WinGD W-X82 Operation Manual

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Operation Manual

"Marine"

Vessel:

Type:

Engine No.:

Document ID: DBAC753771

Winterthur Gas & Diesel Ltd.

Schützenstrasse 1−3

CH-8400 Winterthur

Switzerland

24hrs Support:

Wärtsilä Services Switzerland Ltd.

Zürcherstrasse 12

CH 8400 Winterthur

Switzerland

+41 52 262 80 10

technicalsupport.chts@wartsila.com

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Page 1 Operation Manual “Marine” Vessel: Type: Engine No.: Document ID: DBAC753771 Winterthur Gas & Diesel Ltd. 24hrs Support: Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland +41 52 262 80 10 technicalsupport.chts@wartsila.com...
Page 2 E 2017-08 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.
Page 3 Operation Manual “Marine” Vessel: Type: Engine No.: Document ID: DBAC753771 Winterthur Gas & Diesel Ltd. 24hrs Support: Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur Switzerland +41 52 262 80 10 technicalsupport.chts@wartsila.com...
Page 4 E 2017-04 Winterthur Gas & Diesel Ltd., Printed in Switzerland – All rights reserved No part of this publication may be reproduced or copied in any form or by any means (electron- ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright holder.
Page 5: Table Of Contents
New chapter for 9-cylinder engines added 9-cylinder Date of publication 2014-09-16 OM_2015-05 2015-05 Cover page, Disclaimer Data about Winterthur Gas & Diesel (WinGD) and Wärtsilä and all related pages Services Switzerland (WSCH) added; New Layout WinGD; Disclaimer updated (WinGD and WSCH added); 8019-1/A1...
Page 6 13 cSt to 10 cSt; Table 2: Pour point (upper) winter max. value changed from 0 to -6; Carbon residue max. value removed; minor changes in the text; Data about Wärtsilä Service Switzerland Ltd and WinGD added; 0720-1/A1 2015-07 EAAD085468 Operating Media - Fuel Fig.
Page 7 Modification Service Engine Documentation W-X82 Summary for Operation Manual (OM) Page No. Modification Title Subject Page or Date Manual new exch. 4003-3/A1 2015-01 EAAD085118 Control and Auxiliary Document updated with latest data: Systems -Page 11: PT2041A, PI2041L, 8.11-1 have been removed.
Page 8 Modification Service Engine Documentation W-X82 Summary for Operation Manual (OM) Page No. Modification Title Subject Page or Date Manual new exch. 6510-1/A1 2017-08 Update Cleaning the Minor text changes (only cleaning of compressor) WinGD Turbocharger during Operation 6606-1/A1 2017-08 Update Operating Instructions Fig.
Page 9 Operating Descriptions Bedplate and Tie Rod Cylinder Liner and Cylinder Cover Crankshaft, Connecting Rod and Piston Engine Control and Control Elements Supply Unit, Servo Oil Pump and Fuel Pump Scavenge Air System Cylinder Lubrication Piping Systems Engine Monitoring...
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Page 11: 0020-1/A1
Group0 Operation Operating Descriptions Group 0 For Your Attention ..............0000−1/A1 General Preface...
Page 12 Group0 Operation Operation during Unusual Conditions General Data ............... . 0500−1/A1 Operation with Injection Cut Out (One or More Cylinders) .
Page 13 The data, instructions, graphics and illustrations etc. in this manual are related to drawings from Winterthur Gas & Diesel Ltd. (WinGD). These data relate to the date of issue of the manual (the year of the issue is shown on the title page). All instructions, graphics and illustrations etc can change because of continuous new development and modifications.
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Page 15 In the code book all parts of the engine are marked with a unique code number. The code number is necessary to order spare parts from Winterthur Gas & Diesel Ltd. (WinGD) or the engine supplier. The spare parts can only be ordered with the code number from the code book.
Page 16 0010−1/A1 Operation Preface Structure of the Manual The groups with their illustrations are divided into the design groups. Engine type Group No. (Version) Manual type Design variant 0peration 1132−1/A1 W-X62 Title Variant Subtitle − − − − − description Year of issue 2015 Winterthur Gas &...
Page 17: Technical Documentation
0010−1/A1 Operation Preface Symbols WARNING This symbol shows that the text is safety related. The signal word WARNING is used to show a hazardous condition. If ignored, these conditions could cause serious injury or death to personnel. CAUTION This symbol shows that the text is safety related. The signal word CAUTION is used to show a potentially hazardous condition.
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Page 19 0020−1/A1 Operation Table of Contents Table of Contents Operating Descriptions Group 0 For Your Attention ..............0000−1/A1 General Preface...
Page 20 0020−1/A1 Operation Table of Contents Operation during Unusual Conditions General Data ............... . 0500−1/A1 Operation with Injection Cut Out (One or More Cylinders) .
Page 21 0020−1/A1 Operation Table of Contents Crankshaft, Connecting Rod and Piston Group 3 Axial Damper ................3140−1/A1 Connecting Rod and Connecting Rod Bearing .
Page 22 0020−1/A1 Operation Table of Contents Scavenge Air System Group 6 Scavenge Air Receiver ..............6420−1/A1 Turbocharging .
Page 23 0030−1/A1 Operation Subject Index Alphabetical Table of Contents Abbreviations ............... 0035−1/A1 Adjustment −...
Page 24 0030−1/A1 Operation Alphabetical Table of Contents Emergency operation with exhaust valve closed / opened ....... . . 0520−1/A1 Engine, short description of...
Page 25 0030−1/A1 Operation Alphabetical Table of Contents Leakage and wash-water system ............8345−1/A1 Leakage check of pressure control valve .
Page 26 0030−1/A1 Operation Alphabetical Table of Contents Pick-up for speed measurement ............4628−1/A1 Piston .
Page 27 0030−1/A1 Operation Alphabetical Table of Contents Safety measures and warnings (general information) ........0210−1/A1 Scavenge air .
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Page 29 0035−1/A1 Operation Abbreviations See the table below for the the abbreviations used in this manual. Unit of measures are not shown in the list. Abbreviation Word(s) in Full Ahead Alarm ALM−20 Advanced Lubrication Module−20 Alarm and Monitoring System Astern ASTM American Society for Testing and Materials Bottom Dead Center Base Number...
Page 30 0035−1/A1 Operation Abbreviations Abbreviation Word(s) in Full MARPOL International Convention for the Prevention of Pollution from Ships Main Control Module Modbus Gould-Modicon Fieldbus Maximum Continuous Rating Marine Diesel Oil Main Engine Mean effective pressure Marine Gas Oil Organic Acid Technology Operational Margin Oil Mist Detector Propulsion Control System...
Page 31 0040−1/A1 Operation General How to Use the Operation Manual Contents The Operation Manual, (Operation), contains data and indications about: The servicing of the engine during operation The necessary media (oil, water, air, fuel) The functions of components and systems. Note: The maintenance and overhaul instructions are found in the Maintenance Manual.
Page 32 0040−1/A1 Operation How to Use the Operation Manual Cross section 2751−1 2728−1 2124−1 2722−1 3403−1 8017−1 2138−1 6500−1 5562−1 6545−1 8019−1 6420−1 8016−1 1903−1 8018−1 4325−1 7218−1 2303−1 3326−1 6606−1 3603−1 3303−1 8345−1 5556−1 8016−1 5581−1 4104−1 WCH01165 Fig. 1: Cross Section 2014 2/ 3 Winterthur Gas &...
Page 33 0040−1/A1 Operation How to Use the Operation Manual Longitudinal section 2751−1 2124−1 7218−1 1903−1 2138−1 3403−1 2303−1 3326−1 3140−1 4104−1 3303−1 9223−1 1132−1 1203−1 018.264/09 Fig. 2: Longitudinal Section 2014 3/ 3 Winterthur Gas & Diesel Ltd.
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Page 35 0050−1/A1 Operation General Short Description of the Engine General General data about the engine are given as follows: The W−X engine is a single acting, two-stroke diesel engine of crosshead design with exhaust gas turbocharging and uniflow scavenging. The engine is reversible and is directly connected to the propeller. The W−X concept is based on the Common Rail System, with full electronic control of the fuel injection system and the exhaust valve operation.
Page 36 0050−1/A1 Operation Short Description of the Engine The exhaust gases flow from the cylinders through the exhaust valves into the exhaust gas manifold. The turbocharger uses the pressure of the exhaust gas to operate the compressor. The scavenge air from the turbocharger flows through the air cooler and water separator into the air receiver.
Page 37 0060−1/A1 Operation General Two-stroke Diesel Engine − Operation Piston Movement First Stroke (Compression) The sequence of piston movements during the compression stroke is as follows: The piston is at BDC (see Fig. 1). The scavenge ports and exhaust valve are open. Scavenge air flows into the cylinder and pushes the exhaust gas through the exhaust valve into the exhaust gas manifold and then to the turbocharger.
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Page 39 0070−1/A1 Operation General The Relation between Engine and Propeller General ............Fixed Pitch Propeller (FPP) .
Page 40 0070−1/A1 Operation The Relation between Engine and Propeller Fixed Pitch Propeller (FPP) Continuous Service Rating (CSR) Point A (see Fig. 1) shows the power and speed of a ship that operates at contractual speed in calm seas with a new clean hull and propeller. A power / speed combination at point D is necessary for the same ship at the same speed during service conditions with aged hull and average weather.
Page 41 0070−1/A1 Operation The Relation between Engine and Propeller Load Range Limits When the engine has the best values at CMCR (Rx), the limits that follow give the load range of the engine: Line 1 is a constant mep or torque line through CMCR from 100% speed and power down to 95% speed and power.
Page 42 0070−1/A1 Operation The Relation between Engine and Propeller Controllable Pitch Propeller (CPP) Load Ranges After engine start, the engine is operated at an idle speed of up to 70% of the rated engine speed with zero pitch. From idle speed, the propeller pitch must be increased with constant engine speed to the minimum at point E, the intersection with Line 9.
Page 43 0070−1/A1 Operation The Relation between Engine and Propeller Control System The CPP control functions are usually part of the engine control system and include the functions in the paragraphs that follow. 3.2.1 Combinator Mode 1 Combinator mode for operation without a shaft generator. A combinator curve that includes an applicable light running margin can be set in the permitted operation area, Line 7 (see Fig.
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Page 45: 0080-1/A1
0080−1/A1 Operation General Basic Engine Data General Turbocharger 1 Turbocharger 2 DRAWN FOR 7 CYLINDERS Cylinder Numbering DRIVING FREE Thrust Bearing Main Bearing Pads Numbering Turbocharger 2 Turbocharger 1 DRAWN FOR 9 CYLINDERS Cylinder Number DRIVING FREE 11 12 WCH02734 Thrust Bearing Main Bearing Pads...
Page 46 0080−1/A1 Operation Engine Numbering and Designations Rail Unit FUEL EXHAUST SIDE SIDE DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS Servo Pump Unit Fuel Pump Unit Clockwise Rotation 017.921/08 Rail Unit FUEL EXHAUST SIDE SIDE DRAWN FOR 9 CYLINDERS Servo Pump Unit Fuel Pump Unit (Exhaust Side) Fuel Pump Unit...
Page 47 0080−1/A1 Operation Engine Numbering and Designations Flex Parts DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS Servo Oil Pump 2 Servo Oil Pump 1 Fuel Pump A1 Fuel Pump A2 Fuel Pump A3 EXHAUST SIDE Fuel Pump A4 Actuator A1 Actuator A2 Actuator A3 Actuator A4 FUEL SIDE...
Page 48 0080−1/A1 Operation Engine Numbering and Designations Crank Angle Sensors Sensor 1 Sensor 2 (GT5127C) (GT5126C) FUEL SIDE 013.150/05 FREE END Fig. 4: Flex Parts 2014 4/ 4 Winterthur Gas & Diesel Ltd.
Page 49 0110−1/A1 Operation Prepare the Engine for Operation Prepare for Engine Start after a Short Shut-down Period (One or More Days) Start Position For the start position, the engine must be in the condition that follows: All components that had an overhaul are correctly assembled and installed. All components that had an overhaul have had tests or checks to make sure that they operate correctly.
Page 50 0110−1/A1 Operation Prepare for Engine Start after a Short Shut-down Period (One or More Days) 19) Open the indicator valve on all cylinder covers. WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel. 20) Use the turning gear to turn the engine a minimum of one full turn to make sure that all the running gears will operate correctly.
Page 51 0110−1/A1 Operation Prepare for Engine Start after a Short Shut-down Period (One or More Days) WARNING Injury Hazard: Before you operate the engine make sure that no personnel are near the flywheel. 39) In WECS−9520 manual control panel (on the local control panel), push the SLOW TURNING button (4618−1, Local Control Panel, paragraph 2.1).
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Page 53 0120−1/A1 Operation Prepare the Engine for Operation 6-cylinders to 8-cylinders Prepare the Fuel System for Operation Prepare the Fuel System Diesel Operation See 0720−1, Fig. 1. Set the three-way valve (16) in the suction line of the low pressure feed pump (19) to let diesel oil flow from the daily tank (6) to the pump and to the mixing unit (21).
Page 54 0120−1/A1 Operation Prepare the Fuel Oil System for Operation 6-cylinders to 8-cylinders High Pressure Circuit 8019−1 Fuel System Fig. 1. Make sure that the drain valve 3.65 (21) is closed. At the driving end of the fuel rail 3.05 (13), make sure that the drain screw 3.82 (22) is closed.
Page 55 0120−1/A2 Operation Prepare the Engine for Operation 9-cylinders Prepare the Fuel System for Operation Prepare the Fuel System Diesel Operation See 0720−1, Fig. 1. Set the three-way valve (16) in the suction line of the low pressure feed pump (19) to let diesel oil flow from the daily tank (6) to the pump and to the mixing unit (21).
