraph 5 4 first 5 4 Procedure WARNING Injury Hazard Always use gloves and safety goggles when you do work on hot components Oil can come out as a spray when you open the d...

Page 476: ...do as follows 4 Close fully the two applicable stop valves 5 and 6 or 7 and 8 Torque the applicable stop valves to 100 Nm 5 Torque the stop valves that stay open to 100 Nm Note You can fully operate t...

Page 477: ...its and into the exhaust valve housings Orifices vent the full system For more data see 2751 1 Exhaust Valve Note To do a function check of the exhaust valve movement or a leak test of the servo oil s...

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Page 479: ...e formation and scale deposits in the system see 0760 1 Cooling Water Cooling Water Treatment A heater installed in the plant heats the water to the correct temperature before engine operation CAUTION...

Page 480: ...ack to the pump A balance pipe connects the suction side of the pump to the expansion tank This balance pipe makes sure there is static pressure and adjustment for the expansion and decrease of water...

Page 481: ...ent unit 3 Water guide jacket 17 Condensate drain pipe 4 Cylinder cover 18 Cylinder jacket 5 Exhaust valve cage 19 Ball cock 6 Throttle cylinder outlet 20 Cylinder drain pipe 7 Shut off valve at cylin...

Page 482: ...3 Fig 2 Scavenge Air Cooler Cooling Water 1 Safety valve WD Drain outlet cylinder cooling water 2 Cooling water drain pipe SO Steam outlet from safety valve 3 Vent unit WO Cooling water outlet from pr...

Page 483: ...tervals to remove condensation from the starting air system ENGINE PLANT BS AS CA 13 7 2 1 4 8 9 4 AI BS CA 12 11 6 5 3 10 SA WCH01152 14 14 Fig 1 Schematic diagram starting and control air 1 Shut off...

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Page 485: ...alled in the plant supplies fuel through the fuel inlet pipe 1 to the fuel pumps 3 The fuel quantity supplied is more than necessary for the engine The pressure retaining valve 6 adjusts the booster p...

Page 486: ...aragraph 3 Vent and leak test of fuel system on the engine The fuel pumps 3 supply fuel through the high pressure HP fuel pipes 8 into the fuel rail The fuel pumps supply sufficient fuel to keep the n...

Page 487: ...ure circuit Fuel pipe system Leakage fuel pipe Steam heating pipe 28 16 37 13 17 25 24 23 11 12 22 32 6 33 3 20 19 17 26 18 27 14 35 ENGINE PLANT 21 10 10 30 30 30 28 30 1 30 4 9 9 30 29 30 36 30 34 W...

Page 488: ...on return valve 3 81 2 33 Drain valve fuel outlet 12 Non return valve 3 81 1 34 Drain pipe from fuel overpressure 13 Fuel rail 3 05 safety valve 3 52 14 Injection control unit 3 02 35 Connection from...

Page 489: ...terthur Gas Diesel Ltd 5 12 3 1 5 2 4 WCH02335 Fig 3 Drain Valves 1 Level switch LS3426A 4 Fuel pump 3 14 2 Drain valve fuel inlet 5 HP fuel pipe 3 29 3 Drain valve fuel outlet 2015 05 Fuel System 6 c...

Page 490: ...46A HP fuel pipes 15 injection control units ICU 14 related fuel overpressure safety valve 23 and drain valve 21 LS3444A Leakages fuel and servo oil from the rail unit 4 2 Leakages WARNING Injury Haza...

Page 491: ...ot as follows a If fuel flows out the related HP fuel pipe 5 is defective b If fuel does not flow out tighten the drain screws 10 7 On the HP fuel pipe 4 carefully loosen each of the drain screws 11 a...

Page 492: ...n Points HP Fuel Pipes 3 29 1 HP fuel pipe 3 29 top part 7 Intermediate piece 2 Intermediate piece 8 Drain screw 3 17 3 Intermediate piece 9 Drain screw 3 17 4 HP fuel pipe 3 29 bottom part 10 Drain s...

