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background image

Fig 5-28

Fuel pump - cross section (example)

001

002

003

004

005

006

007

014

013

012

011

010

009

008

Legend

001

HP fuel to fuel rail

008

Guide piston

002

Fuel inlet

009

Driver (of pump plunger)

003

Pump plunger

010

Regulating sleeve

004

Compression spring

011

Toothed rack

005

Bottom spring carrier

012

Fuel outlet

006

Roller

013

Non-return valve

007

Cam

014

Pump cover

5.5.3.2

Lubrication

Engine lubricating oil, which flows through the lubricating oil inlet into the bottom housing,
lubricates the fuel pump.

Leakage fuel lubricates the pump plunger (003). The leakage fuel and the engine lubricating oil
from the regulating sleeve (010) flows through the drain bore. This mixture then flows into an
internal bore in the housing of the fuel pump unit.

5.5.3.3

Operation with an unserviceable fuel pump

If a fuel pump is unserviceable (eg the pump plunger cannot move) or the HP fuel pipe is broken
(between the fuel pump and the fuel rail) the fault must be repaired immediately. If the fault cannot
be repaired, it is possible to cut out the unserviceable fuel pump. Related to the number of installed
fuel pumps, there are limits of operation.

X92-B

AA00-5556-00AAA-043A-A

Operation Manual

Fuel pump

Winterthur Gas & Diesel Ltd.

- 167 -

Issue 002 2021-11

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Summary of Contents for X92-B

Page 1: ...X92 B Issue 002 2021 11 Winterthur Gas Diesel Ltd Sch tzenstrasse 3 Tel 41 0 52 264 8844 Winterthur Gas Diesel AG P O Box 414 8401 Fax 41 0 52 264 8866 Winterthur Gas Diesel S A Winterthur Switzerlan...

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

Page 3: ...e crankcase 52 2 6 Access to engine spaces 54 3 Design and function of the engine 3 1 Short description of the engine 58 3 2 Use of the engine 60 3 3 The relation between engine and propeller 64 4 Des...

Page 4: ...150 5 4 Group 4 Supply unit drive and control components 5 4 1 Supply unit drive 152 5 4 2 Starting air shut off valve 154 5 4 3 Control air supply 156 5 4 4 Local maneuvering stand for UNIC 158 5 4 5...

Page 5: ...MCP page SYSTEM INFO Option for WiCE 232 6 6 5 MCP page TREND Option for WiCE 234 6 6 6 MCP page INSTRUMENTS 236 6 6 7 MCP page FUEL LUBRICATION SYSTEM 238 7 Installation 7 1 Installation 242 8 Operat...

Page 6: ...0 8 Temporary cut out a defective injection valve 354 10 9 Temporary cut out a defective exhaust valve drive 356 10 10 Temporary isolate a cylinder with cooling water leakage 358 10 11 Servo oil pump...

Page 7: ...ues and safeguard settings 422 11 4 Section views 434 12 Operating media 12 1 General for operating media 436 12 2 Compressed air 438 12 3 Scavenge air 440 12 4 Diesel engine fuels 442 13 Attachments...

Page 8: ...X92 B Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 8 Issue 002 2021 11...

Page 9: ...1 10 3 Cylinder cooling water temperature downstream of a cylinder is too high 321 10 4 Supply pressure of the cooling water to the SAC is too low 321 10 5 Supply temperature of the cooling water to t...

Page 10: ...Gas concentration in piston underside is too high 329 10 35 Difference pressure of pilot fuel filter is too high 329 10 36 Gas supply pressure is too low 329 10 37 Exhaust gas temperature downstream...

Page 11: ...2 Rated power 417 11 3 Function code 420 11 4 Function group 421 11 5 Applied system 421 11 6 Cooling water systems XX10NN to XX19NN 423 11 7 Oil systems XX2NNN part 1 424 11 8 Oil systems XX2NNN par...

Page 12: ...X92 B Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 12 Issue 002 2021 11...

Page 13: ...Exhaust gas system generic and simplified 87 4 11 Fuel system with FLV generic and simplified 90 4 12 Fuel system with ICU generic and simplified 91 4 13 LP SCR temperature controlled example 93 4 14...

Page 14: ...5 26 Supply unit example 164 5 27 Fuel pump generic 166 5 28 Fuel pump cross section example 167 5 29 Pressure control valve location example 169 5 30 Flow limiting valve generic 170 5 31 Exhaust val...

Page 15: ...e of inspection point 345 10 3 Leakage on FLV and pipes example 351 10 4 Exhaust valve with pressure element 359 10 5 Location of flanges 372 10 6 Roller lifting tool assembly 373 10 7 Pre tensioner i...

Page 16: ...ta 11 1 Operating range 417 11 2 Signal codes 420 12 Operating media 12 1 Viscosity Temperature diagram 446 13 Attachments 13 1 Line codes 456 13 2 Process codes 457 13 3 Signal codes 458 13 4 Color c...

Page 17: ...0 1 3 Technical documentation set 22 1 4 Data module codes descriptive data 24 1 5 Data module codes procedural data 26 1 6 About this book 28 1 7 About the engine 30 1 8 List of abbreviations 34 X92...

Page 18: ...nd function of the systems Updated descriptions of the design and function of the components Updated the control system section Updated the operation section Updated the service during operation secti...

Page 19: ...X92 B AA00 0000 00AAA 003A A Operation Manual Operation Manual change record Page left intentionally blank Winterthur Gas Diesel Ltd 19 Issue 002 2021 11...

Page 20: ...s manual are related to drawings from WinGD These data relate to the date of issue of the manual the year of the issue is shown on the title page and on the footer All instructions graphics and illust...

Page 21: ...X92 B AA00 0000 00AAA 018A A Operation Manual Preface Page left intentionally blank Winterthur Gas Diesel Ltd 21 Issue 002 2021 11...

Page 22: ...ual gives data about the standard engine with all cylinder numbers alternative designs and special equipment In this manual the engine connections refer to the pipe connection plan are the interface o...

Page 23: ...e setting tables shop trial documents schematic diagrams and survey certificates of the related engine are given with the first supply of the documentation 1 3 6 Marine Installation Manual The Marine...

Page 24: ...numeric char acters 0 9 arbitrary 5551 2 Used for sequential numbering of data modules 2 numeric char acters 0 9 sequential starts with 00 00 1 Used for alternative items differing in de sign but not...

Page 25: ...X92 B AA00 0000 00AAA 018D A Operation Manual Data module codes descriptive data Page left intentionally blank Winterthur Gas Diesel Ltd 25 Issue 002 2021 11...

Page 26: ...ylinders 2 numeric char acters 0 9 arbitrary 00 2 WinGD design group number 4 numeric char acters 0 9 arbitrary 5556 2 Used for sequential numbering for the physical breakdown of components 00 complet...

Page 27: ...has been removed from the prod uct D information related to all three locations A B and C No other combi nations are allowed 1 alphabetic character A D Shipdex specif ic A 1 Placeholder symbol for al...

Page 28: ...itle of the section for example refer to section 1 2 Preface In the electronic version a mouse click on the blue text shows the related section NOTE The text section not applicable for this engine sho...

Page 29: ...ation The signal words have the different hazard levels that follow WARNING The signal word WARNING gives a dangerous situation at which death or large injury are possible Do the related procedure to...

Page 30: ...of the number into 9 groups Group 1 Engine frame and bearings Group 2 Cylinder Group 3 Crankshaft connecting rod and piston Group 4 Supply unit drive and control components Group 5 Supply unit pumps...

Page 31: ...e that has the equipment for the discard of the exhaust gas and for the supply of scavenge air Fig 1 1 Side view generic DE FE n n 1 2 1 005 004 001 002 003 Legend FE Free end DE Driving end 001 Turbo...

Page 32: ...D uses the definitions for the numbering of items as follows refer to Figure 1 2 In axial direction the numbering starts from the flywheel In radial direction the numbering starts from the center of t...

Page 33: ...X92 B AA00 0000 00AAA 018L A Operation Manual About the engine Page left intentionally blank Winterthur Gas Diesel Ltd 33 Issue 002 2021 11...

Page 34: ...C Brake Specific Gas Consumption BSPC Brake Specific Pilot fuel Consumption CAN Controller Area Network CCAI Calculated Carbon Aromaticity Index CCM Cylinder Control Module CCU Cylinder Control Unit C...

Page 35: ...lve FPP Fixed Pitch Propeller FQS Fuel Quality Setting FS Fuel Side FZG Forschungsstelle f r Zahnr der und Getriebebau gear research center GAV Gas Admission Valve GSS Gas Safety System GTD General Te...

Page 36: ...Heating Value LLT Low Load Tuning LNG Liquefied Natural Gas LP Low Pressure LT Low Temperature MARPOL International Convention for the Prevention of Pollution from Ships MARine POLlution MCM Main Con...

Page 37: ...Scavenge Air Cooler SAE Society of Automotive Engineers SCR Selective Catalytic Reduction SCS Speed Control System SHD shutdown SLD slowdown SOI Start Of Injection SPC Spare Parts Catalogue SPC Steam...

Page 38: ...R Waste Heat Recovery WiCE WinGD Integrated Control Electronics WinGD Winterthur Gas Diesel Ltd WLL Work Load Limit X92 B AA00 0000 00AAA 005A A Operation Manual List of abbreviations Winterthur Gas D...

Page 39: ...tion and fire in the scavenge air spaces 46 2 3 Fire fighting in the scavenge air space 48 2 4 Explosions in the crankcase 50 2 5 Prevent explosions in the crankcase 52 2 6 Access to engine spaces 54...

Page 40: ...except if done in closed and protected environment this will prevent spread of grit or swarf particles Make sure that the turbocharger intake filters are covered Keep the external part of the engine c...

Page 41: ...and the engine is not in operation the water in the pipe systems can freeze To prevent this drain the pipe systems or increase the temperature in the engine room Alarms Make sure that all the alarms...

Page 42: ...se personal injury or loss of life Warning This warning is used when an operation procedure or use may cause a latently dangerous state of personal injury or loss of life Caution This warning is used...

Page 43: ...elated system injury to personnel can occur WARNING Injury hazard Do not repair the hydraulic servo oil or rail system when pumps are in operation Injury to personnel can occur WARNING Injury hazard D...

Page 44: ...delines for hot work Outside of safe workspaces The safety officer ensures that the hot work is carried out safely The safety officer provides a permit to everybody related to hot work Hot work proced...

Page 45: ...el to the cables of electronic units Only use DC power supply and OCV below 70 volts Make sure that the connection clamp is near to the work area Make sure that electronic parts have protection to pre...

Page 46: ...The silencer and diffuser on the air side of the turbocharger has contamination The wire mesh and nozzle ring upstream of the turbocharger has contamination The exhaust gas boiler the air cooler and...

Page 47: ...You must do regular checks of the bottom of the cylinder block and scavenge air receiver to keep clean the cylinder block and scavenge air receiver refer to section 8 5 Do checks during operation gene...

Page 48: ...0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QT...

Page 49: ...y 5 minutes to 15 minutes do the checks as follows 3 1 Do a check of the exhaust gas temperature 3 2 Do a careful check of the temperatures of the doors to the piston underside space 4 Find the causes...

Page 50: ...y The cause of crankcase explosions is oil mist Oil mist comes from components that have become unusually hot The engine has oil mist detectors refer to section 5 9 3 Oil mist detector Correct engine...

Page 51: ...X92 B AA00 0000 00AAA 012C A Operation Manual Explosions in the crankcase Page left intentionally blank Winterthur Gas Diesel Ltd 51 Issue 002 2021 11...