Page 56 0120−1/A2 Operation Prepare the Fuel Oil System for Operation 9-cylinders High Pressure Circuit 8019−1 Fuel System Fig. 1. Make sure that the drain valve 3.65 (30) is closed. At the driving end of the fuel rail 3.05 (15), make sure that the drain screw 3.82 (31) is closed.
Page 57 0130−1/A1 Operation Prepare the Engine for Operation Prepare the Servo Oil System Servo Oil System − Checks 6-cylinder to 8-cylinder engines For more data, see 8016−1 Fig. 3 and Fig. 4 and 4003−2, Control Diagram. Do the checks that follow: Make sure that the stop valve 4.37 (14), upstream of the automatic filter 4.20 (1) is open.
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Page 59 0140−1/A1 Operation Prepare the Engine for Operation Prepare the Cylinder Lubricating System For more data, see 7218−1 Cylinder Lubrication, Fig. 1, Fig. 2, Fig. 3, Fig. 4 and Fig. 8. Make sure that: The WECS−9520 engine and remote control systems are set to on. The servo oil service pump 4.88 operates.
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Page 61 0200−1/A1 Operation Operation during Usual Conditions General Data The data that follow are about engine operation during usual conditions e.g. all cylinders operate correctly: 0210−1 Safety Precautions and Warnings 0220−1 Slow Turning 0230−1 Starting 0240−1 Usual Operation. During maneuvering, it is possible to operate the engine from the control room, the bridge or the local maneuvering stand.
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Page 63 0210−1/A1 Operation Operation Safety Precautions and Warnings (General Data) General ............Warnings .
Page 64: Safety Precautions And Warnings (General Data)
0210−1/A1 Operation Safety Precautions and Warnings (General Information) Lighting There must be good permanent lighting. Also, hand lamps must be available at different locations in the engine room. Clean Areas CAUTION Damage Hazard. Do not use water or cleaning fluids to clean the UNIC electronic control boxes on the rail unit.
Page 65: Tools
0210−1/A1 Operation Safety Precautions and Warnings (General Information) Tools Put hand-tools in locations where you can easily get access to them. Put special tools and devices in positions in the engine room near the area where you use them. All tools must be prevented from unwanted movement and must have protection from corrosion.
Page 66: Temperature
0210−1/A1 Operation Safety Precautions and Warnings (General Information) Temperature WARNING Danger: If you think that parts of the running gear or bearings have become too hot, it is possible that the engine must be shut down. Before you open the crankcase doors, you must wait for a minimum of 20 minutes.
Page 67: 13. Turning Gear
0210−1/A1 Operation Safety Precautions and Warnings (General Information) 13. Turning Gear The lubricating oil pump must operate if possible, but the oil pressure cannot fully increase when the exhaust valves are open. WARNING Injury Hazard: After an air run the crankshaft can turn suddenly when the pressurized air in the cylinder releases.
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Page 69: General
0220−1/A1 Operation Operation during Usual Conditions Slow Turning General To make sure that the running gear turns freely, it is recommended (as long as the classification society did not make more primary specifications) to turn the crankshaft a minimum of one full turn before start-up. Note: This does not apply if the engine was stopped during a maneuvering period.
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Page 71 0230−1/A1 Operation Operation during Usual Conditions Engine Start General Before you start the engine (also, before trials and using starting air to turn the engine) see: 0110−1 Prepare the Engine for Engine Start 0120−1 Prepare the Fuel Oil System for Operation 0130−1 Prepare the Servo Oil System 0140−1...
Page 72 0230−1/A1 Operation Engine Start Engine Start Procedure Push the button AUX. BLOWER PRESEL. Push the button FUEL CONTROL MODE. Turn the rotary knob to set the fuel injection quantity to approximately 15%. Push the button START AHEAD or START ASTERN until the engine operates. Slowly turn rotary knob to adjust the fuel injection quantity until the engine operates at the necessary speed.
Page 73 0240−1/A1 Operation Operation Usual Operation General To get the best performance, operate the engine at constant power. You must only change the engine load and / or speed slowly, unless there are unusual conditions. Checks and Precautions During usual operation, you must do regular checks and use precautions. This lets you operate the engine without problems.
Page 74 0240−1/A1 Operation Usual Operation Keep the correct scavenge air temperature downstream of the air cooler with the usual water flow (see 0250−1 Operating Data Sheet). A higher scavenge air temperature will give an unsatisfactory quantity of scavenge air in the cylinder. This will cause more fuel to be used and higher exhaust gas temperatures.
Page 75 0240−1/A1 Operation Usual Operation When you listen to the engine, unusual noises will show that there is a possible defect. Hand-drawn diagrams give data about the combustion process and pressures in the cylinder (see 0420−1 Indicator Diagrams). When the quality of the fuel used changes (diesel oil, HFO from different bunkerings), the maximum pressure in the cylinder at service power must be found as soon as possible.
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Page 77 0250−1/A1 Operation Operating Data Sheet Pressure and Temperature Ranges at Continuous Service Power MCR Medium System Location of Gage Pressure Temperature [bar] [_C] Measurement Min. Max. Min. Max. Diff. Fresh water Cylinder cooling Inlet − max. Outlet each cylinder − −...
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Page 79 0250−2/A1 Operation Operating Data Sheet Alarms and Safeguards at Continuous Service Power Media Unit Location Signal No. Func- Type of Setting Time tion signal value Interval [sec] [bar or _C] Cylinder cooling water Pressure Engine inlet PT1101A 3.0 bar 2.8 bar PS1101S 2.5 bar Temperature...
Page 80 0250−2/A1 Operation Alarms and Safeguards at Continuous Service Power Media Unit Location Signal No. Func- Type of Setting Time tion signal value Interval [bar or _C] [sec] Turbocharger oil Pressure Inlet PT2611−12A 1.0 bar (ABB, A100-L type) 0.8 bar PS2611−12S 0.6 bar Temperature Housing outlet...
Page 81 0250−2/A1 Operation Alarms and Safeguards at Continuous Service Power Media Unit Location Signal No. Func- Type of Setting Time tion signal Value Interval [bar or _C] [sec] ( 3) Condensate Level Water separator LS4071−72A max. max. before LS4075−76A max. water separator max.
Page 82 0250−2/A1 Operation Supply from the starting air pipe upstream the shut-off valve for control and air spring air through the pressure reducing valve 19HA (from starting air bottles 9.01). (10) Signal designation changes downstream of the amplifier (on the engine) from TExxxxA to TTxxxxA.
Page 83 0260−1/A1 Operation Operation Manoeuvring General Correct maneuvering, with a subsequent increase in engine load up to service power and a decrease in load from service power, is very important. Engine loads in the higher power ranges that are changed too quickly can cause increased wear and contamination, specially on piston rings and cylinder liners.
Page 84 0260−1/A1 Operation Manoeuvring When HFO is used for maneuvering, the fuel must be heated sufficiently. This keeps the viscosity at the fuel pump inlets in the range given in 0710−1, Fig. 1 Viscosity-Temperature Diagram. The heating of the fuel oil system must stay set to on. Keep the temperature of the cooling media as close as possible to the higher limits given for usual service (see 0250−1 Operating Data Sheet).
Page 85 0260−1/A1 Operation Manoeuvring Reversing Turn the rotary button to 15% fuel injection quantity (see display). Push the button START AHEAD or START ASTERN until the engine runs in the applicable direction. Note: On ships under way, this procedure can be some minutes, because the flow of water has an effect on the propeller.
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Page 87 Specially make sure that during the procedures HFO never can flow into the MDO tank and pipe system. Note: WinGD recommends to do a manual change−over only, if an automatic change−over system is not installed or if the automatic change−over system is unserviceable.
Page 88 BN. For more data refer to 0750−1, Lubricating oils. WinGD recommends to monitor the change−over of the cylinder lubricating oil. Do a calculation of the cylinder lubricant quantity and make sure that you know cylinder lubricating feed rate.
Page 89 0270−1/A1 Operation Change-over from Heavy Fuel Oil to Marine Diesel Oil and Back Change-over from HFO to MDO 0720−1 Fuel Treatment and Fuel System, Fig. 1. To change−over from HFO to MDO, do as follows: Make a full time schedule for the change−over to obey the ECA rules. If you operate the engine with MDO for a long period, you must change the cylinder lubricating oil to the applicable BN at the related time, refer to paragraph Set to OFF the trace heating of the fuel pipes and fuel rail approximately one...
Page 90 0270−1/A1 Operation Change-over from Heavy Fuel Oil to Marine Diesel Oil and Back Change-over from MDO to HFO 0720−1 Fuel Treatment and Fuel System, Fig. 1. To change−over from MDO to HFO, do as follows: Make a full time schedule for the change−over to obey the ECA rules. Make sure that you have changed the cylinder lubricating oil to the applicable BN, refer to paragraph 5.
Page 91 0280−1/A1 Operation Operation Operation at Low Load General See the data that follow: 0240−1 Usual Operation, paragraph 2 Checks and Precautions Trace heating of the fuel system during operation Temperature of the cooling medium in the usual range (see 0250−1 Operating Data Sheet) Careful treatment of the fuel (see 0720−1, Fuel Treatment and Fuel System)
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Page 93 0290−1/A1 Operation Operation Operation at Overload General Usually, the engine is only operated at overload (110% of CMCR power) during sea trials when there is an authorized representative of the engine builder on board the ship. The limit for operation of the engine at overload is a maximum of one hour each day (see also 0070−1 The Relation between Engine and Propeller).
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Page 95 0310−1/A1 Operation Engine Shutdown General Engine Load Decrease When possible, it is recommended that the engine load is decreased slowly, see 0260−1 Maneuvering. Engine Stop Usual Procedures 2.1.1 Engine Stop from the Control Room − Remote Control Because different types of remote control can be connected to the engine controls, the operation procedure from the manoeuvring stand in the control room is not given.
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Page 97 0320−1/A1 Operation Engine Shutdown Procedures after Engine Stop Procedures for Short Service Breaks (some days to some weeks) Engine is Maneuverable If the engine must still be maneuvered after it has stopped, see the conditions that follow: The WECS−9520 must stay set to on. All the pumps for coolant water, lubricating oil and fuel must operate.
Page 98 0320−1/A1 Operation Procedures after Engine Stop Do the steps that follow: Open the indicator valves in the cylinder covers. Engage the turning gear. Set the WECS−9520 to on. At frequent intervals and with the indicator valves open, use the turning gear to turn the engine as necessary (possibly done daily in damp climates).
Page 99 0320−1/A1 Operation Procedures after Engine Stop WCH01073 Fig. 1: Starting Air System 1 Shut-off valve for starting air 5 Venting valve 2.27 2 Handwheel for shut-off valve 6 Starting air manifold 3 Drain and test valve 2.06 7 Starting air valve 4 Venting valve 2.21 8 5/2-way solenoid valve Procedures for Service Breaks for a Longer Period...
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Page 101 The procedure includes a temporary higher feed rate, refer to Fig. 1. WinGD recommends an inspection of the cylinder liners and of the piston rings after 24 operation hours and after 72 operation hours (1, Fig. 1). For this running−in procedure there is no limit for the engine load.
Page 102: Running-In New Cylinder Liners And Piston Rings
0410−1/A1 Operation Running-in of New Cylinder Liners and Piston Rings Before Engine Start Prepare the engine for start, see 0110−1. Do a check of the condition of the piston rings. Do a check of the condition of the cylinder liners from the piston underside and for signs of condensation or leakage (if the engine has not started for some time).
Page 103: Fuel
0410−1/A1 Operation Running-in of New Cylinder Liners and Piston Rings 15) For the running-in of one cylinder, you can temporarily decrease its load. See step a) and step b): In the remote control, get in the MAINTENANCE SETTINGS in the ADJUST page (see 4002−3, User parameters and Maintenance Settings, paragraph 1.2).
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Page 105 0420−1/A1 Operation Operation − Special Procedures Indicator Diagrams General Indicator diagrams must only be drawn with a serviceable indicator at constant power and speed, and ships sailing in calm sea and deep water. To give you data about the indication diagrams, record the related cylinder number, engine speed, the positions of the load indicator and VIT.
Page 106 0420−1/A1 Operation Indicator Diagrams Maximum Firing pressure Example A Too High at Correct Compression Pressure Possible causes: Ignition (start of injection) too advanced for the fuel type in use. You must adjust the FQS as follows: 004.758/00 In the remote control, get the user Example B parameters page (see 4002−3...
Page 107 0420−1/A1 Operation Indicator Diagrams Example A Compression Pressure and Maximum Firing Pressure Too High Possible causes: Engine has too much load. VEC timing is incorrect. 004.752/00 Example B 004.751/00 2014 3/ 3 Winterthur Gas & Diesel Ltd.
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Page 109: General