Page 493: ...1 7 3 3 6 4 9 WCH01157 5 8 2 Fig 5 Leakage Inspection Points HP Fuel Pipes 3 47 to Injection Valves 1 HP fuel pipe 3 47 6 Plug Inspection point 3 17 2 Injection control unit 3 02 7 Sealing face 3 ICU...

Page 494: ...fuel system has high pressure Replace a defective HP fuel pipe only when the engine has stopped Note If the HP fuel pipe cannot be replaced immediately WinGD recommends to cut out the related injectio...

Page 495: ...ll stop the fuel flow to the related fuel injection valve 2 At the plug 6 do a check for fuel a If fuel stops to flow after some seconds this related HP fuel pipe 1 is defective Do the steps 3 to 6 to...

Page 496: ...ws from the screw in union 4 more than usual compared to the amount of leakage from the other ICU the fuel quantity piston of the related ICU 1 is defective WARNING Injury Hazard The fuel system has h...

Page 497: ...h the fuel inlet pipe 1 to the fuel pumps 3 The fuel quantity supplied is more than necessary for the engine The pressure retaining valves 6 and 7 adjust the booster pressure to the specified setting...

Page 498: ...of fuel system on the engine The fuel pumps 3 deliver fuel under high pressure into the fuel rail 15 via the high pressure pipes 9 collector block 13 and the rising pipes 10 They supply as much fuel a...

Page 499: ...27 29 28 30 23 25 22 24 29 36 36 20 21 19 9 19 13 19 19 13 19 9 42 5 43 6 7 5 2 2 43 42 8 3 3 19 30 17 30 44 30 40 30 37 30 38 30 37 30 37 30 10 30 10 30 4 30 1 30 14 30 14 30 35 30 35 30 39 High pre...

Page 500: ...ail unit DE 13 Collector block 40 Leakage drain from rail unit FE 14 Connection pipe 41 Plug 3 39 15 Fuel rail 3 05 42 Drain valve fuel inlet 16 Injection control unit 3 02 43 Drain valve fuel outlet...

Page 501: ...l Ltd 5 13 019 376 10 2 5 1 4 4 1 2 5 6 FUEL SIDE EXHAUST SIDE 3 Fig 3 Drain Valves 1 HP fuel pipe 4 Drain valve fuel outlet 2 Fuel pump 5 Drain valve fuel inlet 3 Level switch LS3427A 6 Level switch...

Page 502: ...safety goggles when you do work on hot components When you open the screw plugs fuel can come out as a spray and cause injury If the level switches 20 Fig 1 LS3426A 21 LS3427A 22 LS3446A or 23 LS3447...

Page 503: ...follows a If fuel flows out the related HP fuel pipe 5 is defective b If fuel does not flow out tighten the drain screws 12 11 On the HP fuel pipe 13 carefully loosen the drain screw 10 approximately...

Page 504: ...VI 5 V 11 II II 13 II and VIII WCH02334 Fig 4 Leakage Inspection Points HP Fuel Pipes 1 Intermediate piece 8 Drain screw 2 HP fuel pipe 9 HP fuel pipe 3 Intermediate piece 10 Drain screw 4 HP fuel pi...

Page 505: ...wo related stop valves 1 and 6 or 3 and 7 Torque the applicable stop valves to 100 Nm 4 Torque the stop valves that stay open to 100 Nm Note You can fully operate the engine at the necessary temperatu...

Page 506: ...CH01157 1 7 3 3 6 4 9 WCH01157 5 8 2 Fig 6 Leakage Inspection Points HP Fuel Pipes 3 47 to Injection Valves 1 HP fuel pipe 3 47 6 Plug Inspection point 3 17 2 Injection control unit 3 02 7 Sealing fac...

Page 507: ...ry Hazard The fuel system has high pressure Replace a defective HP fuel pipe only when the engine has stopped Note If the HP fuel pipe cannot be replaced immediately WinGD recommends to cut out the re...

Page 508: ...This will stop the fuel flow to the related fuel injection valve 2 At the plug 6 do a check for fuel a If fuel stops to flow after some seconds this related HP fuel pipe 1 is defective Do the steps 3...