Page 52: ...QTY None SAFETY PRECAUTIONS WARNING Danger If an oil mist alarm is activated keep away from the engine There is a risk of explosion WARNING Danger Do not open the crankcase doors or the covers for a...

Page 53: ...ature decrease for a minimum of 20 minutes 1 4 Find the cause and repair the fault NOTE If no fire extinguishing system is installed or not in use a portable fire extinguisher must be kept ready when...

Page 54: ...crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury Hazard Be careful of the sl...

Page 55: ...losed ball valves 30 8605_E0_6 and 30 8605_E0_7 are open 6 Engage the turning gear and lock the lever in this position NOTE Other ships in the water cause currents which cause the movement of the prop...

Page 56: ...X92 B AA00 0000 00AAA 012E A Operation Manual Access to engine spaces Page left intentionally blank Winterthur Gas Diesel Ltd 56 Issue 002 2021 11...

Page 57: ...and function of the engine 3 1 Short description of the engine 58 3 2 Use of the engine 60 3 3 The relation between engine and propeller 64 X92 B Operation Manual Winterthur Gas Diesel Ltd 57 Issue 00...

Page 58: ...operation Related to the design the engine turns clockwise or counterclockwise for the ahead direction For the astern direction the engine can turn in the other direction The engine control system EC...

Page 59: ...ases expand and push the piston down The pressure in the combustion chamber decreases Sequence 4 1 The scavenge air replaces the exhaust gas as follows At 4 the exhaust valve opens At a the scavenge p...

Page 60: ...nge Fig 3 2 Operating range R1 R1 R2 R2 R4 R4 R3 S P Legend R1 Highest power at highest speed R3 Highest power at lowest speed R1 Highest power at highest speed extended R4 Lowest power at lowest spee...

Page 61: ...rect use will be the responsibility of the operating company The actions that follow must be looked as examples to be an incorrect use Operation of the engine with disabled changed or defective safety...

Page 62: ...ass tuning The delta bypass tuning decreases the fuel consumption below 50 engine power compared to delta tuning For more than 50 of engine power the fuel consumption is the same as delta tuning but t...

Page 63: ...X92 B AA00 0000 00AAA 020C A Operation Manual Use of the engine Page left intentionally blank Winterthur Gas Diesel Ltd 63 Issue 002 2021 11...

Page 64: ...clean hull the applicable power is lower and the operation point is below the nominal propeller property During operation a higher torque is necessary for the propeller to keep its speed than at the t...

Page 65: ...he timing of dry dock intervals This margin is usually subtracted from the CMCR Thus to get the 100 power line you divide the power at point D by between 0 85 to 0 90 3 3 2 3 Load range limits Fig 3 4...

Page 66: ...ine speed and power is near the data in Line 5 there will be a decrease in scavenge air which has an effect on the engine The area between Lines 1 3 and 5 show the range in which the engine must be op...

Page 67: ...4 5 Servo oil system 76 4 6 Cylinder oil system 78 4 7 Starting air system 80 4 8 Scavenge air system 82 4 9 Control air system 84 4 10 Exhaust gas system 86 4 11 Fuel system 88 4 12 LP Selective cat...

Page 68: ...e codes in Figure 4 1 Fig 4 1 Line codes for systems 001 002 003 004 007 006 008 009 005 Legend 001 Main supply pipe 006 Double wall pipe 002 Drain leakage pipe 007 Heating pipe 003 Vent pipe 008 Insu...

Page 69: ...X92 B AA00 0000 00AAA 043U A Operation Manual General for systems Page left intentionally blank Winterthur Gas Diesel Ltd 69 Issue 002 2021 11...

Page 70: ...e supply at the engine connection 02 is installed the cylinder liner is supplied with cooling water at a higher temperature than the cylinder cover The cooling water system has the parts that follow A...

Page 71: ...e 002 Shut off valve cooling water outlet 007 Orifice 003 Shut off valve if supply 02 is installed 008 Optional vent valve usually closed 004 Shut off valve if supply 02 is not installed 009 Vent valv...

Page 72: ...ning plant for TC and SAC inlet Connection 12 air for cleaning plant for TC and SAC inlet Connection 13 oily water from receiver outlet Connection 16 SAC condensate water outlet Connection 17 SAC wash...

Page 73: ...GINE 13 18 16 06 17 06 005 002 002 003 003 001 004 Legend 001 Wash water tank 004 Cyclone separator 002 Scavenge air cooler SAC 005 Turbocharger 003 Auxiliary blower X92 B AA00 0000 00AAA 043P A Opera...

Page 74: ...bedplate vertical Connection 25 main oil inlet Connection 26 lubricating oil turbocharger inlet optional Connection 27 lubricating oil turbocharger outlet Connection 30 lubricating oil crosshead inle...

Page 75: ...nd 001 Turbocharger 007 Crosshead 002 iELBA optional 008 Thrust bearing 003 Torsional vibration damper optional 009 Oil sample valve 004 Axial vibration damper 010 Lever 005 Main bearing 011 Supply pi...

Page 76: ...e double wall Inspection points in the pipes let find oil leaks Servo oil service pump The servo oil service pump 005 can supply the servo oil system with oil before the engine start or during mainten...

Page 77: ...trol unit ICU for X82 and X92 006 Oil pipe to exhaust valve 002 Exhaust valve control unit VCU 007 Servo oil rail 003 Square collector pipe 008 Rail unit 004 Servo oil pump 009 Pressure reducing valve...

Page 78: ...x oil filter 004 filters the oil before it flows to the cylinder lubricating pumps The change over valve makes it possible to shut off one filter chamber Cylinder lubricating pump Each cylinder has a...

Page 79: ...AT 007 004 003 002 001 Legend 001 Oil sample valve 005 Square collector pipe 002 Lubricating quill 006 Rail unit 003 Cylinder lubricating pump 007 Change over valve 004 Duplex oil filter 008 Servo oil...

Page 80: ...starting air supply pipe 007 supplies the starting valves of each cylinder with starting air The starting air supply pipe has a safety valve 003 and two drain valves 004 Starting valve Each cylinder h...

Page 81: ...id valve 006 Disengaging device turning gear 002 Flame arrestor 007 Starting air supply pipe 003 Safety valve 008 Valve unit for start E 004 Drain valve 009 Starting air shut off valve 005 Control air...

Page 82: ...liary blowers 010 supply the scavenge air at the engine start and during low load operation Auxiliary blower switch box The auxiliary blower switch box controls the auxiliary blowers Scavenge air cool...

Page 83: ...as outlet 010 Auxiliary blower 003 Scavenge air inlet 011 Piston underside 004 Turbine 012 Piston 005 Compressor 013 Scavenge air receiver 006 Scavenge air cooler 014 Cylinder liner 007 Water separato...

Page 84: ...supply The control air supply 002 decreases the supply air pressure to the specified pressures Air tank The air tank 003 is a container for control air If the two plant air supply systems become defe...

Page 85: ...03 004 Cyl 1 Cyl n Legend 001 Air bottle 005 Starting air shut off valve 002 Control air supply 006 Valve unit for start 003 Air tank 007 Collector for leakage oil from the air spring 004 Disengaging...

Page 86: ...engine connection 71 exhaust gas turbocharger outlet in Figure 4 10 marked with a circle The exhaust gas system has the parts that follow Exhaust valve The exhaust valve 004 of each cylinder releases...

Page 87: ...N G I N E 003 001 002 Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cyl n 004 Legend 001 Turbocharger bypass pipe 003 Exhaust gas manifold 002 Turbocharger 004 Exhaust valve X92 B AA00 0000 00AAA 043D A Operation Manual E...

Page 88: ...el consumption The ECS cuts out a different injection valve at regular intervals to get an equal thermal load in the combustion chamber There is no time limit to operate the engine at low load The fue...

Page 89: ...ex and related DF engines installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity of fuel Injection control unit The injection control units 003 ICU for X82 X...

Page 90: ...004 005 006 007 008 009 Cyl 1 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Flow limiting valve FLV 008 Fuel pump 004 Fuel rail 009 Pressure retaining valv...

Page 91: ...T 001 002 004 005 003 007 008 009 006 Legend 001 Pressure control valve 006 Injection valve 002 Relief valve 007 Supply unit 003 Injection control unit ICU 008 Fuel pump 004 Fuel rail 009 Pressure ret...

Page 92: ...used in diesel mode NOTE For further details about the operation maintenance and troubleshooting aspects of the LP SCR system please refer to the manuals of the manufacturer 4 12 1 Description of the...

Page 93: ...tuning LLT or for steam production control SPC 4 12 1 2 Layout The LP SCR system can be designed in different layouts related to the project Two examples are shown in Figure 4 13 and Figure 4 14 Fig 4...

Page 94: ...s than the permitted limit can cause the catalyst elements to clog A temperature that is more than the permitted limit can cause the catalyst elements to become worn quickly 4 12 2 1 LP SCR system eme...

Page 95: ...e If the operator does not change to Tier III and the timer stops the ECS changes back to bypass mode Tier II 4 12 2 3 LP SCR system Tier III In this operation mode the LP SCR system is set to ON The...

Page 96: ...LP SCR control system layout 001 002 003 Legend 001 Input signals 003 Output signals 002 LP SCR control system The main input signals are as follows Engine parameters Prepare Tier III command from RC...

Page 97: ...This message shows that the LP SCR system is set to ON and thus urea is injected LP SCR minor failure This message shows a failure that does not have an effect on LP SCR system operation LP SCR major...

Page 98: ...ypass switch 006 Indication orange SPC bypass 002 Indication red SCR failure 007 Indication green SPC running 003 Indication orange SCR bypass 008 Indication green SCR running 004 Indication red SPC f...

Page 99: ...room and has switches below the LDU 20 Fig 4 18 Control box E71 with option SPC 001 002 003 Legend 001 LDU 20 003 SCR bypass switch 002 SPC bypass switch X92 B AA00 9270 00AAA 043B A Operation Manual...

Page 100: ...room and has switches below the LDU 20 Fig 4 19 Control boxes E72 and E73 001 002 003 004 Legend 001 LDU 20 003 SPC bypass switch 002 SCR bypass switch 004 Conductor terminal block X92 B AA00 9270 00A...

Page 101: ...ge 004 SCREENSHOT button Makes a screenshot of the current screen 005 RCS CTRL OFF button Gets control from the remote control system if button is active 006 Status indication Shows the SCR status 007...

Page 102: ...S CTRL OFF button Gets control from the remote control system if button is active 005 Status indication Shows the SCR status 006 Status indication Shows the control location 007 Status indication Show...

Page 103: ...t of the current screen 004 RCS CTRL OFF button Gets control from the remote control system if button is active 005 Status indication Shows the SCR status 006 Status indication Shows the control locat...

Page 104: ...ion type Shows the name of the application 005 Software version Shows the software version number major middle minor for example 1 2 0 006 Application CRC Cyclic Redun dancy Check Shows the check sum...

Page 105: ...ex page 002 SCREENSHOT button Makes a screenshot of the current screen 003 RCS CTRL ON button Gets control from the remote control system if button is active 004 Page button Opens the selected page X9...

Page 106: ...alve EWG opens a part of the exhaust gas bypasses the turbocharger 007 As a result the temperature of the exhaust gas increases which is supplied to the steam production 005 The supply of the turbocha...