0450−1/A1 Operation Operation − Special Procedures Procedures to Prevent Contamination and Fire in the Scavenge Air Spaces General The primary cause of contamination is when combustion materials are blown between the piston and cylinder into the scavenge air spaces (blow-by). The contamination will be more if the fuel is not fully burned, causes exhaust smoke.
Page 110 0450−1/A1 Operation Procedures to Prevent Contamination and Fire in the Scavenge Air Spaces Indications of a Fire The indications of a fire as follows: You can hear the related temperature alarms. A large increase in the exhaust gas temperature of the related cylinder and an increase in piston underside temperature.
Page 111 0450−1/A1 Operation Procedures to Prevent Contamination and Fire in the Scavenge Air Spaces After a careful check, or if necessary a repair, do the procedure given in steps a) to c): Start the engine. Start the injection and slowly increase the load. Set the lubricating oil feed rate to the applicable value.
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Page 113 0460−1/A1 Operation Special Procedures − Operation Prevention of Crankcase Explosions − Instructions General Examples of crankcase explosions in diesel engines have shown that they can only occur in special conditions,and thus do not occur frequently. The cause of crankcase explosions is oil mist. Oil mist comes from components that have become unusually hot.
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Page 115 0500−1/A1 Operation Operation during Unusual Conditions General Data General The data below give the procedures for engine operation when: The parts cannot be immediately repaired The engine must continue to operate, or When engine operation must continue as soon as possible. Decreased Power Output In an emergency, when the engine must operate (with one or more cylinders out of operation, turbochargers out of operation or decreased coolant flow etc) the power...
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Page 117 0510−1/A1 Operation Operation during Unusual Conditions Operation with Injection Cut Out (One or More Cylinders) Cut Out the Injection If the injection of one or more cylinders must be cut out, do the procedure give in steps 1) to 4): In the remote control, select Inj.
Page 118 0510−1/A1 Operation Operation with Injection Cut Out (One or More Cylinders) DRIVING END WCH01182 WCH01184 Fig. 1: Rail unit and injection control unit 1 Fuel rail 3.05 6 Drain screw 3.82 2 Servo oil rail 4.11 7 Rail valve 3.76 3 Injection control unit 3.02 8 Electrical connection 4 Fuel pressure control valve 3.06...
Page 119 0515−1/A1 Operation Operation during Unusual Conditions Faults in High Pressure Fuel System Defective Fuel Pump ..........Fault Identification .
Page 120: Faults In High Pressure Fuel System
0515−1/A1 Operation Faults in High Pressure Fuel System Defective Fuel Pump Actuator Fault Identification If an actuator becomes defective, its output stays the same or changes slowly to zero supply. The toothed rack does not change when the load changes. At higher fuel consumption, the serviceable actuator has control of the fuel quantity regulation.
Page 121: Procedure
0515−1/A1 Operation Faults in High Pressure Fuel System Procedure Minimum Position Maximum Position Max. Max. Min. Min. WCH01185 010.513/02 WCH01185 Fig. 1: Minimum / Maximum Position of the Regulating Linkage 1 Fuel pump 3.14 3 Spacer (tool 94555) 2 Toothed rack 4 Actuator 3.21 2.3.1 One Actuator is Defective...
Page 122: Defective Injection Control Unit
0515−1/A1 Operation Faults in High Pressure Fuel System Defective Injection Control Unit Fault Identification Alarm indication in WECS−9520 (remote control). The fuel injection is cut off automatically (Inj. CUT OFF) on the related cylinder, and a SLOW DOWN signal will be released. The injection control unit has a leak.
Page 123: Procedures
0515−1/A1 Operation Faults in High Pressure Fuel System Procedures 3.3.1 Fuel Quantity Sensor It is not necessary to stop the engine. Engine operation is also possible with a defective fuel quantity sensor. Replace the defective fuel quantity sensor as follows: Disconnect the electrical connection from the fuel quantity sensor (2, Fig.
Page 124 0515−1/A1 Operation Faults in High Pressure Fuel System 3.3.3 Rail Valve Replace the defective rail valve as soon as possible. Do the procedure that follows: Note: It is possible to replace a defective rail valve during operation. In the remote control, use the parameter Inj. Cut off to cut out the related cylinder (see 4002−3, paragraphs 1 and 1.1).
Page 125: Defective Fuel Pressure Control Valve
0515−1/A1 Operation Faults in High Pressure Fuel System 3.3.4 Injection Control Unit The fuel injection must be cut out immediately if: The injection control unit has cracks The injection control valve or fuel quantity piston cannot move. Note: When the injection is cut out (Inj. CUT OFF) you can can only operate the engine at decreased load.
Page 126: Procedure
0515−1/A1 Operation Faults in High Pressure Fuel System Procedure WARNING Injury Hazard: Replace the PCV only when the engine has stopped. The oil supply pipe from the bearing oil system and the fuel rail must have zero pressure. Stop the engine. Turn the knurled screw (4, Fig.
Page 127 0520−1/A1 Operation Operation during Unusual Conditions Operation with Exhaust Valve Control Unit Cut Out General ............Emergency Operation with Exhaust Valve Closed .
Page 128 0520−1/A1 Operation Operation with Exhaust Valve Control Unit Cut Out Replace the defective VCU or the hydraulic pipe (see the Maintenance Manual 5612−1 and 8460−1). Torque the drain screw (2) to 200 Nm. Set to on the bearing oil pump. Cut in the injection (see 0510−1, paragraph 2).
Page 129 0520−1/A1 Operation Operation with Exhaust Valve Control Unit Cut Out Emergency Operation with Exhaust Valve Open This mode of operation is only necessary if there is water leakage into the combustion chamber (see also 0545−1). Exhaust Valve − Stop Operation Stop the engine.
Page 130 0520−1/A1 Operation Operation with Exhaust Valve Control Unit Cut Out WCH00700 WCH00699 Fig. 3: Exhaust Valve / Pressure Element 1 Damper 4 Pressure element (tool 94259a) 2 Upper housing 5 Control signal plug 3 Shim VS Maximum exhaust valve stroke 2014 4/ 4 Winterthur Gas &...
Page 131 0525−1/A1 Operation Operation during Unusual Conditions Faults in Servo Oil System Defective Automatic filter ......... . Identification .
Page 132 0525−1/A1 Operation Faults in Servo Oil System Defective Servo Oil Pump Identification The flow sensors FS2061A − FS2063A indicate that a pump is defective, i.e. an alarm is activated in the alarm and monitoring system (Servo oil pump n. flow). Causes The servo oil pump has damage.
Page 133 0525−1/A1 Operation Faults in Servo Oil System Procedures 3.3.1 Rail Valve − Replace Replace the defective rail valve as soon as possible. Stop the engine. Make sure that the servo oil service pump is set to off. Set to off the main bearing oil supply. Carefully loosen the drain screw (7, Fig.
Page 134 0525−1/A1 Operation Faults in Servo Oil System 3.3.2 Defective Exhaust Valve Control Unit The exhaust valve control unit must be shut off as an immediate procedure if the piston or slide rod in the exhaust valve control unit is seized. 0520−1 Emergency operation with exhaust valve closed, paragraph 2.
Page 135 0540−1/A1 Operation Operation during Unusual Conditions Operation with Running Gear Partially or Fully Removed General If the engine must operate after a defect in the running gear (of a cylinder), which cannot be immediately repaired, do the related procedures that follow in paragraph 2 or paragraph 3.
Page 136 0540−1/A1 Operation Operation with Injection Cut Out (One or More Cylinders) Piston, Crosshead and Connecting Rod Removed Breakdown Examples The crosshead or guide shoes are defective. The connecting rod bearing is damaged. The crosshead pin or on the connecting rod are defective. Procedure The exhaust valve stays closed during the emergency operation that follows: Cut out the injection (see...
Page 137 0540−1/A1 Operation Operation with Injection Cut Out (One or More Cylinders) 016.924/08 016.924/08 016.924/08 Fig. 1: Piston Removed 1 Exhaust valve 7 Blank flange (tool 94831) 2 Crosshead 8 Cover plate (tool 94345D) 3 Toggle lever 9 Cover and lifting plate (tool 94324) 4 Starting air pipe 10 Base (tool 94324B) 5 Elbow...
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Page 139 0545−1/A1 Operation Operation during Unusual Conditions Operation with Water Leakage into the Combustion Chamber General If there is water leakage into the combustion chamber (e.g. a crack in the cylinder cover or cylinder liner) the defective part must be replaced immediately. Procedures If it is not possible to replace the defective parts but the engine must continue to operate, do the procedures on the related cylinder as given in steps 1) to 4):...
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Page 141 0550−1/A1 Operation Operation during Unusual Conditions Defective Scavenge Air Cooler / Defective Auxiliary Blowers Defective Scavenge Air Cooler When a scavenge air cooler (SAC) is defective, water can go into the scavenge air receiver. The water then goes out through the condensate collector of the SAC drain. The related level switch activates an alarm.
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Page 143 0560−1/A1 Operation Operation during Unusual Conditions Defective Remote Control General If a fault occurs in the remote control, which prevents engine control from the control room, you can operate the engine from the local control panel. The data are given in the groups that follow: 0230−1 Engine Start 0260−1...
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Page 145 0570−1/A1 Operation Operation during Unusual Conditions Defective Speed Control System General Defects in the speed control system must be repaired as soon as possible (see the documentation of the manufacturer). If this is not possible, you can control the engine from the local control panel.
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Page 147: 0590-1/A1
0590−1/A1 Operation Operation during Unusual Conditions Defective Turbocharger General If a turbocharger becomes defective, you must shut down the engine as quickly as possible to prevent damage. If repair or replacement of a turbocharger is not immediately possible, the engine can operate in Emergency Operation at decreased load after the procedures below is completed.
Page 148 0590−1/A1 Operation Defective Turbocharger Condition Two Defective turbocharger on engines without an exhaust bypass pipe. The engine load output is approximately 10% to 15% of the CMCR. This is related to the output of the auxiliary blowers. 2.2.1 Procedure Lock the rotor of the defective turbocharger (see the turbocharger manual).
Page 149 0610−1/A1 Operation Special Procedures Before and After Operation Prepare for Engine Start after a Long Shutdown Period or an Overhaul General For an engine that that was shut down after a long period or an overhaul, do the special procedures in paragraph 2. Note: If the engine was shut down only for some days, you must do the procedures given in 0110−1...
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Page 151 0620−1/A1 Operation Special Procedures Before and After Operation Prepare the Engine for a Long Shutdown Period General ............Condition One .
Page 152 0620−1/A1 Operation Prepare the Engine for a Long Shutdown Period Close the stop valves on the fuel tanks. Open the drain valves of the exhaust gas manifold and the exhaust gas pipe to drain the condensate. 10) Close the drain valves of the exhaust gas manifold and the exhaust gas pipe. 11) Put a cover (e.g.
Page 153 0620−1/A1 Operation Prepare the Engine for a Long Shutdown Period Procedure Intervals WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel. Do steps 1) to 12) below each week: Make sure that the indicator valves are open. Use the turning gear to turn the engine until the piston is at 60_ before or after TDC (look on the flywheel).
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Page 155 Gas oils and diesel oils (distillates) can be used in all WinGD engines with some limits. WinGD 2-stroke diesel engines are designed to operate on up to 700 mm (cSt) at 50_viscosity heavy fuel oil (ISO 8217:2010 RMK 700 grade) if sufficient fuel heating and treatment is done.
Page 156: 0710-1/A1
0710−1/A1 Operation Diesel Engine Fuels Heavy fuel oil must be treated in an applicable fuel treatment plant. When bunkering, it is possible that the fuel suppliers will report only some of the values given in the Quality Specifications. Frequently, only the density and maximum viscosity is given.
Page 157 0710−1/A1 Operation Diesel Engine Fuels In ISO 8217, foreign substances such as used oil or chemical waste must not be added to the fuel. This is because of the hazards to the crew, machines and the environment. Tests that are done for unwanted substances as acids, solvents and monomers with titrimetric, infrared and chromatographic methods, are recommended.
Page 158 Note: For data about the parameters given in the table above, see paragraph to paragraph 3.12. CAUTION Damage Hazard: For WinGD 2-stroke engines, the maximum permitted fuel temperature at the engine inlet is 150_C. Always make sure to obey this limit. Damage to the engine can occur. For more data, see also 0250−1...
Page 159: Data About Heavy Fuel Oil Specifications
0710−1/A1 Operation Diesel Engine Fuels Data about Heavy Fuel Oil Specifications Viscosity The recommended viscosity range upstream of the engine is between 13 mm /s (cSt) and 17 mm /s (cSt). You get the necessary temperature for a given nominal viscosity from the data in Fig.
Page 160: Density
Sulphur Sulphur limits are not specified in ISO 8217:2010 because statutory specifications put a limit on this value. The maximum sulphur level that can be used in WinGD 2-stroke engines is 4.5% m/m. The alkalinity (base number (BN)) of the cylinder lubricating oil must be selected in relation to the sulphur level of the fuel in use.
Page 161: Acid Number