Page 509: ...s 2 If fuel flows from the screw in union 4 more than usual compared to the amount of leakage from the other ICU the fuel quantity piston of the related ICU 1 is defective WARNING Injury Hazard The fu...

Page 510: ...Intentionally blank...

Page 511: ...es a turbocharger for part load operation The combustion pressure is increased at less than 75 load through an increased scavenge air pressure waste gate closed The waste gate opens at engine loads of...

Page 512: ...ing in the actuator 7 closes the butterfly valve 5 If a part becomes defective alarm messages are activated in the WECS 9520 and shown in the alarm and monitoring system see 0820 1 Operating Problems...

Page 513: ...FOR 6 CYLINDERS TO 8 CYLINDERS Fig 2 Exhaust Waste Gate 6 cylinders to 8 cylinders 1 Exhaust bypass line 7 Actuator ZS5372C 2 Exhaust gas manifold 8 Position Switch ZS5372C 3 Turbocharger 9 Control ai...

Page 514: ...view II see Fig 2 DRAWN FOR 9 CYLINDERS I 1 4 5 7 8 4 WCH02764 II WCH02763 Fig 3 Exhaust Waste Gate 9 cylinders 1 Exhaust bypass line 5 Butterfly valve 2 Exhaust gas manifold 7 Actuator ZS5372C 3 Tur...

Page 515: ...noid valve CV7076C AS Air spring air 13 Screw AV Air Vent 14 Electrical connection CA Control air to actuator 15 Control air pipe 16 Air spring air pipe WCH02753 9 11 12 7 Fig 5 Schematic diagram air...

Page 516: ...Intentionally blank...

Page 517: ...te collectors 20 collect dirt particles 4 Remove dirt particles rust that collect in the condensate collectors 20 at regular intervals see the Maintenance Manual 0380 1 5 At regular intervals look at...

Page 518: ...W 9 VC VC 25 24 17 17 20 7 12 16 6 17 22 21 11 15 19 23 AV 13 14 20 7 26 18 5 16 26 016 749 08 AL 16 PLANT ENGINE USUAL OPERATION SCAVENGE AIR COOLER CLEANING 30 1 30 2 30 4 30 3 30 8 30 10 Fig 1 Sche...

Page 519: ...Sludge oil tank from scavenge air cooler 26 Butterfly valve 7 Level switch for condensate drain 8 Dirty oil from piston rod gland 9 Engine 10 Dirty oil drain from piston underside 11 Condensate drain...

Page 520: ...Intentionally blank...

Page 521: ...ngle Sensor Unit 9223 1 A1 Pressure Switches and Pressure Transmitters 9258 1 A1 Intelligent Combustion Control 9308 1 A1 Oil Mist Detector 6 cylinders to 8 cylinders 9314 1 A1 Oil Mist Detector 9 cyl...

Page 522: ...Intentionally blank...

Page 523: ...ssure indications for fuel and servo oil are given in the local control panel see 4618 1 Local Control Panel I I I I 1 5 2 7 9 3 4 5 5 8 6 4 016 751 08 SCAVENGE AIR CONTROL AIR BEARING OIL FUEL CYLIND...

Page 524: ...ows the schematic diagram of the instrument panel H with the same indications also shown in the Control Diagram 4003 2 Data about the related pressure switches and pressure transmitters are given in 9...

Page 525: ...e crank angle positions A proximity sensor monitors the position of the TDC signal see 4628 1 Pick up for Speed Measurement All differences are monitored and displayed with an alarm You must lubricate...

Page 526: ...Intentionally blank...

Page 527: ...there is no pressure the control signals have an effect on the commands that follow D Alarm ALM D Slow down SLD D Shut down SHD For more data see 0250 2 Alarms and Safeguards at Continuous Service Pow...

Page 528: ...Schematic Diagram 1 Plate 7 Terminal box 2 Pressure transmitter 6 bar 8 Needle valve 3 Pressure transmitter 16 bar 9 Pipe connection terminal 4 Pressure transmitter 40 bar 10 Throttle piece 5 Pressure...

Page 529: ...n Control ICC system makes sure that the engine in service is operated according to its original shop test performance This is done automatically in and independently of the fuel used on board a vesse...