Page 107: ...values 006 SPC EXT CONTROL button Changes to the external control of the SPC 007 MinEWGPos mode button Sets the minimum permitted EWG position Other SPC modes than the initial mode MinEWGPos are only...

Page 108: ...limitations Too wide EWG opening decreases the scavenge air pressure This will start the auxiliary blowers The limit of the EWG opening prevents the scavenge air pres sure to decrease below the switc...

Page 109: ...13 4 LDU screen for steam boost mode Fig 4 27 LDU for the steam boost mode X92 B AA00 9270 00AAA 043C A Operation Manual Steam production control system Winterthur Gas Diesel Ltd 109 Issue 002 2021 1...

Page 110: ...is running with correct power ranges for the steam boost mode The load range 8 indicates OK The steam boost mode is activated 1 a On the right side of LDU Screen turn the control key to the left to de...

Page 111: ...ing rod bearing 146 5 3 6 Crosshead and guide shoe 148 5 3 7 Piston 150 5 4 Group 4 Supply unit drive and control components 5 4 1 Supply unit drive 152 5 4 2 Starting air shut off valve 154 5 4 3 Con...

Page 112: ...der lubrication 188 5 7 2 Integrated electrical balancer iELBA 190 5 8 Group 8 Pipes 5 8 1 Exhaust waste gate 196 5 9 Group 9 Monitoring instruments 5 9 1 Crank angle sensor unit 198 5 9 2 Water in oi...

Page 113: ...X92 B Operation Manual Page left intentionally blank Winterthur Gas Diesel Ltd 113 Issue 002 2021 11...

Page 114: ...t The bottom part of the bedplate is the crankcase and collects lubricating oil This oil flows back to the oil supply system through oil drains 002 The length of the bedplate is related to the number...

Page 115: ...X92 B AA00 1115 00AAA 043A A Operation Manual Bedplate Page left intentionally blank Winterthur Gas Diesel Ltd 115 Issue 002 2021 11...

Page 116: ...nstall procedure The round nuts 002 keep the bearing cover 003 against the bearing girder For the main bearings adjacent to the thrust bearing the oil flows through the oil bore 013 to the running sur...

Page 117: ...X92 B AA00 1132 00AAA 043A A Operation Manual Main bearing Page left intentionally blank Winterthur Gas Diesel Ltd 117 Issue 002 2021 11...

Page 118: ...n the driving end adapt the propeller thrust of the astern direction The thrust pads adapt to the clockwise or counterclockwise rotation of the engine The arbor supports 004 prevent circular movement...

Page 119: ...pipe 010 2 part oil baffle 003 Nozzle 011 Flywheel 004 Arbor support 012 Bedplate 005 Bedplate 013 Thrust pad engine side 006 Thrust pad driving end 014 Thrust bearing flange 007 Bearing cover 015 Co...

Page 120: ...he fuel side FS the monoblock column has one door 002 per cylinder During normal operation the doors are closed and locked For maintenance or inspection work the doors can be opened Obey the safety ru...

Page 121: ...X92 B AA00 1406 00AAA 043A A Operation Manual Monoblock column Page left intentionally blank Winterthur Gas Diesel Ltd 121 Issue 002 2021 11...

Page 122: ...Tie rod generic 001 002 003 004 005 001 Legend 001 Protection cover 004 Tie rod 002 Cylinder block 005 Bedplate 003 Column If a tie rod breaks in the bottom area a special device makes sure that the...

Page 123: ...X92 B AA00 1903 00AAA 043A A Operation Manual Tie rod Page left intentionally blank Winterthur Gas Diesel Ltd 123 Issue 002 2021 11...

Page 124: ...contamination at the piston crown during operation Fig 5 6 Cylinder cooling water outlet generic Legend 001 Exhaust valve cage 003 Cooling water outlet 002 Cylinder cover Cooling water flows from the...

Page 125: ...X92 B AA00 2124 00AAA 043A A Operation Manual Cylinder liner Page left intentionally blank Winterthur Gas Diesel Ltd 125 Issue 002 2021 11...

Page 126: ...out of the nozzle tip 003 and the lubricating point 004 as a spray Some of the cylinder oil flows into the grooves of the cylinder liner wall The non return valve 009 prevents the exhaust gas to flow...

Page 127: ...X92 B AA00 2138 00AAA 043A A Operation Manual Lubricating quill Page left intentionally blank Winterthur Gas Diesel Ltd 127 Issue 002 2021 11...

Page 128: ...Neutral space 010 Gasket 4 part 005 Cylinder jacket 011 Tension spring 006 Support During operation the two scraper rings 001 Figure 5 8 remove dirty oil from the piston rod The dirty oil flows throug...

Page 129: ...X92 B AA00 2303 00AAA 043A A Operation Manual Piston rod gland Page left intentionally blank Winterthur Gas Diesel Ltd 129 Issue 002 2021 11...

Page 130: ...spray the fuel into the combustion chamber The ECS controls the pilot valve of the injection valves indirectly through the solenoid valve ECS also controls the timing and the quantity of the injected...

Page 131: ...X92 B AA00 2722 00AAA 043A A Operation Manual Direct controlled injection valve Page left intentionally blank Winterthur Gas Diesel Ltd 131 Issue 002 2021 11...

Page 132: ...closes at the correct crank angle of the related cylinder This makes the piston move down for engine start or makes the piston speed decrease for engine speed decrease As soon as combustion starts th...

Page 133: ...X92 B AA00 2728 00AAA 043A A Operation Manual Starting valve Page left intentionally blank Winterthur Gas Diesel Ltd 133 Issue 002 2021 11...

Page 134: ...ng piston 011 Air spring 005 Valve spindle 012 Leakage oil collection space 006 Valve cage 013 Hydraulic oil inlet 007 Valve seat 014 Damper The exhaust valve has the parts that follow Inside piston a...

Page 135: ...outer piston and inner piston 002 lubricates the air spring piston 004 Oil in the leakage oil collection space 012 drains to the leakage oil drain While the exhaust valve closes oil flows through the...

Page 136: ...ankshaft gear wheel 005 is part of the thrust bearing On the driving end of the crankshaft there is a flywheel 004 This flywheel decreases the pulsation from the cylinders The length of the crankshaft...

Page 137: ...X92 B AA00 3103 00AAA 043A A Operation Manual Crankshaft Page left intentionally blank Winterthur Gas Diesel Ltd 137 Issue 002 2021 11...

Page 138: ...ns in the shafting system and in other components of the engine If a torsional vibration damper is necessary for the engine one of the two damper types that follow can be used X92 B AA00 3130 00AAA 04...

Page 139: ...vibrations move the steel springs oil is pressurized on one side of the oil chambers and pushed through small clearances to the other side of the chambers This small oil flow creates the damping effec...

Page 140: ...t speeds This difference shears the silicone oil and thus decreases the vibration The damping work causes heat This heat increases the temperature of the outer side of the damper The heat dissipates t...

Page 141: ...X92 B AA00 3130 00AAA 043A A Operation Manual Torsional vibration damper Page left intentionally blank Winterthur Gas Diesel Ltd 141 Issue 002 2021 11...

Page 142: ...half 002 Figure 5 14 and a bottom cylinder half 006 Fig 5 14 Axial vibration damper generic Legend 001 Control plate 007 Bearing girder part of bedplate 002 Top cylinder half 008 Small sealing ring 00...

Page 143: ...ore in the top cylinder half 002 keeps air away from the annular spaces 003 The small oil leakage through the gap of the large sealing rings 005 drains into the crankcase 5 3 3 2 Axial vibration dampe...

Page 144: ...rns the pinion 002 and is attached on the driving end of the engine Related to the ratio of the gear wheels there is approximately one full turn of the crankshaft in ten minutes Fig 5 16 Turning gear...

Page 145: ...X92 B AA00 3206 00AAA 043A A Operation Manual Turning gear Page left intentionally blank Winterthur Gas Diesel Ltd 145 Issue 002 2021 11...

Page 146: ...oil flows through the guide shoe into the crosshead pin A hole in the crosshead pin lets lubricating oil flow into the bearing shells Fig 5 17 Connecting rod and connecting rod bearing generic Legend...

Page 147: ...X92 B AA00 3303 00AAA 043A A Operation Manual Connecting rod and connecting rod bearing Page left intentionally blank Winterthur Gas Diesel Ltd 147 Issue 002 2021 11...

Page 148: ...nto the crankcase The guide shoes 004 are attached to the crosshead pin 006 and move up and down on the guide ways of the column The guide rails 008 hold the guide shoes 004 and thus the crosshead in...

Page 149: ...X92 B AA00 3326 00AAA 043A A Operation Manual Crosshead and guide shoe Page left intentionally blank Winterthur Gas Diesel Ltd 149 Issue 002 2021 11...

Page 150: ...ied compression ratio System oil is used to keep cool the piston crown 001 This oil flows from the crosshead pin into the space 005 between the oil pipe 007 and the piston rod 004 The oil then flows t...

Page 151: ...X92 B AA00 3403 00AAA 043A A Operation Manual Piston Page left intentionally blank Winterthur Gas Diesel Ltd 151 Issue 002 2021 11...

Page 152: ...els 004 for the servo oil pumps The camshaft of the gear wheel 005 also operates the fuel pumps Oil flows through an oil inlet to lubricate the bearings of the gear wheels 004 Oil also flows through t...

Page 153: ...3 007 Legend 001 Intermediate wheel 005 Gear wheel servo oil pumps 002 Flywheel 006 Intermediate wheel 003 Crankshaft gear wheel 007 Crankshaft 004 Gear wheel servo oil pump X92 B AA00 4104 00AAA 043A...

Page 154: ...05 To test valve 014 Solenoid valve CV7014C 006 Spring 015 Double check valve 007 Valve 016 Solenoid valve CV7013C 008 Starting air inlet 017 Control air inlet 009 Balance bore 018 Lever With the leve...

Page 155: ...rom the inlet chamber 012 flows through the non return valve 010 to the starting air outlet 011 When the control valve 001 closes starting air flows through the balance bores 009 and fills the inlet c...

Page 156: ...by supply The non return valves 007 and 010 control the automatic change over of the compressed air supply Fig 5 22 Control air supply generic 003 004 005 006 007 008 009 010 011 012 001 002 Legend 00...

Page 157: ...X92 B AA00 4605 00AAA 043A A Operation Manual Control air supply Page left intentionally blank Winterthur Gas Diesel Ltd 157 Issue 002 2021 11...

Page 158: ...s can look different because the remote control manufacturer supplies the local control panel 001 For data about maneuvering instructions refer to section 8 8 Maneuver the ship general Fig 5 23 Local...

Page 159: ...er The ME tachometer 003 shows the engine speed in the ahead or astern directions Emergency stop button NOTE Not all local control panels have an emergency stop button installed When you operate the e...

Page 160: ...mity sensors measure the speed of the flywheel 003 Figure 5 24 When the flywheel turns the proximity sensors 002 sense the movement of the teeth The engine control system sends signals to the RCS to m...

Page 161: ...X92 B AA00 4628 00AAA 043A A Operation Manual Pick up for speed measurement Page left intentionally blank Winterthur Gas Diesel Ltd 161 Issue 002 2021 11...

Page 162: ...of the servo oil pumps A malfunction of a servo oil pump will show in the alarm and monitoring system If a servo oil pump cannot turn for safety the waisted shaft 003 will break This will prevent too...

Page 163: ...X92 B AA00 5551 00AAA 043A A Operation Manual Servo oil pump Page left intentionally blank Winterthur Gas Diesel Ltd 163 Issue 002 2021 11...