0710−1/A1 Operation Diesel Engine Fuels Acid Number Fuels with high acid numbers have caused damage to fuel injection systems. Most fuels have a low acid number, which is not dangerous, but an acid number above 2.5 mg KOH/g, can cause problems. Some naphthenic fuels can have an acid number of more than 2.5 mg KOH/g, but still be permitted.
Page 162: 3.12 Used Lubricating Oil And Chemical Waste
0710−1/A1 Operation Diesel Engine Fuels 3.11.2 Aluminum and Silicon Aluminum (Al) and silicon (Si) in the fuel are an indication of catalytic fines (cat fines). These are particles of hard oxides (round particles of material almost the same as porcelain) which cause high abrasive wear to pistons, piston rings and cylinder liners. Cat fines are used as a catalyst in some processes in petroleum refining and can be found in diesel engine fuels.
Page 163 0710−1/A1 Operation Diesel Engine Fuels Distillate Fuel Specifications Note: For data about the parameters given in Table 2, see paragraphs 5.1 to 5.12. Table 2: Fuel Specifications Parameter Unit Bunker Limit Test Method Necessary Fuel Quality at the Engine Inlet /s [cSt] Maximum 11.0 ISO 3104...
Page 164: Data About Distillate Fuel Specifications
They are easier to operate than residual fuel, but caution is necessary for some problems. See Service Bulletin RT−82: Distillate Fuel Use. ISO 8217: 2010 specifies DMX, DMA, DMZ and DMB categories. The WinGD engine inlet specification is based on the DMB grade which is the highest viscosity grade.
Page 165: Hydrogen Sulphide
0710−1/A1 Operation Diesel Engine Fuels Hydrogen Sulphide WARNING Danger: Hydrogen Sulphide (H S) is a very toxic gas and exposure to high concentrations is dangerous and can kill you. Be careful when tanks or fuel lines are opened because there can be H S vapor.
Page 166: Bio-Derived Products And Fatty Acid Methyl Esters
ISO 8217 standard or for fuels that WinGD has recommended. If you think, that it is necessary to use additives, WinGD recommends to speak to the fuel supplier and to the additive supplier. They can give you the related results of the use of additives.
Page 167: General
0720−1/A1 Operation Operating Media Fuel Treatment and Fuel System General ............Treatment of HFO and Treatment Plant .
Page 168 0720−1/A1 Operation Fuel Treatment and Fuel System HFO and Diesel Fuel Separation It is recommended that modern centrifuges are used for the treatment of heavy fuels. The separation effect, i.e. the cleaning effect, is related to the flow rate and viscosity of the HFO.
Page 169 0720−1/A1 Operation Fuel Treatment and Fuel System Configuration of the Fuel System In the recommended standard plant, pressure is kept in the full fuel system to prevent the evaporation of water in the fuel at the temperature necessary for the heavy fuel oil (HFO).
Page 170 0720−1/A1 Operation Fuel Treatment and Fuel System Key to Fig. 1 1 HFO settling tank 18 Suction filter 2 HFO/LSHFO settling tank 19 Low pressure supply pump 3 HFO daily tank 20 Air overflow pipe 4 LSHFO daily tank 21 Mixing unit, heatable and insulated 5 MDO settling tank 22 Booster pump 6 MDO daily tank...
Page 171 W-X82 0720−1/A1 Operation Fuel Treatment and Fuel System WCH03254 Fig. 1: Schematic Diagram − Fuel System 2015-07 5 / 5 Winterthur Gas & Diesel Ltd.
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Page 173: Scavenge Air
0740−1/A1 Operation Operating Media Scavenge Air and Starting Air Scavenge Air The turbocharger compresses the air from the engine room or from outside for the scavenge air and air for the cylinders, (see 6500−1 Turbocharging). The air must be as clean as possible to keep the wear of cylinder liner, piston rings, turbocharger compressor etc.
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Page 175 The oil must also have good thermal stability, anti-corrosion and anti-foam properties, and good demulsifying performance. Note: Validated system oils for WinGD 2-stroke engines are shown in paragraph 8.2. For different or new lubricating oils, speak to or send a message to WinGD.
Page 176: Lubricating Oils
0750−1/A1 Operation Lubricating Oils Oil Care 2.1.1 System Oil To keep the lubricating oil in good condition for long periods, good oil treatment is necessary. To do this, a self-cleaning centrifugal separator is used. A self-cleaning centrifugal separator is used as a purifier in bypass. The oil flows from the oil tank through the centrifugal separator.
Page 177 0750−1/A1 Operation Lubricating Oils Table 1: Alert Limits of System Oil Parameters Parameter Limit Test Method Viscosity at 40_C Maximum 140 mm /s [cSt] ASTM D 445 Flash point (PMCC) Minimum 200_C ASTM D 92 Total insolubles Maximum 0.70% m/m ASTM D 893b Base Number (BN) Maximum 12 mg KOH/g...
Page 178: Particle Size And Count
If there is an important decrease in the flash point below the recommended value shown above, WinGD recommends a replenishment of the oil charge. By a replenishment, an increase in the system oil BN is prevented. A small increase in BN is often an indication that the system oil consumption is low.
Page 179 0750−1/A1 Operation Lubricating Oils Table 3: ISO 4406 Particle Count and Size Classes Number of particles per 100 ml More Than Up To and Includes Class 250 000 000 − Less than 28 130 000 000 250 000 000 64 000 000 130 000 000 32 000 000 64 000 000...
Page 180 0750−1/A1 Operation Lubricating Oils The (older) NAS 1638 and SAE AS 4059 cleanliness classes for oils are given in Table 4. Table 4: NAS 1638 and SAE AS 4059 Cleanliness Classes Contamination (particles/100 ml) Particle size (mm or microns) Class 5 to 15 15 to 25 25 to 50...
Page 181 2.3.2 Recommended Limits for NAS and SAE AS Particle Count For particles larger than 21 mm, WinGD recommends the NAS and SAE AS specification for a 100 ml oil sample in the system oil as in Table 5. Table 5: Limits for NAS 1638 and SAE AS 4059 Cleanliness Classes...
Page 182: Oil Samples
0750−1/A1 Operation Lubricating Oils Oil Samples At regular intervals, (i.e. at approximately each 300 operation hours), it is recommended that you get a sample of the system oil. Send the the sample of the system oil to a laboratory to make an analysis. The analysis must include ISO 4406 particle counts for samples taken from downstream of the coarse filter or fine filter.
Page 183: Cylinder Lubricating Oil
0750−1/A1 Operation Lubricating Oils Cylinder Lubricating Oil A high-alkaline cylinder lubricating oil of the SAE 50 viscosity grade that has a minimum kinematic viscosity of 18.5 cSt at 100_C is recommended. But, cylinder lubricating oils of the viscosity grades SAE 40 and SAE 60 can be used in some conditions.
Page 184 0750−1/A1 Operation Lubricating Oils Range 1 (see Fig. 1): When the fuel sulphur content is more than 0.1% m/m and less than 0.5% m/m during operation with BN 15 to BN 25 cylinder lubricating oil, you must do an analysis of the piston underside drain oil from the on-board monitoring system.
Page 185 Note: Use only the cylinder lubricating oils given in paragraph 8.2. The oil company assumes all responsibility for the performance of the cylinder lubricating oils in service of all WinGD 2-stroke engines to the exclusion of any liability of any WinGD company belonging to the WinGD group.
Page 186: Oil Samples − Piston Underside Drain Or Scrape-Down
Operation Lubricating Oils Oil Samples − Piston Underside Drain or Scrape-down WinGD recommends to get piston underside drain oil (scrape-down oil) samples at regular intervals from each cylinder and to make an analysis to monitor the engine condition. These analyses are used to make an estimate of the cylinder liner and piston ring wear and to set the applicable alkalinity and feed rate of the cylinder lubricating oil.
Page 187 0750−1/A1 Operation Lubricating Oils It is necessary to find the safe value for continuous operation on fuel oil with a low sulphur content (of between 0.0% m/m and 0.5% m/m) and a low BN cylinder lubricating oil (between BN 15 and BN 25) for each engine. To find this safe value, you monitor the piston underside samples and do regular checks of the pistons, piston rings and cylinder liners for excessive deposits, corrosion and wear.
Page 188: General Recommendations
60% CMCR) and the sulphur content of the used HFO is more than 2.5% m/m, WinGD strongly recommends the use of a BN 100 cylinder lubricating oil, as the cylinder oil feed rate cannot be adjusted to adequately compensate for the lower alkalinity.
Page 189: Turbocharger Oil
0750−1/A1 Operation Lubricating Oils Turbocharger Oil To select the turbocharger lubricating oil and keep this oil in a satisfactory condition, refer to the recommendations given in the turbocharger instruction manual. The turbocharger lubricating oil is usually system oil or turbine oil. Turning Gear Oil To select the turning gear oil and keep this oil in a satisfactory condition, refer to the recommendations given in the instruction manual of the turning gear manufacturer.
Page 190: Validated Lubricating Oils
Lubricating Oils Validated Lubricating Oils Lubricating Oil Instruction and Liability The application and handling of lubricating oils must be in compliance with the WinGD general lubricating oil specifications and recommendations given in the Operation Manual (this manual) and the Maintenance Manual.
Page 191 0750−1/A1 Operation Lubricating Oils Pertamina − − − Medripal 570 − − Petrobras − Marbrax Marbrax Marbrax − − CID−54−APN CID−55 CID−57 (BN 50) PetroChina − − − KunLun DCA − − 5070H Premier Six − Opt−Max BoB 300 additives for on−board blended cylinder oils (BN 40 to BN 120) Opt−Max −...
Page 192: System Oils
0750−1/A1 Operation Lubricating Oils System Oils Table 7: List of Validated System Oils (Last Update: May 2017) Oil Supplier Brand Base Number (BN) Aegean Alfasys 305 Castrol CDX 30 Chevron Veritas 800 Marine 30 Marilube Oil AC−30 Cladium 50 ExxonMobil Mobilgard 300 C FL Selenia MESYS 3006...
Page 193: General
0760−1/A1 Operation Operating Media Cooling Water / Cooling Water Treatment General An applicable treatment is used to give the cooling water the correct properties, which will prevent service problems. Cooling water that has not had treatment can soon cause problems in the cooling system from corrosion, sediment and hard particles (crust).
Page 194 0760−1/A1 Operation Cooling Water / Cooling Water Treatment Cleaning the Cooling Water System For new cooling water, the full system must be clean. The system must not contain grease, oil or unwanted particles. During operation oil or sediment can go into the system, which can cause a decrease in the heat transfer and cooling effect.
Page 195 0800−1/A1 Operation Problems during Operation General General If the operation and maintenance instructions are obeyed, problems during operation can be prevented. If a fault occurs, do not search randomly for the cause. Use a sequence to find possible causes. This applies specially to problems during engine start and engine stop.
Page 196 0800−1/A1 Operation General Problems and Damage to Engine Parts Hot running of a piston Hot running of the running gear. For more data, see 0840−1 Failures and Defects of WECS Components WECS passive fault WECS common fault WECS cylinder fault WECS pressure fault WECS critical fault (WECS engine fault) Cylinder lubrication has a malfunction.
Page 197 0810−1/A1 Operation Operation Problems Problems during Engine Start and Stop Problems during Engine Start For the names and part code numbers, see 4003−2 Control Diagram. Problem Possible Cause Procedure The engine does not turn The shut-off valves on the starting air bottles Open the shut-off valves.
Page 198 0810−1/A1 Operation Problems during Engine Start and Stop Problem Possible Cause Procedure Engine will not start from the The starting air shut-off valve does not open, Do an overhaul of the starting control stand at the engine (cannot move), the non-return valve cannot air shut-off valve.
Page 199 0810−1/A1 Operation Problems during Engine Start and Stop Problem Possible Cause Procedure The engine turns on starting The fuel booster pressure is not sufficient. Adjust the fuel booster air but gets no fuel Pressure retaining valve is set too low. Booster pressure.
Page 200 0810−1/A1 Operation Problems during Engine Start and Stop Problem Possible Cause Procedure A cylinder does not fire or does No power supply to FCM−20. Electrical Set to on the power supply. not fire correctly when starting connection disconnected, or incorrectly Connect the electrical (continued).
Page 201 0820−1/A1 Operation Operating Problems Irregular Operation Load Indications ..........Cylinder Lubrication .
Page 202 0820−1/A1 Operation Irregular Operation Problem Possible Causes Procedure The exhaust temperature of a The air flaps in the scavenge air receiver are Clean, overhaul or replace cylinder increases dirty or defective. the air flaps. The injection nozzles are worn. Replace with the spare kit. The scavenge ports in the cylinder liner are Clean the scavenge ports.
Page 203 0820−1/A1 Operation Irregular Operation Problem Possible Causes Procedure There is smoke from the Air supply is not sufficient. Unwanted material Scavenge air pressure exhaust in the exhaust side or air side of the decreases. turbocharger, scavenge air cooler, air flaps in the receiver, scavenge ports in cylinder liners or in the exhaust boiler.
Page 204 0820−1/A1 Operation Irregular Operation Problem Possible Causes Procedure Irregular operation of the Air collects in the cooling spaces or in the Release the pressure. cylinder cooling water system pipes because pressure release is not sufficient. Pressure increases and There is a decrease of static pressure at the See the plant instructions.
Page 205 0820−1/A1 Operation Irregular Operation Problem Possible Causes Procedure Cylinder lubrication is The daily tank is empty. The ball valve Fill the daily tank. Open the defective. No lubricating oil downstream of the lubricating oil filter 8.17 is ball valve. Replace or clean closed or the filter element is clogged.
Page 206 0820−1/A1 Operation Irregular Operation Turbocharger Short, loud noise and at the same time the pressure changes on the air side. Surges do not have a direct effect on the engine when this occurs at irregular intervals, but the air flow rate is decreased. Problem Possible Causes Procedure...