Page 530: ...VDE 0105 or IEC 364 2 2 Residual Dangers The ICC system is manufactured in accordance with the generally recognized rules of engineering industrial safety and accident prevention regulations However d...

Page 531: ...justments in case of open loop control 3 1 Pressure Transducers The precise and continuously measured in cylinder pressure of all units forms the basis of the ICC system The pressure transducers Press...

Page 532: ...nd the compression pressure see Fig 2 The ICC sets the pressure increase limit e g to 40 bar to prevent mechanical overload to the engine 3 3 ICC Installation and Control The necessary firing pressure...

Page 533: ...ure signals Fig 3 Installation Schematic of the ICC System Initially the signal is filtered in the WECS 9520 then routed to a controller Adjustments of this actual measured pressure value to its corre...

Page 534: ...g range of the auxiliary blowers the auxiliary blowers are switched off The balanced compression and firing pressures are obtained by individually adjusting the exhaust valve timing and injection timi...

Page 535: ...ssion pressure balancing function is set to OFF see Fig 7 this offset is the same as on the flexView Adjust card adjusted by the operator Fig 7 Compression Pressure Balancing Set to OFF From the ICC E...

Page 536: ...ng pressure set point On the right hand diagram the injection begin timing offset and the average offset value is shown Fig 9 FlexView ICC INJ Card When the firing pressure balancing function is set t...

Page 537: ...rkflow When the firing pressure control function is set to ON see Fig 13 the related Fuel Quality Setting FQS is calculated by the ICC system and displayed in the top left hand corner of the ICC INJ c...

Page 538: ...kflow in Fig 15 Fig 15 Firing Pressure Control Set to ON Workflow 4 4 ICC INDICATION Card The ICC indication card see Fig 16 displays the data that follows The compression firing pressures and firing...

Page 539: ...losions The sensors 3 are installed on the fuel side of the engine for D Each cylinder of the divided crankcase D The fuel pump drive D The fuel pump unit 2 Function Each sensor 3 optically monitors t...

Page 540: ...Gas Diesel Ltd 2 3 WCH01142 I I II 3 1 2 I I II 3 3 4 3 5 FUEL SIDE DRIVING END Fig 1 Location of Sensors 1 Cable guide 4 Fuel pump unit 2 Control unit E15 1 5 Column 3 Sensor 2014 09 Oil Mist Detect...

Page 541: ...9 PS 7 AM SS 9 8 Fig 2 Schematic Diagram 2 Control unit E15 1 8 Control panel 3 Sensor 9 Communications cable Modbus 4 Fuel pump unit PS Power supply 6 Crankcase and gearbox AM to alarm and monitorin...

Page 542: ...Intentionally blank...

Page 543: ...stalled on the fuel side of the engine for D Each cylinder of the divided crankcase D The fuel pump drive D The fuel pump units 2 Function Each sensor 3 optically monitors the concentration of oil mis...

Page 544: ...857 I I II 2 1 I I II 3 3 5 FUEL SIDE DRIVING END 2 3 3 4 4 WCH02857 10 11 3 Fig 1 Location of Sensors 1 Cable guide 5 Column 2 Control unit E15 1 10 Control unit E15 2 3 Sensor 11 Terminal box E15 0...

Page 545: ...9 7 9 7 Fig 2 Schematic Diagram 2 Control unit E15 1 9 Communications cable Modbus 3 Sensor 10 Control unit E15 2 4 Fuel pump unit 11 Terminal box E15 0 6 Crankcase and gearbox PS Power supply 7 Powe...

Page 546: ...Intentionally blank...

Page 547: ...1 to E95 0 These control boxes are attached to the rail unit near their related cylinders Each control box has an FCM 20 2 3 E41 01 to E41 0 These control boxes are attached to the cylinder block near...

Page 548: ...1 A1 Winterthur Gas Diesel Ltd 2 2 1 2 3 WCH01144 4 Fig 1 Flex Electronic Components 1 Control box E90 3 Rail unit 2 Control box E95 01 Cyl 1 4 Control box E41 01 Cyl 1 2014 Location of Flex Electron...

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