Page 164: ...gear wheels and intermediate wheels in the supply unit operate the fuel pumps and servo oil pumps refer to section 5 4 1 Supply unit drive Fig 5 26 Supply unit example Legend 001 Fuel pump 004 Bedpla...

Page 165: ...X92 B AA00 5552 00AAA 043A A Operation Manual Supply unit Page left intentionally blank Winterthur Gas Diesel Ltd 165 Issue 002 2021 11...

Page 166: ...ession spring 004 The pump plunger 003 then moves up The control grooves in the pump plunger 003 control the fuel quantity When the toothed rack 011 moves the teeth engage with the teeth on the regula...

Page 167: ...l lubricates the pump plunger 003 The leakage fuel and the engine lubricating oil from the regulating sleeve 010 flows through the drain bore This mixture then flows into an internal bore in the housi...

Page 168: ...ressure Prevent a longer engine operation time in this operation mode to prevent a possible damage to the PCV After this operation mode do a check of the PCV for a tight seal The seal can be damaged Y...

Page 169: ...001 Solenoid valve ZV7061S 005 Fuel return pipe 002 Pressure control valve 10 5562_E0_5 006 Rail unit 003 Relief valve 007 Fuel rail 004 Fuel return pipe 008 Drain pipe X92 B AA00 5562 00AAA 043A A O...

Page 170: ...the piston 003 moves back to the start position If the injection time is too long for example if an injection valve is stuck open the piston 003 closes the supply If an injection valve is damaged the...

Page 171: ...X92 B AA00 5565 00AAA 043A A Operation Manual Flow limiting valve Page left intentionally blank Winterthur Gas Diesel Ltd 171 Issue 002 2021 11...

Page 172: ...erates servo oil is released to the slide rod 001 Figure 5 31 This releases servo oil to the piston 003 Thus servo oil from the servo oil outlet 004 opens the exhaust valve Fig 5 31 Exhaust valve cont...

Page 173: ...X92 B AA00 5612 00AAA 043A A Operation Manual Exhaust valve control unit Page left intentionally blank Winterthur Gas Diesel Ltd 173 Issue 002 2021 11...

Page 174: ...two fuels pumps are connected to there related actuator The ECS controls the fuel pump actuators During operation the fuel pump actuators move at the same time Each fuel pump actuator has an overload...

Page 175: ...X92 B AA00 5583 00AAA 043A A Operation Manual Fuel pump actuator Page left intentionally blank Winterthur Gas Diesel Ltd 175 Issue 002 2021 11...

Page 176: ...data about the scavenge air system refer to section 4 8 Scavenge air system Fig 5 32 Scavenge air receiver example 001 002 003 004 005 Legend 001 Scavenge air from turbocharger 004 Auxiliary blower 0...

Page 177: ...example 001 002 005 004 003 Legend 001 Air space 004 Outlet to piston underside 002 Longitudinal wall 005 Flap 003 Receiver space X92 B AA00 6420 00AAA 043A A Operation Manual Scavenge air receiver Wi...

Page 178: ...f a turbocharger becomes defective you must stop the engine as quickly as possible to prevent damage If repair or replacement of a turbocharger is not immediately possible you can cut out the defectiv...

Page 179: ...X92 B AA00 6500 00AAA 043A A Operation Manual Turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 179 Issue 002 2021 11...

Page 180: ...ir inlet 004 Electric motor During the engine start operation the auxiliary blowers start one by one at two or three seconds interval to avoid electric overload Minimum one auxiliary blower is necessa...

Page 181: ...X92 B AA00 6545 00AAA 043A A Operation Manual Auxiliary blower Page left intentionally blank Winterthur Gas Diesel Ltd 181 Issue 002 2021 11...

Page 182: ...stop the auxiliary blowers manually In Off mode the auxiliary blowers are switch off Fig 5 36 Switch box 001 002 003 004 005 006 007 008 009 010 011 012 013 014 Legend 001 Indicator auxiliary blower...

Page 183: ...X92 B AA00 6547 00AAA 043A A Operation Manual Auxiliary blower switch box Page left intentionally blank Winterthur Gas Diesel Ltd 183 Issue 002 2021 11...

Page 184: ...SAC has a cover 004 Figure 5 37 For maintenance you can remove the cover Fig 5 37 Scavenge air cooler generic 001 002 003 004 Legend 001 Air flow 003 Cooling water inlet 002 Cooling water outlet 004...

Page 185: ...X92 B AA00 6606 00AAA 043A A Operation Manual Scavenge air cooler Page left intentionally blank Winterthur Gas Diesel Ltd 185 Issue 002 2021 11...

Page 186: ...f wet air Water also occurs during the wash procedure of the SAC The profiles 002 Figure 5 38 hold back the water in the air flow This water collects at the bottom of the frame 003 and then flows back...

Page 187: ...X92 B AA00 6708 00AAA 043A A Operation Manual Water separator Page left intentionally blank Winterthur Gas Diesel Ltd 187 Issue 002 2021 11...

Page 188: ...t the cylinder lubrication oil refer to section 12 1 General for operating media For information about the cylinder oil system in general refer to section 4 6 Cylinder oil system X92 B AA00 7218 00AAA...

Page 189: ...X92 B AA00 7218 00AAA 043A A Operation Manual Cylinder lubrication Page left intentionally blank Winterthur Gas Diesel Ltd 189 Issue 002 2021 11...

Page 190: ...he forces F are always canceled The vertical elements Fvert are always added to a resulting vertical force This resulting force operates up and down with the same frequency as the counterweights 002 t...

Page 191: ...function Legend 001 Gear wheel 004 Housing 002 Counterweight 005 Column 003 Bearing X92 B AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas Diesel Ltd 191 Iss...

Page 192: ...eavy sea mode the iELBA does not operate The engine can also operate if one or the two balancers do not operate eg in manual mode or if a balancer is defective Then it is possible that there are more...

Page 193: ...1 shows the buttons and indications on the control cabinet of the iELBA Fig 5 41 iELBA control cabinet X92 B AA00 7752 00AAA 043A A Operation Manual Integrated electrical balancer iELBA Winterthur Gas...

Page 194: ...Shows the state of the running iELBA Lamp blinks iELBA is in swing state Lamp is steady iELBA is in run state H4 Synch OK indicator light Shows the synchronisation state of the iELBA Lamp is steady iE...

Page 195: ...st to Control Speed Threshold not OK OFF 2 Start OK Setpoint Speed not OK in 60 s OFF 3 Start OK speed OK Phase Synchronisation not OK in 60 s OFF 4 Overspeed error OFF 5 Electric motor error OFF 6 Th...

Page 196: ...001 002 003 004 005 006 007 008 Legend 001 Air inlet 005 Exhaust gas manifold 002 Compressor 006 Turbine 003 Scavenge air receiver 007 Valve 004 Engine 008 Exhaust gas outlet If the turbochargers del...

Page 197: ...X92 B AA00 8135 00AAA 043A A Operation Manual Exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 197 Issue 002 2021 11...

Page 198: ...teeth on the intermediate wheel The two sets of proximity sensors 003 Figure 5 43 operate independently to sense the teeth on the intermediate wheel 002 Fig 5 43 Crank angle sensor unit on intermediat...

Page 199: ...ollows First sensor pair to MCM 20 and CCM 20 1 Second sensor pair from CCM 20 2 to CCM 20 n TDC and BDC to all CCM 20 Fig 5 44 Crank angle sensor unit on flywheel example Legend 001 Cover 003 Flywhee...

Page 200: ...l to the alarm and monitoring system AMS On the display 001 Figure 5 45 you can see the data that follow aw water activity T temperature in C H2O water content in ppm Fig 5 45 Water in oil monitor gen...

Page 201: ...X92 B AA00 9313 00AAA 043A A Operation Manual Water in oil monitor Page left intentionally blank Winterthur Gas Diesel Ltd 201 Issue 002 2021 11...

Page 202: ...and explosions in the crankcase can be prevented The system includes the sensors 002 Figure 5 46 and the control unit 003 on the engine Fig 5 46 Oil mist detector example 004 003 001 002 Legend 001 D...

Page 203: ...adjustments can be programmed in the display unit 001 The menu driven software has three user levels User Read only of data Operator Password protected level for access to most adjustments and functio...

Page 204: ...X92 B AA00 9314 00AAA 043A A Operation Manual Oil mist detector Page left intentionally blank Winterthur Gas Diesel Ltd 204 Issue 002 2021 11...

Page 205: ...optional 220 6 6 Manual Control Panel MCP Option for WiCE 6 6 1 Operate the manual control panel MCP 222 6 6 2 MCP page MAIN 226 6 6 3 MCP page Adjust user parameters 228 6 6 4 MCP page SYSTEM INFO O...

Page 206: ...ol and common engine functions for example starting air shut off valve Gateway unit GTU 1 and 2 The gateway units GTU 1 and 2 are installed on the rail unit in the terminal box E90 The GTU transmits d...

Page 207: ...l pressure control Exhaust valve control Cylinder lubricating control Engine speed and crank angle sensor monitoring Diesel fuel pressure control Diesel fuel injection control For a DF engine also gas...

Page 208: ...documentation from the approved propulsion control system manufacturer 6 1 3 1 Propulsion control system The propulsion control system PCS has the subsystems that follow Remote control system The rem...

Page 209: ...nd satisfactory engine operation The functions of the AMS are specified in the diesel engine control and optimizing specification DENIS The AMS sends signals to the engine safety system to slow down o...

Page 210: ...d exhaust valve closing time for each cylinder This decreases the excessive wear of engine components This decreases the risk of an engine overload This prevents manual adjustment failures In the ECS...

Page 211: ...of ignition pI is smaller than the compression pressure at TDC pC The pressure increase is the difference between the maximum firing pressure pF and the pressure at start of ignition pI The ICC system...

Page 212: ...he sensors and then transmits these signals to a controller The measured value is adjusted to the correct setpoint value and is related to the engine load This real time site correction and comparison...

Page 213: ...X92 B AA00 9308 00AAA 043A A Operation Manual Intelligent combustion control Page left intentionally blank Winterthur Gas Diesel Ltd 213 Issue 002 2021 11...

Page 214: ...re and pressure of the gas Fig 6 3 iGPR schematic diagram In the chapters that follow you find a short description of the automatic control functions for the iGPR control system 6 3 1 Transfer to gas...

Page 215: ...tion and stabilisation Activates the pressure stabilisation OK signal from iGPR to PCS and ECS Deactivates the pressure stabilisation active signal from iGPR to PCS and ECS Activates the transfer prep...

Page 216: ...utomatic inerting A gas trip with automatic inerting is necessary in the conditions that follow Emergency gas trip switches are active Gas trip from gas detection system is active Incorrect gas inlet...

Page 217: ...es the inerting failed signal from iGPR to PCS 6 3 6 Engine maintenance If you have to do maintenance on the engine or on the iGPR or on the supply line you have to start the related maintenance mode...

Page 218: ...SELECT 00209 001 009 008 008 008 008 008 008 007 006 002 003 005 004 Legend 001 Power LED 006 CHECK button used to accept the action or enter data 002 Status LED 007 HOME button push to show the main...

Page 219: ...n orange arrow 001 shows the active item A 3D rectangle 002 indicates a command button An orange frame 003 indicates the edit mode A black dotted frame 004 around an item shows the position of the cur...

Page 220: ...ge iELBA Control optional Fig 6 6 iELBA Control 002 001 004 003 005 006 007 008 009 X92 B AA00 9606 42AAA 043B A Operation Manual LDU 20 page iELBA Control optional Winterthur Gas Diesel Ltd 220 Issue...