Page 207 0820−1/A1 Operation Irregular Operation Exhaust Waste Gate The exhaust waste gate is defective, low-load tuning causes too much thermal load on the engine, or a scavenge air pressure that is too high. Problem Possible Causes Procedure The engine has too much The butterfly valve stays in the OPEN Adjust the screw for manual thermal load...
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Page 209 0840−1/A1 Operation Operation Problems Irregular Operation Piston − Hot Operation The possible indications of a piston that operates at a temperature that is too hot, but where combustion is correct are as follows: A temperature increase at the piston cooling oil outlet A temperature increase at the jacket cooling water outlet A temperature increase of the piston underside.
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Page 211 0850−1/A1 Operation Operation Problems Failures and Defects of WECS Components General ............Failure ID and LED Indications on FCM-20 .
Page 212: Failures And Defects Of Wecs Components
0850−1/A1 Operation Failures and Defects of WECS Components Failure ID and LED Indications on FCM-20 Ó Ó Ó Ó Ó Ó Ó Ó Ó Inject Ó Ó Ó Ó Ó Ó Ó Ó Ó Exhaust Ó Ó Ó Start Vlv Ó...
Page 213: Led Indication On Alm-20
0850−1/A1 Operation Failures and Defects of WECS Components LED Indication on ALM-20 PART NO : SER. NO : HW REV. : PROD. DATE : 014.537/06 014.538/06 Fig. 2: LED Indications on ALM-20 1 Connector (COMBICON) 3 Screw 2 Control box 41.nn 4 LEDs 2014 3/ 39...
Page 214: Failure Indications
0850−1/A1 Operation Failures and Defects of WECS Components Failure Indications Failure Groups All WECS failure indications are part of the failure groups that follow and are always shown together with the related group. Failure Groups Failure Effects Procedures WECS passive failures Failures of redundant systems (failure of Find the cause and repair as a redundant component, system or an...
Page 215: Led On / Off Codes
0850−1/A1 Operation Failures and Defects of WECS Components LED On / Off Codes 4.3.1 Red Fail LED and Two-digit LED Display The red Fail LED shows a failure on the related FCM-20 and if the failure status is active or inactive (see Fig. 1). Type of Failure Failure Effects Procedures...
Page 216 0850−1/A1 Operation Failures and Defects of WECS Components 4.3.5 LED Indication on FCM-20 at Start-up On the right side of the the FCM−20: After the power is set to on, the SSI CA1, CA2 and CAN S1, S2 and M LEDs show red for approximately four seconds.
Page 217: Failure Id
0850−1/A1 Operation Failures and Defects of WECS Components Failure ID Display Failure Text Failure Group ME crank angle #1+2 fail. WECS critical WECS critical failure WECS critical WECS pressure failure WECS pressure WECS cylinder failure WECS cylinder WECS common failure WECS common WECS passive failure WECS passive...
Page 218 0850−1/A1 Operation Failures and Defects of WECS Components Display Failure Text Failure Group ME crank angle #1 / TDC low shift WECS common ME crank angle #2 / TDC low shift WECS common ME both CA / TDC low shift WECS cylinder ME excessive engine speed WECS critical...
Page 219: Wecs Passive Failure
0850−1/A1 Operation Failures and Defects of WECS Components WECS Passive Failure Failure Text ME scavenge air pressure sensor #1 meas. fail. (ID 8) FCM−20 No. Display Indication Cause Sensor signal < 2mA or > 22mA Procedure ⇒ Do a check of the pressure transmitter PT4043C for damage. ⇒...
Page 220 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME servo oil pressure sensor #1 meas. fail. (ID 16) FCM−20 No. Failure ID Display Indication Cause Sensor signal < 2 mA or > 22 mA (failure signal is released after 3 seconds). Procedure ⇒...
Page 221 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME fuel rail pressure sensor #1 meas. fail. (ID 27) FCM−20 No. Failure ID Display Indication Cause Sensor signal < 2 mA or > 22 mA (failure signal is released after 3 seconds). Procedure ⇒...
Page 222 0850−1/A1 Operation Failures and Defects of WECS Components Indication FCM−20 No. Failure ID Display Cause The sensor power supply has a short circuit (red LED) Procedure ⇒ In E95.04, disconnect pressure transmitter PT3462C and plug X25 Remark: ID fault FCM−20 #04 comes on ⇒...
Page 223 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text WECS Modbus fail. FCM−20 #01 or #02 (ID 39) FCM−20 No. Failure ID Display Indication #01 and #02 Modbus Cause Modbus monitoring, no communication (failure signal is released after 3 seconds). Procedure ⇒...
Page 224 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME exhaust valve #nn position meas. fail. (ID 71) FCM−20 No. Failure ID Display Indication #01 to #08 Ex.D or Ex.F Cause Sensors ZT5421C to 27C (driving end) signal < 2 mA or > 22 mA (failure signal is released after 3 seconds).
Page 225 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME crank angle #1 fail. (ID 1.0) FCM−20 No. Failure ID Display Indication #01 to #09 SSI CA1 Cause No data received from sensor #1 (GT5126C). Procedure ⇒ If the failure is shown on all cylinders do a check of the sensor GT5126C for increased clearance on the sensor pulley and bearings.
Page 226 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text WECS CAN S1-bus fail. (ID 1.2) FCM−20 No. Failure ID Display Indication #01 to #09 Cause CAN system bus #1 monitoring / CAN failure (failure signal is released after 3 seconds). Procedure ⇒...
Page 227 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text WECS cylinder lubrication passive failure. (ID 2.5) FCM−20 No. Failure ID Display Indication #03 and #04 None Cause Disconnected power supply #1 or #2. Procedure ⇒ In E85, E90 and E41.xx, make sure that the cables have no damage and are connected correctly.
Page 228: Wecs Common Failure
0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME waste heat recovery valve #2 not closed (ID 3.4.) FCM−20 No. Failure ID Display Indication None 3.4. Cause Waste heat recovery valve #2 (second valve) is not closed. A command to close the second valve was sent to the valve, but the sensor responses that the valve is in the open position.
Page 229 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME scavenge air pressure meas. fail. diff. high (ID 10) FCM−20 No. Failure ID Display Indication #03 and #04 Cause The pressure transmitters PT4043C and PT4044C have a difference of more than 0.2 bar (failure signal is released after 5 seconds) Procedure ⇒...
Page 230 0850−1/A1 Operation Failures and Defects of WECS Components Failure text ME servo oil pressure high (ID 19) FCM−20 No. Failure ID Display Indication #01 and #02 Cause Servo oil pressure is 15 bar more than the setpoint, engine speed is more than 8% of nominal speed (failure signal is released after 5 seconds).
Page 231 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME servo oil pump #2 fail. (ID 26) FCM−20 No. Failure ID Display Indication Cause The setpoint pressure controller of the servo oil pump actuator CV7222C is > 100 mA (failure signal is released after 30 seconds) Procedure ⇒...
Page 232 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME fuel rail pressure meas. fail. diff. high (ID 29) FCM−20 No. Failure ID Display Indication #03 and #04 Cause The sensors PT3461C and PT3462C have a difference of more than 50 bar (failure signal is released after 7 seconds).
Page 233 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME fuel rail pressure low (ID 31) FCM−20 No. Failure ID Display Indication #03 and #04 Cause Fuel rail pressure is 100 bar less than the fuel pressure setpoint (failure signal is released after 10 seconds).
Page 234 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME crank angle #1 and #2 difference (ID 60) FCM−20 No. Failure ID Display Indication #01 and #02 SSI CA1 Cause Crank angle sensor #1 and #2 are serviceable, but the difference between the two systems is more than 1.0_ CA.
Page 235 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME crank angle #1 / TDC high shift (ID 63) FCM−20 No. Failure ID Display Indication Cause The difference between the TDC pick-up and the crank angle sensor #1 is 4.0_ CA The crank angle sensor or toothed belt has moved.
Page 236 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME crank angle #2 / TDC high shift (ID 64) FCM−20 No. Failure ID Display Indication Cause The difference between the TDC pick-up and the crank angle measurement system #2 is 4.0_ CA.
Page 237 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME crank angle #2 / TDC low shift (ID 67) FCM−20 No. Failure ID Display Indication Cause The difference between the TDC pick-up and the crank angle sensor #2 is ± 2.0_ The crank angle sensor or toothed belt has moved Remark: No failure shown at shut-down Procedure ⇒...
Page 238 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME injection quantity sensor #nn meas. fail. (ID 80) FCM−20 No. Failure ID Display Indication #01 to #09 InjQ Cause The sensor power supply has a short circuit (red LED). Procedure ⇒...
Page 239 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME exhaust waste gate not closed (ID 5.5) FCM−20 No. Failure ID Display Indication InjQ Cause Butterfly valve stays open at a load range of less than 85%. Connection to the position sensor ZS5372C is broken, or there is a short circuit (failure signal released after 20 seconds) Procedure ⇒...
Page 240: Wecs Cylinder Failure
0850−1/A1 Operation Failures and Defects of WECS Components WECS Cylinder Failure Failure Text ME manual injection cutoff cylinder #nn (ID 45) FCM−20 No. Failure ID Display Indication #01 to #09 Cause The fuel injection is cut off manually Procedure ⇒ For more data, see the related alarms (WECS cylinder fail) Remark: This failure is not shown if a cylinder is cut off automatically.
Page 241 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME Exh. Valve Late/Not Opening (slowdown) (ID 75) FCM−20 No. Failure ID Display Indication #01 to #09 Cause The exhaust valve opens 15_CA or more after the crank angle setpoint Procedure ⇒...
Page 242 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME Exh. Valve Late/Not Closing (slowdown) (ID 77) FCM−20 No. Failure ID Display Indication #01 to #09 Cause The exhaust valve closes 15_CA or more after the crank angle setpoint Procedure ⇒...
Page 243 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME Inj. Quantity Piston, No Movement (slowdown) (ID 91) FCM−20 No. Failure ID Display Indication #01 to #09 InjQ Cause The fuel quantity piston moves less than 4% during the injection. Remark: This alarm is first transmitted after three revolutions.
Page 244: Wecs Pressure Failure
0850−1/A1 Operation Failures and Defects of WECS Components WECS Pressure Failure Failure Text ME Scavenge Air Pressure very HI (ID 11) FCM−20 No. Failure ID Display Indication #03 and #04 Cause The scavenge air pressure is more than 105% (failure signal is released after 2 seconds). The exhaust waste gate has a malfunction.
Page 245 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME fuel rail pressure very low (ID 32) FCM−20 No. Failure ID Display Indication #03 and #04 Cause The fuel rail pressure is 150 bar more than the fuel pressure setpoint (failure signal is re- leased after 10 seconds) Remark: No failure is shown during the conditions that follow: Stop command, shut-down, engine is stopped, fuel rail pressure sensor #1+2 meas.
Page 246: Wecs Critical Failure (Wecs Engine Failure)
0850−1/A1 Operation Failures and Defects of WECS Components WECS Critical Failure (WECS Engine Failure) Failure Text ME crank angle #1+2 fail. (ID 1) Indication FCM−20 No. Display #03 and #04 None Cause The two crank angle sensor measurements fail. Procedure ⇒ Do a check of the crank angle sensor unit and terminal box E96 for damage. ⇒...
Page 247: 4.10 Malfunction Of Cylinder Lubrication
0850−1/A1 Operation Failures and Defects of WECS Components 4.10 Malfunction of Cylinder Lubrication LEDs on the ALM−20 show malfunctions and defects of the cylinder lubrication control system (see Fig. 2). Data about irregular functions with the lubricating pump components, or in the lubricating and servo oil system are given in 0820−1, paragraph 2 Cylinder lubrication.
Page 248 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME cylinder lubrication malfunction cylinder #nn ALM−20 No. On / Off Code Indication #01 to #09 CAN1 and/or CAN2 None Cause LED indication on one module: a cable is broken on the plug X2 on the related ALM−20. LED indication on all modules: CAN Bus #1 / #2 malfunction.
Page 249 0850−1/A1 Operation Failures and Defects of WECS Components Failure Text ME cylinder lubrication malfunction cylinder #nn ALM−20 No. On / Off Code Indication #01 to #09 Fail Two times each interval Cause A cable is broken between an ALM−20 (plug X1, terminals 13 and 14) and the pressure trans- mitter (PT3131C to PT3139C).
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Page 251 Group1 Operation Bedplate and Tie Rod Group 1 Main Bearing ................1132−1/A1 Thrust Bearing .
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Page 253: Main Bearing
1132−1/A1 Operation Main Bearing General The main bearing has a lower bearing shell (7, Fig. 1) and an upper bearing shell (5). The running surfaces of the bearing shells are lined with white metal. The lower bearing shell (7) is installed in the bearing girder (9) of the bedplate and the upper bearing shell (5) in the bearing cover (4).
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Page 255: Thrust Bearing
1203−1/A1 Operation Thrust Bearing General The thrust bearing is installed at the driving end of the engine. The thrust bearing flange (17, Fig. 2) transmits the force from the propeller through the thrust pads (5, 13) into the bedplate. The arbor supports (6, Fig. 1) prevent circular movement of the thrust pads (5, 13, see Fig.
Page 256 1203−1/A1 Operation Thrust Bearing 018.087/09 Fig. 1: Cross Section 1 Column 6 Arbor support 2 Oil pipe 7 Bearing cover 3 Nozzle 8 Intermediate wheel (pump unit) 4 Bedplate 9 Intermediate wheel (supply unit) 5 Thrust pad (free end) OI Bearing oil inlet 2017−08 2/ 3 Winterthur Gas &...