Page 221: ...Auto Mode Changes between automatic and manual control mode of the iELBA 007 Free End ON OFF In manual mode starts and stops the iELBA on the related en gine end 008 Operator Phase Setpoint In manual...

Page 222: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None S...

Page 223: ...e LED indication comes on NOTE You only can start one function at the same time also when you touch two or more function buttons 3 To change the control location do the steps that follow 3 1 Shortly t...

Page 224: ...speed command setting turn the fuel dial knob clockwise 5 2 To decrease the speed command setting turn the fuel dial knob counterclockwise CLOSE UP None X92 B AA00 4618 00AAC 131A A Operation Manual O...

Page 225: ...X92 B AA00 4618 00AAC 131A A Operation Manual Operate the manual control panel MCP Page left intentionally blank Winterthur Gas Diesel Ltd 225 Issue 002 2021 11...

Page 226: ...6 6 2 MCP page MAIN Fig 6 8 MCP page MAIN 001 002 003 005 004 X92 B AA00 4618 01AAA 043B A Operation Manual MCP page MAIN Winterthur Gas Diesel Ltd 226 Issue 002 2021 11...

Page 227: ...e Shows the fuel mode Shows Diesel Transfer Gas Gas DCC Active Fuel Sharing Diesel Manual 003 Gas System Shows data for the gas system Shows Available Int Gas Trip Ext Gas Trip Transfer Prep Operation...

Page 228: ...igation fields INFO TRENDING USER PARAMETERS 002 Sub navigation field USER PARAMETERS Opens the user parameter options VIT FQS deg Heavy Sea Mode Compressor Balancing Firing Balancing Firing Control F...

Page 229: ...parameter Item Name Effect when touched 001 User parameter Makes the related user parameter ad justable X92 B AA00 4618 05AAA 043B A Operation Manual MCP page Adjust user parameters Winterthur Gas Die...

Page 230: ...n adjustable 002 User parameter regulators Two possible effects Increase or decrease user pa rameter value or Set user parameter value to on off 003 Enter field Makes the related adjustable user pa ra...

Page 231: ...X92 B AA00 4618 05AAA 043B A Operation Manual MCP page Adjust user parameters Page left intentionally blank Winterthur Gas Diesel Ltd 231 Issue 002 2021 11...

Page 232: ...Effect 001 Engine Shows data for the engine 002 Engine Software Shows data for the engine software 003 NOx Compliance Shows data for the IMO CRC compliance NOTE CRC Cyclic Redundancy Check X92 B AA00...

Page 233: ...X92 B AA00 4618 03AAA 043B A Operation Manual MCP page SYSTEM INFO Option for WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 233 Issue 002 2021 11...

Page 234: ...6 4 TREND Item Function Effect 001 Selection field Highlights the selected parameters 002 Diagram field Shows the trend of the selected parameters X92 B AA00 4618 04AAA 043B A Operation Manual MCP pa...

Page 235: ...X92 B AA00 4618 04AAA 043B A Operation Manual MCP page TREND Option for WiCE Page left intentionally blank Winterthur Gas Diesel Ltd 235 Issue 002 2021 11...

Page 236: ...hows the values of the displayed instruments NOTE The number of the displayed instruments is related to the engine NOTE If an instrument is unservicable the background of the related instrument change...

Page 237: ...X92 B AA00 4618 02AAA 043B A Operation Manual MCP page INSTRUMENTS Page left intentionally blank Winterthur Gas Diesel Ltd 237 Issue 002 2021 11...

Page 238: ...ATION SYSTEM Fig 6 15 MCP page FUEL LUBRICATION SYSTEM 001 008 011 010 009 007 002 003 004 005 006 X92 B AA00 4618 08AAA 043B A Operation Manual MCP page FUEL LUBRICATION SYSTEM Winterthur Gas Diesel...

Page 239: ...r buttons Manually select the cylinder for manual lubrication Set 1 to n for the related cylinder Set 0 zero for all cylinders 008 Manual Lub Pulses buttons Manually set the number of injections for l...

Page 240: ...X92 B AA00 4618 08AAA 043B A Operation Manual MCP page FUEL LUBRICATION SYSTEM Page left intentionally blank Winterthur Gas Diesel Ltd 240 Issue 002 2021 11...

Page 241: ...7 Installation 7 1 Installation 242 X92 B Operation Manual Winterthur Gas Diesel Ltd 241 Issue 002 2021 11...

Page 242: ...es Outline views Platform arrangement Engine seating Engine coupling Propulsion shaft earthing Engine stays Extinguishing system Auxiliary systems NOTE The latest version of the Marine Installation Ma...

Page 243: ...the ship 270 8 10 Change over the diesel fuel general 272 8 11 Change over the diesel fuel automatically 276 8 12 Change over from HFO to MDO manually 278 8 13 Change over from MDO to HFO manually 280...

Page 244: ...il system Make sure that the quality of the system oil obeys the related specifications Make sure that main lubricating oil is available at the engine connection 25 main lubricating oil inlet Make sur...

Page 245: ...ure that the quality of the gas obeys the related specifications in section section not applicable for this engine Make sure that gas is available at the engine connection 78 gas supply inlet Pilot fu...

Page 246: ...ion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No C...

Page 247: ...tem ECS and the remote control system RCS 2 2 Set to ON all circuit breakers in the power supply box E85 2 3 Set to ON the control box for the cylinder oil filter refer to the documentation of the man...

Page 248: ...valves 003 in the cylinder liner supply pipes of the first half of cylinders for example cylinder 1 to 3 for a 5 or 6 cylinder engine NOTE This increases again the pressure and thus the flow rate to t...

Page 249: ...Close the shut off valves 001 in the cylinder liner supply pipes of the first half of cylinders for example cylinder 1 to 3 for a 5 or 6 cylinder engine NOTE This increases the pressure and thus the...

Page 250: ...he other cylinder liners for approximately ten minutes 3 3 3 Open the shut off valves 003 in the cylinder liner supply pipes of the first half of cylinders 3 3 4 Do Step 3 3 1 to Step 3 3 3 again for...

Page 251: ...ure in the oil supply pipes Pressure before the torsional vibration damper if applicable Pressure in the servo oil rail only pressure of servo oil service pump Pressure in the distributor pipe mini ra...

Page 252: ...the engine has been stopped for more than approximately five days start a manual pre lubrication procedure NOTE This makes sure that the cylinders get sufficient lubrication before start up 13 Turn t...

Page 253: ...X92 B AA00 0000 00AAA 121A A Operation Manual Prepare the engine before start Page left intentionally blank Winterthur Gas Diesel Ltd 253 Issue 002 2021 11...

Page 254: ...on You can find data about the barred speed ranges near the telegraph on the bridge near the local control panel and in the related documentation of vibration calculations 8 3 2 Start conditions limit...

Page 255: ...etween 10 as a minimum to approximately 15 related to the power of the auxiliary blowers 8 3 2 2 One or more cylinders are unservicable Obey the rules for operation if one or more cylinders are unserv...

Page 256: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description P...

Page 257: ...el to 30 5 Push the button START AHD or START AST to start the engine NOTE The ECS starts an automatic pre lubrication sequence with a specified number of pulses NOTE The ECS increases the engine spee...

Page 258: ...erences in the values find the causes and repair the faults Do not open the covers of the rail unit during engine operation NOTE For data about regular maintenance work refer to the Maintenance Manual...

Page 259: ...X92 B AA00 0000 00AAA 130B A Operation Manual Do checks during operation general Page left intentionally blank Winterthur Gas Diesel Ltd 259 Issue 002 2021 11...

Page 260: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts De...

Page 261: ...ontrol air Pressure difference of the oil filter For a DF engine also pressure of gas 8 If there are unusual operating values find the cause and repair the fault 9 Do regular checks of pipes for leaks...

Page 262: ...replace the related pressure transmitter refer to the Maintenance Manual 13 4 Do daily a check of the cylinder liner wall temperatures on the related control panel 13 5 If there is a drift that is to...

Page 263: ...X92 B AA00 0000 00AAA 131B A Operation Manual Do checks during operation Page left intentionally blank Winterthur Gas Diesel Ltd 263 Issue 002 2021 11...

Page 264: ...50 1 Smoke test instrument N A 1 Ampere meter N A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Equipment Hazard Leaks can cause faults in the...

Page 265: ...s 3 5 Decrease the pressure to less than the SHD pressure 3 6 Make sure that the pressure switch closes at the related pressure 3 7 If the pressure switch does not close find the cause and repair the...

Page 266: ...a check of the wiring to the starter box 7 9 Stop the auxiliary blowers 7 10 On the IOM 10 connect terminal X11 7 11 Get control at the local control panel 7 12 Do Step 7 1 to Step 7 10 again from th...

Page 267: ...id valves CV7013C and CV7014C 8 11 Disengage the turning gear NOTE On each control panel the indication changes to Turning Gear Disengaged The start command is canceled in the remote control 9 If ther...

Page 268: ...ction Load changes must be done slowly to let the piston rings adapt the new conditions This also prevents increased wear and contamination of the piston rings and the cylinder liners The total time t...

Page 269: ...gine If there are unusual indications you must decrease the load power The load indication fuel injection quantity and the exhaust gas temperature upstream of the turbocharger show the engine load The...

Page 270: ...quirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare...

Page 271: ...er the ship general 3 To operate the engine in the opposite direction do the steps that follow 3 1 Use the rotary button to select the fuel command button 3 2 Turn the rotary button to set the fuel in...

Page 272: ...ample fuel pump plungers The safety functions decrease the risk of damage because of thermal loads You can do the change over procedure at a load of up to 100 CMCR The time period for automatic change...

Page 273: ...as no iCAT system integrated Cylinder lubricant Auto Transfer system WinGD recommends to monitor the change over of the cylinder oil Do a calculation of the cylinder lubricant quantity and make sure t...

Page 274: ...ensity of the cylinder lubricant can be found in the technical data sheet If not available an average value of 920 3 is suitable for this purpose Lead time until new lubricant is in use 1000 00595 X92...

Page 275: ...X92 B AA00 0000 00AAA 130D A Operation Manual Change over the diesel fuel general Page left intentionally blank Winterthur Gas Diesel Ltd 275 Issue 002 2021 11...

Page 276: ...lization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINAR...

Page 277: ...omatic change over procedure refer to the instructions of the manufacturer CLOSE UP None X92 B AA00 0000 00AAA 131E A Operation Manual Change over the diesel fuel automatically Winterthur Gas Diesel L...

Page 278: ...zation QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY...

Page 279: ...the procedure Try to decrease the temperature as linearly as possible 9 When the temperature of the fuel is near the applicable value you can start the cooler slowly to give a linear and smooth temper...

Page 280: ...zation QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY...

Page 281: ...ple the larger the mixing tank the less decrease in load is necessary 8 Set the viscosimeter to 13 cSt to increase the temperature of the fuel NOTE The viscosimeter controls the end heater which keeps...

Page 282: ...burns NOTE If the crankshaft cannot turn 360 the ECS sends a signal for an exhaust ventilation request The ESS or ECS sends a cancelable shutdown signal The engine safety system ESS or the ECS sends...

Page 283: ...X92 B AA00 0000 00AAA 130G A Operation Manual Stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 283 Issue 002 2021 11...

Page 284: ...completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description P...

Page 285: ...rol panel push the STOP button NOTE The ECS shuts down the engine in a controlled manner 4 For a DF engine start the exhaust ventilation sequence if there is a ventilation request CLOSE UP None X92 B...

Page 286: ...neral To stop the engine in an emergency do the procedure given in section 8 17 Emergency stop the engine X92 B AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Winterthur Gas...

Page 287: ...X92 B AA00 0000 00AAA 140A A Operation Manual Emergency stop the engine general Page left intentionally blank Winterthur Gas Diesel Ltd 287 Issue 002 2021 11...

Page 288: ...letion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part N...

Page 289: ...r an emergency stop you must reset the EMERGENCY STOP button CAUTION Damage Hazard Do this step only as a last alternative selection if the EMERGENCY STOP button is not working Damage to the engine ca...

Page 290: ...od after an engine stop of one week or less usually you keep the auxiliary systems in operation refer to section section not applicable for this engine For a long period after an engine stop of more t...

Page 291: ...X92 B AA00 0000 00AAA 150A A Operation Manual Prepare the engine after stop general Page left intentionally blank Winterthur Gas Diesel Ltd 291 Issue 002 2021 11...

Page 292: ...ours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None S...

Page 293: ...lubricating oil supply to the engine as follows 6 1 Stop the oil supply systems from the plant 6 2 Close the shut off valves to the engine at engine connection 33 cylinder oil inlet 6 3 Set to OFF the...

Page 294: ...are in degassing state 8 2 2 On the iGPR cabinet switch the button S8 to maintenance to activate the maintenance mode 8 2 3 On the LDU 20 iGPR page make sure that all conditions are satisfactory 8 2 4...

Page 295: ...sary apply anti corrosion oil to give protection 11 5 Close the covers 12 Do a check of the supply unit as follows 12 1 Make sure that there is no condensation or corrosion 12 2 If you find condensati...

Page 296: ...X92 B AA00 0000 00AAA 151B A Operation Manual Prepare the engine for standstill or for maintenance Page left intentionally blank Winterthur Gas Diesel Ltd 296 Issue 002 2021 11...

Page 297: ...cylinder oil 300 9 3 Replace the filter element of the duplex filter 304 9 4 Clean the turbocharger during operation 306 9 5 Clean the scavenge air cooler during operation 308 9 6 Do a test of the ex...

Page 298: ...one Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard The system oil is hot Put on gloves and safety goggles to prevent...

Page 299: ...l the sample bottle NOTE The necessary quantity of oil is as follows 100 ml for regular oil analysis 5 l for FZG and particle count analysis 2 3 Close the sample valve 2 4 Close the sample bottle tigh...

Page 300: ...ialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Sample bottles A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTIO...

Page 301: ...valve 001 to flush out oil and possible dirt 2 4 Close the oil sample valve 001 2 5 Open the ball valve 002 to drain the remaining oil from the dirty oil pipe 003 2 6 Close the ball valve 002 3 Get a...

Page 302: ...om 8 Send the oil samples to a laboratory for an oil analysis 8 1 Make sure that the sample bottles are tightly closed 8 2 Put the sample bottles in an applicable package 9 Compare the oil analysis fr...

Page 303: ...X92 B AA00 0000 00AAA 371A A Operation Manual Do an analysis of the cylinder oil Page left intentionally blank Winterthur Gas Diesel Ltd 303 Issue 002 2021 11...

Page 304: ...er job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Pa...

Page 305: ...lean the filter chamber 6 Clean the filter element or take a new filter element 7 Install the new filter element into the filter chamber 8 Install the cover on the filter chamber 9 Make sure that the...

Page 306: ...termediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Damage Hazard For an...

Page 307: ...turbocharger refer to the documentation of the manufacturer 3 Clean the turbine of the turbocharger refer to the documentation of the manufacturer CLOSE UP None X92 B AA00 6500 00AAA 200A A Operation...

Page 308: ...s after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY None Supplies Description QTY Cleaning fluid A R...

Page 309: ...Aux Blower 13 LS 4075A LS 4071A PI 1361L TI 1371L TI 1381L PT 1361A TE 1371A TE 1381A Washing Plant SAC PLANT ENGINE PLANT ENGINE 003 00520 004 005 006 007 008 009 001 002 X92 B AA00 6600 00AAA 200A...

Page 310: ...re that the shut off valve in the supply pipe stays closed 3 3 Close the shut off valve 009 in the water supply pipe 3 4 Close the vent valve 002 and the valve 007 of the tank 006 4 Open the shut off...

Page 311: ...X92 B AA00 6600 00AAA 200A A Operation Manual Clean the scavenge air cooler during operation Page left intentionally blank Winterthur Gas Diesel Ltd 311 Issue 002 2021 11...

Page 312: ...crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS None PRELIMINARY OPERATIONS This procedur...

Page 313: ...e sure that the exhaust waste gate is open 3 Close the exhaust waste valve 4 If the check is incorrect find the cause and repair the fault CLOSE UP None X92 B AA00 8135 00AAA 320A A Operation Manual D...

Page 314: ...X92 B AA00 8135 00AAA 320A A Operation Manual Do a test of the exhaust waste valve Page left intentionally blank Winterthur Gas Diesel Ltd 314 Issue 002 2021 11...

Page 315: ...libration for Dynex pump 364 10 13 Servo oil pump Calibration for Bosch pump 366 10 14 Servo oil pump Calibration for Hawe pump 368 10 15 Fuel pump cutting out 370 10 16 Fuel pump cutting in 376 10 17...

Page 316: ...repair malfunctions on the engine The tables give the data that follow Title of the table The title of the table gives the description of the malfunction Indication This list specifies the number of...

Page 317: ...X92 B AA00 0000 00AAA 410B A Operation Manual Troubleshooting general data Page left intentionally blank Winterthur Gas Diesel Ltd 317 Issue 002 2021 11...

Page 318: ...flow at a servo oil pump inlet is too low Table 10 14 Bearing oil temperature at a bearing outlet is too high Table 10 15 Oil mist concentration is too high Table 10 16 Piston cooling oil temperature...

Page 319: ...ble 10 43 Scavenge air temperature in the receiver is too high Table 10 44 Scavenge air temperature in the receiver is too low Table 10 45 Scavenge air pressure is too high Table 10 46 Scavenge air pr...

Page 320: ...e 10 61 Unwanted engine speed decrease Table 10 62 Unwanted engine stop X92 B AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Winterthur Gas Diesel Ltd 320 Issue 002 202...

Page 321: ...rature downstream of a cylinder is too high Indication Possible cause Procedure TE1121 nnA This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low Do...

Page 322: ...too high Indication Possible cause Procedure TE1381 nnA This is a result of the malfunction in Table 10 4 Supply pressure of the cooling water to the SAC is too low Do the repair shown there This is...

Page 323: ...ion Possible cause Procedure TE2011A TE2012A if applica ble The oil supply system is defective Find the cause and repair the fault Tab 10 10 Lubricating oil supply pressure upstream of the crossheads...

Page 324: ...nnA TE2201 nnA TE2301 nnA This is a result of the malfunction in Table 10 7 Lubricating oil supply pressure at the engine inlet is too low Do the repair shown there A bearing is defective Find the cau...

Page 325: ...oil temperature at a turbocharger outlet is too high Indication Possible cause Procedure TE2601 nnA This is a result of the malfunction in Table 10 9 Lubricating oil supply temperature at the engine i...

Page 326: ...ent is clogged Change over to the other filter chamber Replace or clean the clogged filter element The cylinder oil tank is empty Fill the cylinder oil tank Tab 10 24 Cylinder oil flow is too low Indi...

Page 327: ...ible cause Procedure TE3431 nnA Flow control valve of a fuel pump is defective Clean or replace the defective flow control valve One of the two fuel pumps is de fective Replace the defective fuel pump...

Page 328: ...related fuel pump Flow control valve of a fuel pump is defective Clean or replace the defective flow control valve Tab 10 33 Fuel pressure in the fuel rail is too low for X35 B or X40 B engine Indica...

Page 329: ...ication Possible cause Procedure PS3464A The pilot fuel filter is clogged Replace the filter element Tab 10 36 Gas supply pressure is too low Indication Possible cause Procedure PT3901C The gas supply...

Page 330: ...example cracks in a cylinder liner Find the cause and repair the fault There is a fire in the piston under side Do the procedure in section 2 3 Fire fighting in the scavenge air space Tab 10 38 Exhaus...

Page 331: ...ng air pressure is too low Find the cause and repair the fault The opening oil pressure is too low Find the cause and repair the fault An exhaust valve is defective pis ton cannot move or a piston is...

Page 332: ...malfunction in Table 10 5 Supply temperature of the cooling water to the SAC is too low Do the repair shown there Tab 10 45 Scavenge air pressure is too high Indication Possible cause Procedure PT404...

Page 333: ...fire in the piston underside Refer to section 2 3 Fire fighting in the scav enge air space A piston ring is defective As a temporary procedure decrease the load and cut out the injection of the relate...

Page 334: ...air supply system is de fective Find the cause and repair the fault There is an incorrect setting of the control air supply Set the control air supply to the correct val ue Tab 10 55 Control air suppl...

Page 335: ...tive injection nozzle This is a result of the malfunction in Table 10 1 Supply pressure of the cylinder cooling water is too low or in Table 10 3 Cylinder cooling wa ter temperature downstream of a cy...

Page 336: ...ection quantity from the speed control system is decreased A procedure is not necessary because the control system prevents too much load in heavy sea The fuel injection system is defec tive Find the...

Page 337: ...X92 B AA00 0000 00AAA 410C A Operation Manual Malfunctions of systems and components Page left intentionally blank Winterthur Gas Diesel Ltd 337 Issue 002 2021 11...

Page 338: ...cause one cylinder to cut off The AMS sends a slowdown signal to the ECS The SHD sub group contains failures that prevent an engine operation The engine safety system ESS sends a shutdown signal to t...

Page 339: ...ailures If there is an indication of a UNIC flex failure use the data that follows to find the failure and to repair it Use the failure ID to find the related system or item If applicable compare the...

Page 340: ...the requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare...

Page 341: ...003 Screw plug 002 Flange 4 Do Step 3 again for the other inspection points NOTE Step 5 to Step 8 are only applicable for an X82 engine 5 Do a check of the level switch LS2076A if applicable also LS2...

Page 342: ...mum of two turns 8 2 Do a check for oil flow 8 3 If there is an oil flow shut off the related connecting pipe an repair it at the next occasion refer to the Maintenance Manual 8 4 Tighten the screw pl...

Page 343: ...X92 B AA00 0000 00AAA 311A A Operation Manual Examine the supply unit for servo oil leakage Page left intentionally blank Winterthur Gas Diesel Ltd 343 Issue 002 2021 11...

Page 344: ...ngine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on...

Page 345: ...005 at the highest inspection point 004 for leaks 4 1 Carefully loosen the screw plug a maximum of two turns 4 2 Do a check for fuel flow 4 3 If there is fuel flow repair the cause of the fuel flow a...

Page 346: ...fuel pump refer to the Maintenance Manual 5556 1 NOTE If the defective HP fuel pipe cannot be replaced immediately or the engine must continue to operate the related fuel pump must be cut out CLOSE U...

Page 347: ...X92 B AA00 0000 00AAA 311B A Operation Manual Examine the supply unit for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 347 Issue 002 2021 11...

Page 348: ...alization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard...

Page 349: ...2 Carefully look into the rail unit to find the cause of the leakage NOTE Possible causes can be a defective pipe to the exhaust valve a defective flange or an other defective item 3 Repair the defec...