Page 257 1203−1/A1 Operation Thrust Bearing Lubrication During operation, bearing oil flows through the oil pipe (2, Fig. 2) to the two nozzles (3). The oil flows out of the two nozzles (3) as a spray, which becomes an oil layer between the thrust bearing flange (17) and the thrust pads (5, 13). I - I 018.088/09 Fig.
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Page 259 1903−1/A1 Operation Tie Rod General The tie rods (1, Fig. 1) keep the cylinder block (2), column (3) and bedplate (4) together at four locations around the cylinders. WCH01187 WCH01187 FOR 7-CYLINDER ENGINES Fig. 1: Tie Rod Configuration and Locations 1 Tie rod 3 Column 2 Cylinder block...
Page 260 1903−1/A1 Operation Tie Rod A two-part bush (2, Fig. 2) is welded on the tie rod (1) as shown in view II. At the bottom of the cylinder block, two set screws (7) tightly hold the two-part bush (2) and prevent vibration of the tie rods (1).
Page 261 Group2 Operation Cylinder Liner and Cylinder Cover Group 2 Cylinder Liner ................2124−1/A1 Lubricating Quills on Cylinder Liner .
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Page 263: Cylinder Liner
2124−1/A1 Operation Cylinder Liner General The screws (12, Fig. 1) and holders (6) attach the cylinder liner (1) in the cylinder jacket (4). The nuts of the elastic studs attach the cylinder cover (9) and cylinder liner (1) with the upper and lower water guide jackets (2, 3) to the cylinder jacket (4). The surfaces of the cylinder liner (1) and the cylinder jacket (4) make a metallic seal MS.
Page 264 2124−1/A1 Operation Cylinder Liner WCH01114 Fig. 1: Cylinder Liner 1 Cylinder cover 14 Insulating bandage 2 Top water guide jacket 15 Antipolishing ring 3 Bottom water guide jacket 4 Cylinder jacket AS Annular space in upper water guide jacket 5 Lubricating quill CB Cooling bores in cylinder cover 6 Holder CI Cooling water inlet...
Page 265: General
2138−1/A1 Operation Lubricating Quills on Cylinder Liner General Eight lubricating quills (1, Fig. 1) are are installed around the circumference of the cylinder liner (2). The lubricating pump (3) supplies lubricating oil through pipes to each lubricating quill (1). WCH01128 Fig.
Page 266 2138−1/A1 Operation Lubricating Quills on Cylinder Liner Function The lubricating pump supplies a set quantity of lubricating oil at high pressure through the connection (OI) into the lubricating quills (see Fig. 2). The non-return valve (6, Fig. 2) opens and the lubricating oil comes out of the the nozzle tip (5) and the lubricating point (LP) as a spray.
Page 267 2303−1/A1 Operation Piston Rod Gland General The piston rod gland (1, Fig. 1) keeps the dirty oil in the scavenge space (SS) and prevents contamination of the bearing oil. Also, the piston rod gland box seals the scavenge air from the crankcase (2). Damaged gaskets cause an increase in the quantity of oil in the leakage oil drain.
Page 268 2303−1/A1 Operation Piston Rod Gland I - I WCH01179 FUEL SIDE WCH01179 Fig. 2: Piston Rod Gland 1 Housing (2-part) 10 Cylinder jacket 2 Support 11 Piston rod 3 Scraper ring (4-part) 4 Ring support (3-part) BD Bearing oil drain 5 Scraper ring (3-part) LD Leakage oil drain 6 Gasket (4-part)
Page 269 2722−1/A1 Operation Injection Valve (FAST Nozzle) General Three Fuel Actuated Sacless Technology (FAST) injection valves (3, Fig. 1) are installed in each cylinder cover (1). Fuel, which leaks because of the needle clearance, drains through the connection leakage fuel drain (LD, Fig. 2) to the fuel leakage pipe (6) and into the collector block (5) (see 8019−1 Fuel Oil System).
Page 270 2722−1/A1 Operation Injection Valve (FAST Nozzle) 016.921/08 Fig. 1: Location of Injection Valves 1 Cylinder cover 5 Collector block 2 Fuel leakage pipe 6 Fuel leakage pipe 3.49 3 Injection valve 3.01 7 Injection control unit 3.02 4 Injection pipe 3.47 8 Fuel rail 3.05 2017−08 2/ 3...
Page 271 2722−1/A1 Operation Injection Valve (FAST Nozzle) II - II I - I WCH00879 Fig. 2: Injection Valve 9 Nozzle holder FS Fuel supply (high pressure) 10 Tappet carrier LO Leakage fuel outlet 11 Nozzle body FB Fuel bore 12 Nozzle tip SF Sealing face 13 Clamping nut LD Leakage fuel drain...
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Page 273 2728−1/A1 Operation Starting Valve General A starting air valve is installed in each cylinder cover (5, Fig. 1). The starting air valves start the engine, or decrease the engine speed for reversing. The Wärtsilä Engine Control System (WECS-9520) monitors and controls the starting air valve operation (see 4002−1, paragraph 4.4).
Page 274 2728−1/A1 Operation Starting Valve I - I 016.856/08 016.856/08 Fig. 1: Starting Valve 1 Cover SA Starting air 2 Piston RB Relief bore 3 Housing Air space 4 Compression spring Air space 5 Cylinder cover CA Control air from starting air pipe 6 Valve spindle 7 3/2-way solenoid valve 2014...
Page 275 2751−1/A1 Operation Exhaust Valve General ............Function .
Page 276: Exhaust Valve
2751−1/A1 Operation Exhaust Valve The air spring (AS) is below the air spring piston (10, Fig. 2). The valve stroke sensor (18) monitors and transmits the open and closed positions of the valve spindle (6) to the WECS-9520. If there is a large pressure difference between when the exhaust valve opens and the pressure in the air spring (AS), damage can occur to the exhaust valve.
Page 277 2751−1/A1 Operation Exhaust Valve I - I IV - IV 016.874/08 WCH00851 Fig. 2: Exhaust Valve and Leakage Oil Drain 2014 3/ 6 Winterthur Gas & Diesel Ltd.
Page 278: Function
2751−1/A1 Operation Exhaust Valve Key to Fig. 2: Exhaust Valve and Leakage Oil Drain 1 Valve cage 12 Thrust piece 2 Lower housing 13 Connection (hydraulic oil) 3 Upper housing 14 Orifice 4 Outside piston 15 Cup spring 5 Inside piston 16 Rotation wing 6 Valve spindle 18 Valve stroke sensor...
Page 279 2751−1/A1 Operation Exhaust Valve Lubrication Leakage oil from the outside piston (4, Fig. 2) and inside piston (5) lubricates the air spring piston (10). Oil in the leakage oil collection space (LS) drains to the leakage oil drain (LD). While the exhaust valve closes, oil flows through the air spring piston (10) and goes into the air spring (AS).
Page 280 2751−1/A1 Operation Exhaust Valve Combustion Control The pressure transducer (2, Fig. 4) (one for each cylinder) is installed on the cylinder cover (3). A relief valve (1) is installed on each pressure transducer (2). For more data, see 9308−1 Intelligent Combustion Control. I - I WCH00830 Fig.
Page 281 Group3 Operation Crankshaft, Connecting Rod and Piston Group 3 Axial Damper ................3140−1/A1 Connecting Rod and Connecting Rod Bearing .
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Page 283: Monitoring System
3140−1/A1 Operation Axial Damper General The engine has a built-in axial damper. The function of the axial damper is to decrease axial vibrations. The axial damper includes a top cylinder half (1, Fig. 1) and a bottom cylinder half (2) attached with bolts to the last bearing girder.
Page 284 3140−1/A1 Operation Axial Damper I - I 018.091/09 Fig. 1: Axial Damper 1 Top cylinder half 9 Bearing cover 2 Bottom cylinder half 10 Crankshaft 3 Housing 11 Bearing girder (part of bedplate) 4 Spindle 12 Oil pipe 5 Locking device 13 Flange (on crankshaft) 6 Small gasket (two parts) and spring 7 Large gasket (two parts) and spring...
Page 285 3303−1/A1 Operation Connecting Rod and Connecting Rod Bearing General The connecting rod connects the crosshead to the crankshaft and converts the linear movement of the piston into a circular movement. Bearing shells (4, 5, and 6, Fig. 1) (that can be replaced) are installed on the connecting rod (1) for the bottom end bearing and top end bearing.
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Page 287 3326−1/A1 Operation Crosshead and Guide Shoe General The crosshead guides the piston rod (8) and absorbs the lateral forces that come from the connecting rod (4) (see Fig. 1 and Fig. 2). The piston rod (8) is attached to the crosshead pin (6) with screws. The bearing oil necessary to cool the piston flows through the groove (11) and the bore (OB) to the piston.
Page 288 3326−1/A1 Operation Crosshead and Guide Shoe FUEL SIDE EXHAUST SIDE 016.783/08 Fig. 2: Crosshead and Guide Shoe (Top View) 3 Guide shoe 11 Groove 4 Connecting rod 12 Guide rail 6 Crosshead pin 9 Holding plate CO Crosshead lubricating oil inlet 10 Column PC Piston cooling oil inlet 2017−08...
Page 289 3403−1/A1 Operation Piston General The piston has the parts that follow: Piston crown (1, Fig. 1) Piston rings (2) Piston skirt (3) Piston rod (4) Oil pipe (5) Compression shim (6). Ten elastic bolts (9) and round nuts (8) attach the piston crown (1) and the piston rod (4) together.
Page 290 3403−1/A1 Operation Piston 016.784/08 Fig. 1: Piston 1 Piston crown 9 Elastic bolt 2 Piston rings 10 Spray plate 3 Piston skirt 4 Piston rod 5 Oil pipe to spray plate OI Oil inlet 6 Compression shim OR Oil return from piston 7 Crosshead pin CO Piston cooling oil 8 Round nut...
Page 291 3603−1/A1 Operation Crosshead Lubrication and Piston Cooling General Lubricating oil keeps the pistons cool. High pressure bearing oil lubricates the crosshead. Each oil system operates independently. The oil from each system flows through a double articulated lever to the crosshead. Crosshead Lubrication The crosshead lubricating oil flows from the oil inlet (OI) through the support (4, Fig.
Page 292 3603−1/A1 Operation Crosshead Lubrication and Piston Cooling Key to Fig. 1: Articulated Lever − Location 1 Piston rod 10 Connecting rod 2 Guide shoe 11 Crosshead pin 4 Support 12 Bore (crosshead lubricating oil) 5 Column 17 Oil inlet (crosshead lubrication) 6 Bottom lever OB Oil bore (crosshead lubricating oil to 7 Top lever...
Page 293 Group4 Operation Engine Control and Control Elements Group 4 Engine Control Engine Control System WECS-9520 ........... 4002−1/A1 User Parameters and Maintenance Settings .
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Page 295 4002−1/A1 Operation Engine Control System WECS-9520 General ............Components .
Page 296: Engine Control System Wecs-9520
4002−1/A1 Operation Engine Control System WECS-9520 Components Fig. 1 shows the related components and their connections. The primary components of the WECS−9520 are as follows: The Shipyard Interface Box (SIB) E90 has communication to the external systems. The SIB also contains an FCM−20 as an online spare. Each cylinder has a control box E95.xx, which contains an FCM−20 for engine and cylinder-related control functions.
Page 297 4002−1/A1 Operation Engine Control System WECS-9520 Alarm and Propulsion Control System Connector for Service Access Monitoring System (AMS) Remote Telegraph Safety Electr. Speed Manual Control System System Control System Control System Engine Control Room Rail Unit FCM−20 System Bus Online Spare PCS Bus Alarm Bus FCM−20...
Page 298: Engine-Related Control Functions
4002−1/A1 Operation Engine Control System WECS-9520 Engine-related Control Functions General All engine-related control functions are divided between six of the FCM−20 (cylinders 1 to 6) for 6-cylinder to 8-cylinder engines, and eight FCM−20 for 9-cylinder engines. The last and last but one FCM−20 are for the control functions of the cylinder lubricating system.
Page 299: Fuel Pressure Control
4002−1/A1 Operation Engine Control System WECS-9520 Fuel Pressure Control Injection Fuel Rail (one, or two part design related to number of cylinders) Fuel Overpressure Safety Valve Fuel Pressure Fuel Shut-down Supply Unit Control Valve Pilot Valve Drive Fuel Pumps Main Bearing Oil Drawn for Fuel Pump 6-cylinders to 8-cylinders...
Page 300: Servo Oil Pressure Setpoint
4002−1/A1 Operation Engine Control System WECS-9520 3.2.5 Monitored Items The pressure is monitored. If the pressure is out of the tolerance, a failure indication shows. The sensors are monitored. If the sensors are out of range, a failure is shown. Also, the LEDs on the FCM−20 of cylinders 3 and 4 will flash (see 0850−1 Failures and...
Page 301: Cylinder Lubricating System − Control
4002−1/A1 Operation Engine Control System WECS-9520 3.3.3 Monitored Items The pressure is monitored. If the pressure is out of the tolerance, a failure indication shows. The sensors are monitored. If the sensors are out of range, a failure indication shows and the related LEDs will flash on the FCM−20 of cylinders 1 and 2 (see 0850−1 Failures and Defects of WECS Components).
Page 302: Cylinder-Related Control Functions
4002−1/A1 Operation Engine Control System WECS-9520 Cylinder-related Control Functions General Each cylinder has an FCM−20. A redundant system bus gives communication between each FCM−20. The last and last but one FCM−20 receive the crank angle signal from a redundant SSI bus. If an FCM−20 becomes defective, the related cylinder is cut out.
Page 303: Fuel Injection Control
4002−1/A1 Operation Engine Control System WECS-9520 Fuel Injection Control Injection Control Valves Injection Valves Fuel Quantity Piston Fuel Quantity Sensor Injection Return Rail Valves Servo Fuel Quantity Seal for Injection Fuel Rail Signal Emergency Quantity Stop All components are shown in Fuel the NO INJECTION position Fig.
Page 304: Exhaust Valve Control
4002−1/A1 Operation Engine Control System WECS-9520 4.3.4 Injection Control Fuel injection is controlled as follows: Data from the crank angle and VIT are used to calculate the injection start. The rail valves are activated to release the injection. The time difference between the injection start signal and the injection start is known as the injection deadtime.
Page 305: Starting Valve Control
4002−1/A1 Operation Engine Control System WECS-9520 4.4.3 Initial Set-pulse Because the rail valves are bistable, their initial position is not specified. Thus, when the engine has stopped, set-pulses are sent to the rail valves at intervals to get a specified position. 4.4.4 Exhaust Valve −...
Page 306: Communication Between Wecs-9520 And External Systems