Page 350: ...ngine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS CAUTION Injury Hazard Always put on...

Page 351: ...3 1 Make sure that the screws 002 are tightened correctly refer to the Maintenance Manual 8733 1 3 2 On the fuel leakage pipe 004 carefully loosen the screw in union 003 a maximum of two turns 3 3 Do...

Page 352: ...nion 007 a maximum of two turns 4 3 Do a check of the fuel flow 4 4 If fuel flows from the screw in union 007 more than usual compared to the amount of leakage from the other FLV the piston rod is def...

Page 353: ...X92 B AA00 0000 00AAA 311C A Operation Manual Examine the FLV or fuel pipes for fuel leakage Page left intentionally blank Winterthur Gas Diesel Ltd 353 Issue 002 2021 11...

Page 354: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 355: ...tion from the injection control unit ICU 4 If it is necessary to operate the engine with the injection cut out for an extended period do as follows 4 1 Record the settings of the cylinder oil feed rat...

Page 356: ...nel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS...

Page 357: ...the related exhaust valve control unit VCU 3 Repair the fault as soon as possible refer to the Maintenance Manual CLOSE UP The engine can be started and operated at decreased load refer to section 8...

Page 358: ...ption Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY Pressure element 94259 A R Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY...

Page 359: ...the pressure element 003 Fig 10 4 Exhaust valve with pressure element 001 002 003 004 Legend 001 Top housing 003 Pressure element 002 Damper 004 Shim 4 Cut out the defective cylinder from the injecti...

Page 360: ...ted and operated at decreased load refer to section 8 3 Start the engine general X92 B AA00 0000 00AAA 662B A Operation Manual Temporary isolate a cylinder with cooling water leakage Winterthur Gas Di...

Page 361: ...X92 B AA00 0000 00AAA 662B A Operation Manual Temporary isolate a cylinder with cooling water leakage Page left intentionally blank Winterthur Gas Diesel Ltd 361 Issue 002 2021 11...

Page 362: ...ervo oil pump operation 10 11 2 Servo oil pump operation check To check for the servo oil pump operation refer to the following instructions 1 Engine must be at low load 2 Remove the solenoid connecto...

Page 363: ...X92 B AA00 5551 00AAA 410A A Operation Manual Servo oil pump troubleshooting Page left intentionally blank Winterthur Gas Diesel Ltd 363 Issue 002 2021 11...

Page 364: ...ew 4 Loosen the locknut 5 Turn the setting screw 22 5 degrees 6 Tighten the locknut 7 Monitor if there is a change in flow alarm indication for 10 minutes NOTE If the flow alarm indication remains rep...

Page 365: ...X92 B AA00 5551 00AAA 273A A Operation Manual Servo oil pump Calibration for Dynex pump Page left intentionally blank Winterthur Gas Diesel Ltd 365 Issue 002 2021 11...

Page 366: ...t 7 Monitor the condition for 5 minutes on the pump angle indicators NOTE If the pump angle indicators show different angles an adjustment of the pump angles is required 8 Put the plastic cover on the...

Page 367: ...X92 B AA00 5551 00AAB 273A A Operation Manual Servo oil pump Calibration for Bosch pump Page left intentionally blank Winterthur Gas Diesel Ltd 367 Issue 002 2021 11...

Page 368: ...degrees 5 Tighten the locknut 6 Monitor the condition for 5 minutes on the pump angle indicators NOTE If the pump angle indicators show different angles an adjustment of the pump angles is required 7...

Page 369: ...X92 B AA00 5551 00AAC 273A A Operation Manual Servo oil pump Calibration for Hawe pump Page left intentionally blank Winterthur Gas Diesel Ltd 369 Issue 002 2021 11...

Page 370: ...escription QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury hazard The cutting out procedure can only be done when the engine is stop WARNING Injury hazard Befor...

Page 371: ...tation in available engine power based on engine configuration and rating Power can be increased to that when the fuel rail pressure starts to drop PRELIMINARY OPERATIONS The engine must be stopped an...

Page 372: ...DURE Fig 10 5 Location of flanges 1 Release the pressure of the fuel supply unit to 0 bar X92 B AA00 5556 00AAB 510B A Operation Manual Fuel pump cutting out Winterthur Gas Diesel Ltd 372 Issue 002 20...

Page 373: ...g 004 NOTE Make sure that the applicable supply unit cam is at TDC and if not do Step 7 Fig 10 6 Roller lifting tool assembly 7 Operate the turning gear to turn the supply unit cam at TDC to push the...

Page 374: ...4 Remove the pre tensioner 005 Refer to the Maintenance Manual for more information 15 Make sure that the roller 007 is approximately 3 0 mm above the cam 006 16 Install the cover 006 Figure 10 6 NOTE...

Page 375: ...X92 B AA00 5556 00AAB 510B A Operation Manual Fuel pump cutting out Page left intentionally blank Winterthur Gas Diesel Ltd 375 Issue 002 2021 11...

Page 376: ...Pre tensioner 94430A 1 Supplies Description QTY None Spare Parts Description Part No CSN QTY None SAFETY PRECAUTIONS WARNING Injury hazard The cutting in procedure can only be done when the engine is...

Page 377: ...engine must be stopped and prepared for maintenance refer to section 8 18 Prepare the engine after stop general X92 B AA00 5556 00AAB 730B A Operation Manual Fuel pump cutting in Winterthur Gas Diesel...

Page 378: ...DURE Fig 10 8 Location of flanges 1 Release the pressure of the fuel supply unit to 0 bar X92 B AA00 5556 00AAB 730B A Operation Manual Fuel pump cutting in Winterthur Gas Diesel Ltd 378 Issue 002 202...

Page 379: ...er 007 Figure 10 9 of the guide piston 001 is at the highest position 8 Install the pre tensioner 005 on to the elastic bolt 004 9 Make sure that pre tensioner 005 touches the pad 003 10 Use the pre t...

Page 380: ...0 0 man hours Personnel Description Specialization QTY Engine crew Intermediate 1 Support equipment Description Part No CSN QTY Cover 94653A A R Cover 94653B A R Cover 94653C A R Cover 94653D A R Sup...

Page 381: ...er and the exhaust gas manifold 2 3 Install the covers 94653A and 94653B 001 and 002 2 4 Remove the expansion joint 005 between the defective turbocharger air outlet and the diffusor 2 5 Install the c...

Page 382: ...001 if the turbochargers are connected to a suction duct 3 4 Open the covers 003 and 004 on the scavenge air receiver 3 5 Set to ON the auxiliary blowers Fig 10 11 All turbochargers are defective exam...

Page 383: ...X92 B AA00 6500 00AAA 662A A Operation Manual Temporary isolate a defective turbocharger Page left intentionally blank Winterthur Gas Diesel Ltd 383 Issue 002 2021 11...

Page 384: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 385: ...cator 002 Cardan rod 007 Ball valve 50 8135_E0_3 air spring air 003 Positioner and feedback with EMC module 008 Flange 004 Actuator 009 Valve 005 Plate X92 B AA00 8135 00AAA 662A A Operation Manual Te...

Page 386: ...f the two middle screws 3 Turn the flange 008 to close the exhaust waste gate 4 Tighten the screws to attach the flange 008 5 Start the engine CLOSE UP None X92 B AA00 8135 00AAA 662A A Operation Manu...

Page 387: ...X92 B AA00 8135 00AAA 662A A Operation Manual Temporary isolate the exhaust waste gate Page left intentionally blank Winterthur Gas Diesel Ltd 387 Issue 002 2021 11...

Page 388: ...e requirements after job completion 0 0 man hours Personnel Description Specialization QTY Engine crew Basic 1 Support equipment Description Part No CSN QTY None Supplies Description QTY None Spare Pa...

Page 389: ...e shaft clutch are unserviceable make sure that you operate the auxiliary systems 4 If installed change the pitch of the controllable propeller CPP to the lowest resistance WARNING Injury Hazard Do no...

Page 390: ...there are labels attached to the cables 9 Loosen the cables fixing rail from the module housing 003 10 Loosen the six screws 006 NOTE Make sure that you do not remove them completely 11 Remove the co...

Page 391: ...ware and config image check initiated U CK software and config image check initiated U PU pull update check initi ated U PU pull update check initiated U PU pull update check initiated U SI push singl...

Page 392: ...sen the cables fixing rail from the module housing 004 9 Loosen the six screws 005 NOTE Make sure do not remove them completely 10 Remove the control module carefully 006 11 Attach a Faulty label to t...

Page 393: ...g image check initiated U PU pull update check initiat ed U PU pull update check initiated U PU pull update check initiated U SI push single update initiat ed U SI push single update initiated SM I US...

Page 394: ...el to the control module NOTE If the part need to be returned to WinGD service station fill the return sheet attached to the box of the spare control module 12 Install the new control module 006 13 Ti...

Page 395: ...te initiat ed U SI push single update initiated SM I USM state Initialization U SW software update initiated U CF config update initiated SM R USM state Ready Reboot Reboot Blank Fig 10 15 WiCE Cylind...

Page 396: ...rt need to be returned to WinGD service station fill the return sheet attached to the box of the spare control module 9 Install the new control module 004 10 Tighten the six screws 003 to attach the c...

Page 397: ...6 WiCE Angle Control Unit ACM20 module replacement 002 001 003 004 X92 B AA00 0000 00AAA 200E A Operation Manual WiCE Angle Control Unit ACM20 module replacment Winterthur Gas Diesel Ltd 397 Issue 002...

Page 398: ...ttach a Faulty label to the control module NOTE If the part need to be returned to WinGD service station fill the return sheet attached to the box of the spare control module 9 Attach new MCP either t...

Page 399: ...replacement E26 001 002 Fig 10 18 WiCE Manual Control Panel MCP replacement Back Cover 003 002 004 001 X92 B AA00 0000 00AAA 200F A Operation Manual WiCE Manual Control Panel MCP replacement Winterth...

Page 400: ...ng 2 right link down Re establish the wiring of the Ethernet Ring 2 TRX R2 to the adjacent control module E L1 Ethernet ring 1 left link down Re establish the wiring of the Ethernet Ring 1 TRX L1 to t...

Page 401: ...X92 B AA00 0000 00AAA 410A A Operation Manual WiCE module troubleshooting Page left intentionally blank Winterthur Gas Diesel Ltd 401 Issue 002 2021 11...

Page 402: ...engine under special running conditions for more than 2 5 days can damage the engine If the engine is run under special running conditions for more than that contact the engine builder to obtain advic...

Page 403: ...s is 40 The load restriction for 1 out of 3 turbochargers is 55 The load restriction can be increased considerably if an orifice plate is also inserted in the turbine inlet NOTE If reducing the load d...

Page 404: ...ial running condition E For engines with two or more turbochargers 1 Stop the engine 2 Open the cover E 3 Lock the rotor of the faulty turbocharger check your turbocharger manual for details 4 Remove...

Page 405: ...Lock the rotor of the faulty turbocharger check your turbocharger manual for details 4 Insert the blanking plate T1 T2 T3 T4 according to your turbocharger manual 5 Remove the compensator 1 between t...

Page 406: ...Fig 10 20 Turbocharger cut out procedure Illustration 2 X92 B AA00 0000 00AAB 100A A Operation Manual Special running condition Turbocharger cut out Winterthur Gas Diesel Ltd 406 Issue 002 2021 11...

Page 407: ...Fig 10 21 Turbocharger cut out procedure Illustration 3 X92 B AA00 0000 00AAB 100A A Operation Manual Special running condition Turbocharger cut out Winterthur Gas Diesel Ltd 407 Issue 002 2021 11...

Page 408: ...Fig 10 22 Turbocharger cut out procedure Illustration 4 X92 B AA00 0000 00AAB 100A A Operation Manual Special running condition Turbocharger cut out Winterthur Gas Diesel Ltd 408 Issue 002 2021 11...

Page 409: ...is chapter an auxiliary blower becomes inoperative it will automatically be cut out thanks to the built in non return valve This will restrict the operation of the engine X92 B AA00 0000 00AAB 100A A...

Page 410: ...s for more than that contact the engine builder to obtain advice NOTE If only the fuel for the respective cylinders is cut off while the same time the starting air connections remain intact then the e...

Page 411: ...exhaust valve are still working and the compression is off 1 On the LDU access the Fuel Injection Adjust Page 2 On the page turn off the fuel injection for the corresponding cylinder 3 Disconnect the...

Page 412: ...If the exhaust valve isn t completely closed disconnect the plug for the cylinder starting valve 8 After 15 minutes of running open the crankcase and check The bearings The temporarily secured parts T...

Page 413: ...now cut out and the engine performs under special running conditions E Cylinder cut out while the piston piston rod crosshead and connecting rod are all totally out 1 Stop the engine 2 On the LDU acc...

Page 414: ...bearings The temporarily secured parts The oil flow through bearings The tightness of blanked off openings The cylinder is now cut out and the engine performs under special running conditions Fig 10 2...

Page 415: ...Engine data 416 11 2 List of usual values and safeguard settings general 418 11 3 List of usual values and safeguard settings 422 11 4 Section views 434 X92 B Operation Manual Winterthur Gas Diesel Lt...

Page 416: ...d reference conditions Total barometric pressure is 1 0 bar Suction air temperature is 25 C Relative humidity is 30 Cooling water temperature at the engine inlet is 25 C BSFC This list gives the Brake...

Page 417: ...155 8 8 1 15 1 180 Fig 11 1 Operating range R1 R1 R2 R2 R4 R4 R3 S P Legend R1 Highest power at highest speed R3 Highest power at lowest speed R1 Highest power at highest speed extended R4 Lowest pow...

Page 418: ...operation the current values can have small differences to the given values Signal number This list gives the signal number as follows refer also to Para 11 2 2 First two letters XX Function code Four...

Page 419: ...ximum concentration For the level switches LS and flow switches FS min minimum or no flow max maximum flow Delay This list gives the delay of the action in seconds after the trigger value occurs X92 B...

Page 420: ...de Code First position Second position A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Tempera...

Page 421: ...o 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals to the engi...

Page 422: ...2NNN part 1 Table 11 8 Oil systems XX2NNN part 2 Table 11 9 Oil systems XX2NNN part 3 turbocharger bearing oil Table 11 10 Oil systems XX2NNN part 4 Table 11 11 Fuel system XX34NN Table 11 12 Exhaust...

Page 423: ...tlet connec tion 03 90 2 1 90 4 2 TE1121 nnA ALM H 95 0 SLD H 97 60 Scavenge air cooler SAC SAC LT cooling water pressure bar en gine inlet connection 07 2 5 to 4 PT1361A ALM L 2 0 0 SAC LT cooling wa...

Page 424: ...able external oil SAE 40 temper ature C inlet fuel pump 50 2 1 50 4 2 TE2012A ALM H 55 0 SLD H 60 0 External crosshead bearing oil pressure bar engine inlet connection 30 10 2 to 13 PT2021A ALM L 10 0...

Page 425: ...AS2401 02A ALM H max 0 AS2401S SLD H max 60 Oil mist concentration gearcase AE2415A ALM H max 0 Oil mist concentration fuel supply unit AE2421 22A ALM H max 0 Piston cooling oil Piston cooling oil te...

Page 426: ...ger 45 to 80 TE2621A ALM H 85 0 SLD H 90 60 TC bearing oil temperature C outlet each turbocharger 45 to 120 TE2601 nnA ALM H 130 0 SLD H 140 60 Bearing oil turbocharger MHI MET with internal oil TC be...

Page 427: ...M L 1 7 60 Damper oil pressure bar axial vibration damper space fore side 1 8 to 5 0 PT2722A ALM L 1 7 60 Cylinder oil Cylinder oil pressure bar cylinder oil rail 2 0 4 PT3124A ALM L 0 1 30 Cylinder o...

Page 428: ...l supply unit 7 5 to 10 2 PT3421A ALM L 7 0 Fuel temperature C inlet fuel supply unit 3 20 to 150 TE3411A ALM H 50 to 160 0 ALM L 20 to 130 0 Fuel leakage flow outlet fuel supply unit LS3426A ALM H ma...

Page 429: ...gas temperature C outlet each cylinder TE3701 nnA ALM H 515 0 ALM D 50 0 SLD H 530 60 SLD D 70 60 Exhaust gas temperature C inlet each turbocharger TE3721 nnA ALM H 515 0 SLD H 530 60 Exhaust gas tem...

Page 430: ...ng air supply Starting air supply pressure bar engine inlet connection 40 20 to 30 Control air supply unit Control air supply pressure bar engine inlet connection 45 7 to 9 Control air pressure bar ou...

Page 431: ...ALM H 260 0 SLD H 290 60 Powertrain Crankshaft speed of CMCR crankshaft ST5111 12S SHD H 110 0 Tachometer turbocharger if signal is available as alarm Impeller shaft overspeed rpm each ABB turbocharge...

Page 432: ...o Table 11 15 Failure messages Tab 11 15 Failure messages Medium location Signal number Delay Failure of oil mist detector XS2411A 0 Failure of fuel heating XS3463A 0 Failure of fuel pump actuator XS5...

Page 433: ...X92 B AA00 0000 00AAA 033B A Operation Manual List of usual values and safeguard settings Page left intentionally blank Winterthur Gas Diesel Ltd 433 Issue 002 2021 11...

Page 434: ...11 4 Section views X92 B AA00 0000 00AAA 034A A Operation Manual Section views Winterthur Gas Diesel Ltd 434 Issue 002 2021 11...

Page 435: ...2 Operating media 12 1 General for operating media 436 12 2 Compressed air 438 12 3 Scavenge air 440 12 4 Diesel engine fuels 442 X92 B Operation Manual Winterthur Gas Diesel Ltd 435 Issue 002 2021 11...

Page 436: ...ating media that follow Fuel Lubricants Water NOTE On the WinGD website go to your engine type then to OPERATION MAINTENANCE then to FUEL LUBRICANTS WATER On the pages that follow the specifications a...

Page 437: ...X92 B AA00 0000 00AAA 018M A Operation Manual General for operating media Page left intentionally blank Winterthur Gas Diesel Ltd 437 Issue 002 2021 11...

Page 438: ...ss 2 4 2 ISO 8573 1 12 2 2 Recommended procedures for compressed air WinGD recommends to regularly do the procedures that follow to prevent explosions Regularly drain the starting air bottles to remov...

Page 439: ...X92 B AA00 0000 00AAA 030E A Operation Manual Compressed air Page left intentionally blank Winterthur Gas Diesel Ltd 439 Issue 002 2021 11...

Page 440: ...piston rings turbocharger compressor etc to a minimum Silencers are installed to the suction part The silencers have filter mats in them which help to keep the air clean The filter mats must be servi...

Page 441: ...X92 B AA00 0000 00AAA 030D A Operation Manual Scavenge air Page left intentionally blank Winterthur Gas Diesel Ltd 441 Issue 002 2021 11...

Page 442: ...n bunkering it is possible that the fuel suppliers will report only some of the values given in the Quality Specifications Frequently only the density and maximum viscosity is given This makes the ful...

Page 443: ...8217 2017 RMK700 show the minimum quality of heavy fuel as supplied and bunkered to the ship installation Good operation results come from commercially available fuels that are in the ISO 8217 2017 li...

Page 444: ...pm ISO 10478 IP501 IP470 Used lubricating oils ULO must not be present Calcium Ca and zinc Zn ULO shows if Ca 30 and Zn 15 or Ca 30 and P 15 Do no use if Ca 30 and Zn 15 or Ca 30 and P 15 mg kg ppm IP...

Page 445: ...xhaust gas 12 4 3 Data about heavy fuel oil specifications The paragraphs that follow give more data about the specifications for HFO 12 4 3 1 Viscosity WinGD recommends a viscosity range at the engin...

Page 446: ...ommended viscosity range for Generation X X DF and RT flex engines Required viscosity range for Generation X X DF and RT flex engines X92 B AA00 0000 00AAA 030A A Operation Manual Diesel engine fuels...

Page 447: ...sary equipment related to the statutory specifications 12 4 3 5 Flash point The flash point is an important safety and fire hazard parameter for diesel fuels Fuel is always a fire hazard There can be...

Page 448: ...in relation to the viscosity For high viscosity fuels the separation temperature must be increased and the flow rate must be decreased in relation to the nominal capacity of the separator For the reco...

Page 449: ...nation The limits in ISO 8217 2017 and the WinGD specifications make sure that no used lubricating oil is in the fuel Chemical waste eg polymers styrene and other chemical substances must not be added...

Page 450: ...Water Maximum 0 3 Maximum 0 2 volume ISO 3733 Ash Maximum 0 01 Maximum 0 01 mass ISO 6245 Lubricity corrected wear scar diameter WSD at 60 C 7 Maximum 520 Maximum 520 m 1 1 mm2 s 1 cSt Centistoke 2 Th...

Page 451: ...composition of the fuel A high density indicates a high aromatic quantity 12 4 5 4 Cetane index The ignition and combustion properties of a distillate fuel in a diesel engine is related to the specifi...

Page 452: ...ure of the fuel must be kept between approximately 5 C and 10 C above the pour point to make sure that the fuel flows easily It is possible that in very cold conditions there could be problems for dis...

Page 453: ...D 6751 FAME has good ignition properties and very good lubrication and environmental properties but FAME has also known negative properties as follows Possible oxidation and thus long term storage pro...

Page 454: ...Objection Letters done by W rtsil Switzerland Ltd are no longer applicable and have no more support by WinGD NOTE WinGD does not accept liability or responsibility for the performance or potential dam...

Page 455: ...13 Attachments 13 1 Schematic diagrams general 456 X92 B Operation Manual Winterthur Gas Diesel Ltd 455 Issue 002 2021 11...

Page 456: ...gram 13 1 1 1 Area codes in the engine control diagram The area codes in the engine control diagram are as follows A Control air supply unit B Fuel supply D Servo oil supply E Valve unit for start K L...

Page 457: ...99 Pipe diagram Code 900 Engine room 13 1 1 4 Component codes in the engine control diagram The component codes in the engine control diagram are shown as example in Figure 13 2 Fig 13 2 Process codes...

Page 458: ...osition A Analysis n a C Control Control E n a Element F Flow n a G Gauge n a H Hand n a I n a Indication J Power n a L Level n a P Pressure n a S Speed Switch T Temperature Transmitter V n a Valve X...

Page 459: ...ust gas 40 to 49 Signals from the engine Air systems 50 to 59 Signals from the engine Miscellaneous 60 to 69 Signals from the engine Spare 70 to 79 Signals to the engine Miscellaneous 80 to 89 Signals...

Page 460: ...4 Color codes and symbols electric connection diagram 00221 ECR component Color codes Power Option Diesel Speed Bus CCM 20 A1 Cylinder 1 13 1 3 Piping and instrumentation diagram The piping and instr...

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