4002−1/A1 Operation Engine Control System WECS-9520 Communication between WECS-9520 and External Systems WECS−9520 gives the data communications that follow to the: Propulsion control system Alarm and monitoring system (AMS) Control panel at local maneuvering stand BACKUP control box in the control room. The standard version of WECS−9520 has the external communications that follow: Two redundant data cables to the remote control Two redundant data cables to the AMS...
Page 307: Backup Control Box
4002−1/A1 Operation Engine Control System WECS-9520 The operator can adjust the user parameters e.g. maximum fuel limit, running-in mode and fuel quality setting (FQS). The operator selects the necessary command on the RCS (e.g. AHEAD or ASTERN). The RCS sends the commands to operate the engine. The related FCM−20 sends a load signal to the RCS from the average measured fuel quantity signals.
Page 308: Safety System
4002−1/A1 Operation Engine Control System WECS-9520 Safety System The safety system has the primary functions that follow: Emergency stop Overspeed protection Automatic shut-down Automatic slow-down. The WECS−9520 will transmit a signal to the safety system for each malfunction. For more data, see 0850−1 Failures and Defects of WECS Components.
Page 309 4002−1/A1 Operation Engine Control System WECS-9520 Alarm and Propulsion Control System Monitoring System DENIS−9520 Remote Control Specification Alarm Signals Independent Subsystems: Alarms Slow-down signals Remote Electronic Alarm and Safety Telegraph Control Speed Control Slow-down System System System System Signals 2 x PCS Bus CANopen 2 x AMS Bus or Modbus Modbus...
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Page 311: General
4002−3/A1 Operation User Parameters and Maintenance Settings General The operator can get access to the user parameter settings without a password. The operator can get access to the maintenance settings only with a password or a key. You use the Operator Interface of the remote control to change or set the parameters in the WECS−9520 as follows: User parameters in USER Maintenance settings in ADJUST.
Page 312 4002−3/A1 Operation User Parameters and Maintenance Settings Maintenance Settings Parameter Function Crank Angle (PARA3) For crank angle settings and checks after maintenance, or when the crank angle sensor unit is replaced. Crank angle offset, engine TDC offset For the input of crank angle differences (mean values) and to do checks of the measured values.
Page 313 4002−4/A1 Operation Regular Checks and Recommendations for WECS-9520 General For safety, you must do a check of the redundant control systems and the components in standby mode at regular intervals. Monthly Checks LOCAL MANUAL CONTROL (Local Control) Do an engine start in LOCAL MANUAL CONTROL mode. Quarterly Checks Level Switch For more data about the level switches, see...
Page 314 4002−4/A1 Operation Regular Checks and Recommendations for WECS-9520 Starting Air Control Valves In the remote control, set to off one of the starting air control valves activated by FCM−20 of cylinder 1 or 2 (user parameter, function Start Valves Checking). Do an an engine start with starting air (AIR RUN) only, or slow turning.
Page 315 4003−1/A1 Operation Engine Control General ............Engine Control Diagram .
Page 316: Engine Control Functions
4003−1/A1 Operation Engine Control Engine Control Functions The engine control lets you do the functions that follow: Engine start, running, reversing, maneuvering and stop Engine speed adjustment and control Partial safeguarding and monitoring the engine. You do the function checks before you put the engine into operation (see paragraph 4 Engine control system checks).
Page 317: Reverse
4003−1/A1 Operation Engine Control Reverse Turn the rotary knob to 15% fuel injection quantity (see display). Push the button START AHEAD or START ASTERN until the engine runs in the applicable direction. Note: On ships under way, this procedure can be some minutes, because the propeller is dragged in the opposite sense of rotation.
Page 318: Control Air Supply Unit
4003−1/A1 Operation Engine Control Control Air Supply Unit At connection A2, use the shut−off cock 36HC to open a 30 bar supply to the control air supply. Make sure that the shut-off cock 36HA is open. Use the valve 19HA to adjust the air pressure for the air spring air to 6 bar. Do a check of the pressure gages PI4341M and PI4412M.
Page 319 4003−1/A1 Operation Engine Control 4.4.1 Passive Failures To monitor the passive failures, connect an applicable resistor between connections 2 and 3 of the pressure switches that follow: PS1101S PS2002S PS4341S. The values of resistors that are related to the the different remote controls are given in Table 3: Table 3: Resistor Values Supplier...
Page 320: Automatic Filter
4003−1/A1 Operation Engine Control Automatic Filter Make sure that control air is available at the automatic filter. In the oil pipe upstream and downstream of the automatic filter, make sure that stop valves 4.37 and 4.80 are open. In the pressure compensating pipe near the oil outlet, make sure that the stop valve is closed.
Page 321: Auxiliary Blowers
4003−1/A1 Operation Engine Control Auxiliary Blowers Set to on the power supply for the two auxiliary blowers. On the WECS−9520 manual control panel, push the button LOCAL MANUAL CONTROL (see 4618−1) to get control. Push the button AUX. BLOWER PRESEL. No shutdown must be active. Make sure that: Auxiliary blower 1 starts immediately.
Page 322: Servo Oil System
4003−1/A1 Operation Engine Control 4.6.1 Auxiliary Blowers Test from ECR Control Panel Set to off the power supply to FCM−20 #4. Make sure that there is command and feedback of the auxiliary blowers. If there is no command and feedback, do a check of the cables to the starter box(es).
Page 323: Cylinder Lubrication
4003−1/A1 Operation Engine Control Cylinder Lubrication Make sure that all ALM−20 are electrically connected. The green power LED comes on when the power supply is set to on and the lubricating system software operates correctly (no red LEDs). For 6-cylinder to 8-cylinder engines: Open the stop valve 4.30−5. Make sure that the servo oil pressure is 60 bar.
Page 324: 4.11 Fuel System
4003−1/A1 Operation Engine Control 4.11 Fuel System Start the fuel booster pump 3.15. Make sure that the pressure retaining valve 3.53 is set to the correct pressure (see 0250−1 Operating Data Sheet). The pressure upstream of the pressure retaining valve is shown on the pressure gage PI3421L. Make sure that the pressure downstream of the pressure retaining valve 3.53 is correct (see 0250−1...
Page 325 4003−1/A1 Operation Engine Control 4.12.2 Starting Air Shut-off Valve Remove the shuttle valve 115HA from valve unit E. Make sure that the three O-rings stay in position. On the WECS−9520 manual control panel, select LOCAL MANUAL CONTROL (see 4618−1) to get control. Push the button AIR RUN.
Page 326: 4.13 Overspeed System And Start Procedure
4003−1/A1 Operation Engine Control 4.13 Overspeed System and Start Procedure Close the venting valves 2.21 and 2.27. Put the handwheel 2.10 of shut-off valve for starting air 2.03 in the position AUTOMAT. Open the shut-off valves on the starting air bottles. Make sure that the turning gear is disengaged.
Page 327 4003−2/A0 Operation Identification of Parts Control Diagram Summary of Part Code Numbers Table 1: List of Part Code Numbers A − Control air supply unit B − Fuel supply C − Fuel injection D − Servo oil supply E − Valve unit for start F −...
Page 328 4003−2/A0 Operation Designations Speed setting system Ball valve Crank angle sensor unit High pressure pipe (9 cylinders) Speed pick-ups Fuel rising pipe 33−3 Stop valve (9-cyl. engines) Starting system 33−4 Stop valve (9-cyl. engines) Shut off valve for starting air 33−5 Stop valve (9-cyl.
Page 329 4003−2/A0 Operation Designations Exhaust valve drive Supply pipe Exhaust valve Non-return valve Air spring Flow sensor Valve drive Servo oil rising pipe Non-return valve with throttle Servo oil return piping Air spring venting Actuator pipe Exhaust valve control unit Disc spring Servo oil rail Two-stage piston Servo oil pump...
Page 330 4003−2/A0 Operation Designations Sensors Actuators PS3121A Cyl. lube oil filter diff. pres. CV7231−36C Fuel pump actuator No. A1−B3 PT2041A Cyl. lubr. servo oil free end CV7221−23C Servo oil pump actuator No. 1−3 PT2042A Cyl. lubr. servo oil driving end PT2046A Cyl.
Page 331 W-X82 4003−2/A1 Operation Control Diagram 6-cylinders to 8-cylinders Note: Systems are drawn for engine in the STOP position with unpressurized circuits. WCH03263 2015-07 1/ 1 Winterthur Gas & Diesel Ltd.
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Page 333 W-X82 4003−2/A2 Operation Control Diagram 9-cylinders Note: Systems are drawn for engine in the STOP position with unpressurized circuits. WCH03264 2015-07 1/ 1 Winterthur Gas & Diesel Ltd.
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Page 335 4003−3/A1 Operation Control and Auxiliary Systems General On pages 3 to 21 the full engine control with the auxiliary systems, divided into their various functions, is shown. The data includes all interfaces to the plant and the remote control with clear identification of the internal and external connections. Overview of the systems Path No.
Page 336 4003−3/A1 Operation How to Read the Diagrams Each diagram has a Path No. range given to the system part. The Path No. range is divided into 10 sections on the right side of the page. These path numbers give the connections between related diagrams.
Page 337 4003−3/A1 Operation Air Supply 2014 3/ 21 Winterthur Gas & Diesel Ltd.
Page 338 4003−3/A1 Operation Bearing and Cooling Oil Supply 2014 4/ 21 Winterthur Gas & Diesel Ltd.
Page 339 4003−3/A1 Operation Servo Oil Supply 6-cylinders to 8-cylinders 2014 5/ 21 Winterthur Gas & Diesel Ltd.
Page 340 4003−3/A1 Operation Servo Oil Supply 9-cylinders 2014 6/ 21 Winterthur Gas & Diesel Ltd.
Page 341 4003−3/A1 Operation Fuel Supply 6-cylinders to 8-cylinders 2014 7/ 21 Winterthur Gas & Diesel Ltd.
Page 342 4003−3/A1 Operation Fuel Supply 9-cylinders 2014 8/ 21 Winterthur Gas & Diesel Ltd.
Page 343 4003−3/A1 Operation Starting System 2014 9/ 21 Winterthur Gas & Diesel Ltd.
Page 344 4003−3/A1 Operation Speed Control 2014 10/ 21 Winterthur Gas & Diesel Ltd.
Page 345 4003−3/A1 Operation Cylinder Lubrication Pulse Jet 6-cylinders to 8-cylinders 2015-07 11/ 21 Winterthur Gas & Diesel Ltd.
Page 346 4003−3/A1 Operation Cylinder Lubrication Pulse Jet 9-cylinders 2015-07 12/ 21 Winterthur Gas & Diesel Ltd.
Page 347 4003−3/A1 Operation Exhaust Gas / TC Type TPL and MET / Scavenge Air / Auxiliary Blower 1-stage SAC 2015-07 13/ 21 Winterthur Gas & Diesel Ltd.
Page 348 4003−3/A1 Operation Exhaust Gas / TC Type TPL and MET / Scavenge Air / Auxiliary Blower 2-stage SAC 2015-07 14/ 21 Winterthur Gas & Diesel Ltd.
Page 349 4003−3/A1 Operation Exhaust Valve Drive / Air Spring 6-cylinders to 8-cylinders / 2 pumps 2015-07 15/ 21 Winterthur Gas & Diesel Ltd.
Page 350 4003−3/A1 Operation Exhaust Valve Drive / Air Spring 6-cylinders to 8-cylinders / 3 pumps 2015-07 16/ 21 Winterthur Gas & Diesel Ltd.
Page 351 4003−3/A1 Operation Exhaust Valve Drive / Air Spring 9-cylinders / 3 pumps 2015-07 17/ 21 Winterthur Gas & Diesel Ltd.
Page 352 4003−3/A1 Operation Fuel Injection 6-cylinders to 8-cylinders 2015-07 18/ 21 Winterthur Gas & Diesel Ltd.
Page 353 4003−3/A1 Operation Fuel Injection 9-cylinders 2015-07 19/ 21 Winterthur Gas & Diesel Ltd.
Page 354 4003−3/A1 Operation Cooling Water 2014 20/ 21 Winterthur Gas & Diesel Ltd.
Page 355 4003−3/A1 Operation Main Bearing Lubrication / Piston Cooling / OMD 2015-07 21/ 21 Winterthur Gas & Diesel Ltd.
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Page 357: 4104-1/A1
4104−1/A1 Operation Supply Unit Drive General The drive supply unit is installed at the driving end of the engine. The crankshaft gear wheel (4, Fig. 1 and Fig. 2) moves the intermediate wheels (2) and (5). These intermediate wheels move the drive wheel (6) of the fuel pump unit and drive wheel (1) of the servo pump unit.
Page 358 4104−1/A1 Operation Supply Unit Drive WCH02837 Fig. 2: View of Supply Unit Drive (9-cylinders) 1 Drive wheel (servo pump unit) 4 Crankshaft gear wheel 2 Intermediate wheel 5 Intermediate wheel 3 Column 6 Drive wheel (fuel pump unit) 2014-09 2/ 3 Winterthur Gas &...
Page 359 4104−1/A1 Operation Supply Unit Drive Lubrication The bearings (6, Fig. 3) of intermediate wheels (5) and (7) are lubricated with bearing oil through the oil inlets (OI). The gear teeth are supplied with bearing oil through the spray nozzles (for more data, see Lubricating Oil Diagram 8016−1). WCH02838 Fig.
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Page 361 4325−1/A1 Operation Starting Air Shut-off Valve General For more data, see the Control Diagram in 4003−2). The starting air shut-off valve (shut-off valve) stops or releases the starting air into the engine (see Fig. 1). You use the handwheel (5) to put the shut-off valve in the positions that follow: CLOSED (closed manually) AUTOMAT...
Page 362 4325−1/A1 Operation Shut-off Valve Starting Air 018.896/09 Fig. 1: Starting Air Shut-off Valve 1 Valve IP To instrument panel and 2 Valve body (non-return valve) pressure transmitter PT4301C 3 Spring BB Balancing bore 4 Spindle AI Air inlet space 5 Handwheel VV To venting valve 2.21 6 Lever AP Air inlet pipe (hidden)
Page 363 4605−1/A1 Operation Control Air Supply General The compressed air necessary for the air spring air (exhaust valves) and the turning gear interlock comes from the control air board supply. The air must be clean and dry to prevent blockages in the control units. If the control air board supply system becomes defective, a decreased quantity of compressed air will come from the starting air system.
Page 364 4605−1/A1 Operation Control Air Supply Fig. 2: Schematic Diagram − Control Air Supply Unit A1 Control air from board system A3 Connection to air tank 287HA A2 Starting air from starting air system A6 Air supply to air spring 2014 2/ 3 Winterthur Gas &...
Page 365 4605−1/A1 Operation Control Air Supply 010.475/02 Fig. 3: Control Air Supply Unit 1 Pressure transmitter PT4411A 8 Pressure reducing valve 19HA 2 Pressure transmitter PT4401A 9 Non-return valve 342HB 3 Shut-off / venting cock 36HB for control air 10 Filter 351HA 4 Shut-off / venting cock 36HC for starting air 11 Pressure gauge PI4411L 5 Shut-off / venting cock 36HA (4.08) for air spring...
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Page 367 4618−1/A1 Operation Local Control Panel General The local control panel is attached to the engine at the free end and has the components necessary for engine operation (see Fig. 1). Because the remote control manufacturer supplies the local control panel, some components can look different from those shown in Fig 2.
Page 368 4618−1/A1 Operation Local Control Panel AST. AHD. 013.781/06 FREE END SPEED / FUEL EMERG. STOP TELEGRAPH Fig. 1: Location of Control Air Supply 1 Local control panel 5 Telegraph 2 ME tachometer 6 Emergency stop button 3 WECS−9520 manual control panel 7 Nameplate with instructions 4 Rotary knob (speed / fuel) 8 Instrument panel...
Page 369 4618−1/A1 Operation Local Control Panel WECS-9520 Manual Control Panel The WECS−9520 manual control panel is a multi-purpose module that has an LCD display (1, Fig. 2) and 15 function buttons (3). START AUX. SPEED REMOTE SAFETY AHEAD BLOWER CONTROL AUTOM. SYSTEM PRESEL.
Page 370 4618−1/A1 Operation Local Control Panel Button Function Effect / Procedure Name Color START GREEN None Engine START AHEAD Auxiliary blower preselect signal is AHEAD Interruption running ASTERN activated automatically. (reversing from ASTERN - AHEAD) STOP GREY Engine STOP interrupts fuel LED comes on while STOP is injection selected.
Page 371 4618−1/A1 Operation Local Control Panel Button Function Effect / Procedure Name Color FUEL GREY Setting of fuel injection quantity to LED comes on when FUEL CONTROL WECS−9520. CONTROL MODE is selected. MODE Adjustable with the rotary knob If the speed control system (speed / fuel) becomes defective, or if fuel injection quantity adjustment is...
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Page 373 4628−1/A1 Operation Pick-up for Speed Measurement General Proximity sensors are installed in a speed pick-up unit (1, Fig. 1) and attached to the support of the fuel pump unit. The proximity sensors measure the engine speed (rpm). For safety, there are three electrically isolated proximity sensor groups as follows: Speed identification in the remote control system (RCS) Overspeed safety system Speed control system.
Page 374 4628−1/A1 Operation Pick-up for Speed Measurement WCH01174 DRIVING END CRANKSHAFT WCH01174 Fig. 1: Location of Proximity Sensors and Speed Pickup Unit 1 Speed pick-up unit 6 Bedplate 2 Pick−up holder 7 Terminal box 3 Proximity sensor (crank angle) 8 Proximity sensors (flywheel) 4 Flywheel 9 Casing 5 Crank angle mark...
Page 375 Group5 Operation Supply Unit, Servo Oil Pump and Fuel Pump Group 5 Fuel Pump ................5556−1/A1 Fuel Pump −...
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Page 377: General
5556−1/A1 Operation Fuel Pump General Four fuel pumps (6-cylinder to 8-cylinder engines) or six fuel pumps (9-cylinder engines) are installed on the fuel pump unit (see Fig. 1 and 5581−1 Fuel Pump Unit). The fuel pumps (1) supply high pressure fuel through the HP fuel pipes to the fuel rail. The fuel pumps (1) are controlled to supply as much fuel to keep the necessary pressure (which is load related) in the fuel rail.
Page 378 5556−1/A1 Operation Fuel Pump WCH00832 Fig. 2: Fuel Pump 1 Lower housing 16 Orifice 2 Upper housing 17 Oil pipe 3 Pump cover 18 Cover (toothed rack) 4 Non-return valve 5 Regulating sleeve 6 Toothed rack AS Accumulation space 7 Upper spring carrier DB Drain Bore 8 Compression spring FI Fuel inlet...
Page 379 5556−1/A1 Operation Fuel Pump POSITION 0 POSITION 5 POSITION 8 008.645/00 008.645/00 008.645/00 Fig. 3: Control Grooves of Pump Plunger 14 Pump cylinder 20 Control groove 15 Pump plunger 21 Inlet bore 19 Plunger chamber Lubrication The fuel pump is lubricated with engine lube oil, which flows through the inlet bore (OI, Fig.
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Page 381 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In General ............Cutting Out and Cutting In .
Page 382 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In Cutting Out and Cutting In Cutting Out Procedure Stop the engine. Remove the applicable HP fuel pipe (4, Fig. 1) from the related fuel pump (7) (see also the Maintenance Manual 8752−1 HP Fuel Pipe Removal). Install the blank flange (3, tool 94569) to the fuel pump (7).
Page 383 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel. Use the turning gear to turn the engine until the roller (1, Fig. 2) of the guide piston (2) is at the highest position (cam peak).
Page 384 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In 11) Put the pre-tensioner (6, Fig. 3) on to the elastic bolt (3). The pre-tensioner must touch the pad (4). 12) Use the pre−tensioner (6) for tensioning the elastic bolt (3) (see the procedure in the Maintenance Manual 9403−4).
Page 385 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In Cutting In Procedure Stop the engine. Remove the inspection cover (6, Fig. 2). Find the position of the related cam (9, Fig. 3). WARNING Injury Hazard: Before you operate the turning gear, make sure that no personnel are near the flywheel.
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Page 387 5562−1/A1 Operation Fuel Pressure Control Valve General Operation CAUTION Damage Hazard: In usual operation, make sure that the knurled screw (10) is turned fully clockwise (down). WECS−9520 controls the fuel pressure, which stays below the opening pressure of the pressure control valve (1, Fig. 1). The fuel pressure control valve is usually closed (see also 4002−1, paragraph 3.2 Pressure control).
Page 388 5562−1/A1 Operation Pressure Control Valve Emergency Stop The safety system activates the fuel shut-down pilot valve (7, Fig. 1), which decreases the fuel pressure to less than 200 bar (in most conditions to 0 (zero) bar). Therefore an injection is not possible. Note: The fuel shut-down pilot valve (7) is one of three devices to shut down the engine.
Page 389 5562−1/A1 Operation Pressure Control Valve Functions Control Function Oil pressure on the piston (8, Fig. 2) pushes the valve tip (7) down on to the valve seat (6). The fuel pressure also operates against the axial slide valve (5). When the fuel pressure increases, the oil pressure decreases.
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Page 391 5581−1/A1 Operation Fuel Pump Unit General For 6-cylinder to 8-cylinder engines, one fuel pump unit is installed at the driving end on the fuel side. For 9-cylinder engines, two fuel pump units are installed at the driving end. One fuel pump unit on the exhaust side and one fuel pump unit on the fuel side.
Page 392 5581−1/A1 Operation Fuel Pump Unit 016.862/08 DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS Fig. 1: Fuel Pump Unit 1 Fuel pump 3.14 7 Thrust bearing ring half 2 Housing 8 Gear wheel 4.42 3 Bearing half 9 Fuel pump actuator 3.21 4 Camshaft 5 Screw OI Oil inlet...
Page 393 5583−1/A1 Operation Fuel Pump Actuator General Each fuel pump (1, Fig. 1) has an electrically-operated actuator (2). The regulating linkage connects the actuator (2) to the fuel pump (1). The lever (6) moves the connecting element (5), which moves the toothed rack (4) to the applicable position to control the fuel flow through the fuel pump (1).
Page 394 5583−1/A1 Operation Fuel Pump Actuator DRAWN FOR 6 CYLINDERS TO 8 CYLINDERS WCH01162 Fig. 1: Fuel Pump Actuator 1 Fuel pump 3.14 4 Toothed rack 2 Fuel pump actuator 3.21 5 Connecting element 3 Fuel pump unit 6 Lever 2017−08 2/ 2 Winterthur Gas &...
Page 395 5591−1/A1 Operation Servo Pump Unit with Dynex Servo Oil Pump General The servo pump unit (1, Fig. 1) has two built−in servo oil pumps. These pumps supply HP servo oil, which operates the exhaust valves and the injection. The servo oil flows from the main bearing oil supply, through the automatic filter (10) to the servo oil pumps.
Page 396 5591−1/A1 Operation Servo Pump Unit with Dynex Servo Oil Pump Data from RT−flex82C 016.896/08 WCH01126 Fig. 1: Location Servo Pump Unit with Dynex Servo Oil Pump 1 Servo pump unit 11 Flow sensor 4.54 2 Servo oil pump 4.15 12 Stop valve 4.37 3 (Driving) gear wheel 4.43 13 Oil inlet pipe on exhaust side 4 Gear wheel 4.44...
Page 397 5591−1/A2 Operation Servo Pump Unit with Bosch Servo Oil Pump General The servo pump unit (1, Fig. 1) has two or three built−in servo oil pumps (related to the number of cylinders on the engine). These pumps supply HP servo oil, which operates the exhaust valves and the injection.
Page 398 5591−1/A2 Operation Servo Pump Unit with Bosch Servo Oil Pump WCH00838 WCH00833 Fig. 1: Servo Pump Unit with Bosch Servo Oil Pump 1 Servo pump unit 11 Flow sensor 4.54 2 Servo oil pump 4.15 12 Stop valve 4.37 3 (Driving) gear wheel 4.43 13 Oil inlet pipe on exhaust side 4 Gear wheel 4.44 14 Stop valve 4.80...
Page 399 Group6 Operation Scavenge Air System Group 6 Scavenge Air Receiver ..............6420−1/A1 Turbocharging .
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Page 401 6420−1/A1 Operation Scavenge Air Receiver General The scavenge air receiver (5, Fig. 1) is a welded assembly and attached to the cylinder jacket (19, Fig. 2) on the exhaust side. The scavenge air receiver has the parts that follow: Receiver Turbocharger support Air duct Charging unit...
Page 402 6420−1/A1 Operation Scavenge Air Receiver For view II, see Fig. 2 WCH01159 Fig. 1: Scavenge Air Receiver 1 Auxiliary blower 5 Scavenge air receiver 2 Electric motor 6 Cover 3 Hinged cover 7 Cup springs 4 Relief valve 8 Compression spring 2014 2/ 3 Winterthur Gas &...
Page 403 6420−1/A1 Operation Scavenge Air Receiver WCH01159 018.893/09 Fig. 2: Scavenge Air Receiver − Section View 1 Auxiliary blower 17 Air flaps 2 Electric motor 18 Hinged cover 6 Suction box (fixed support 19 Cylinder jacket for exhaust gas manifold) 9 Scavenge air cooler PU Piston underside 10 Charging unit RS Receiver space...
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Page 405 6500−1/A1 Operation Turbocharging General The turbocharger is accurately tuned to the engine and related to the number of cylinders, service output, mode of operation etc. The number of turbochargers is related to the number of cylinders on the engine. Data about operation, maintenance and servicing are given in the related documentation of the manufacturer (which is part of the Operating Instruction).
Page 406 6500−1/A1 Operation Turbocharging 016.747/08 WD WS Fig. 1: Schematic Diagram − Turbocharger Operation 1 Exhaust valve 16 Scavenge air cooler 2 Cylinder cover 17 Air duct 3 Cylinder liner 18 Air flaps upstream of auxiliary blower 4 Cylinder jacket 5 Inlet ports 6 Piston EG Exhaust gas 7 Auxiliary blower...
Page 407 6510−1/A1 Operation Turbocharger All Types Cleaning the Turbocharger during Operation General The turbochargers have a system to clean the compressor. It is possible to clean the compressor while the turbocharger operates. Regular procedures to clean the compressor prevent or decrease contamination and increase the time between overhauls.
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Page 409 6545−1/A1 Operation Auxiliary Blower and Switch Box Auxiliary blower General The electric motors (4, Fig. 1) operate the auxiliary blowers (3), which are installed on the scavenge air receiver (2). The auxiliary blowers supply air from the air space through the suction casing into the receiver space during the start and operation at low load.
Page 410 6545−1/A1 Operation Auxiliary Blower and Switch Box Switch box General The engine builder supplies an electrical switch box (1, Fig. 2) for each auxiliary blower. Function During the engine start procedure, the first auxiliary blower starts immediately. After approximately two to three seconds, the other auxiliary blower starts. When the turbocharger produces sufficient pressure in the scavenge air receiver, the auxiliary blowers stop.
Page 411: Operating Instructions
6606−1/A1 Operation Operating Instructions and Cleaning Scavenge Air Cooler General ............Operating Instructions .
Page 412 6606−1/A1 Operation Operating Instructions and Cleaning ENGINE PLANT Fig. 1: Location of Wash-water System Parts 1 Container 16 Throttling disc 2 Scavenge air cooler (SAC) 17 Level switch 3 Water separator 18 Condensate and wash-water drain 4 Receiver 19 3-way ball valve 5 Fresh water supply pipe 20 Cleaning fluid and wash-water drain 6 Compressed air supply pipe...
Page 413: Cleaning Agents
6606−1/A1 Operation Operating Instructions and Cleaning SAC Air Side − Clean during Operation The equipment necessary to clean the air side of the SAC is installed on the engine. Intervals Initially, it is recommend that you clean the SAC one time each week. If there is no change in the pressure difference (Dp) through the SAC, the interval can be extended (e.g.
Page 414 6606−1/A1 Operation Operating Instructions and Cleaning Open the ball valves (5 and 3, Fig. 2). PLANT ENGINE Carefully open the shut-off valve (1) sufficiently to prevent back-flow of Fresh Water water in the funnel (2). Control Air Fill the container (6) through the funnel (2) with fresh water and the specified quantity of cleaning fluid (max.
Page 415 6606−1/A1 Operation Operating Instructions and Cleaning Instruction Leaflets Data about operation, maintenance and repair of the SAC are given in the Instruction Leaflets from the engine manufacturer or supplier. You can get these Instruction Leaflets directly from the manufacturers. It is also possible to send an order for Instruction Leaflets from the engine manufacturer or supplier.
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Page 417 6735−1/A1 Operation Scavenge Air Waste Gate General Some engine versions have a scavenge air waste gate, which protects the engine from scavenge air pressure that is too high in arctic conditions (when the outside air temperature is below the related value). The waste gate valve operates as a safety valve, i.e.
Page 418 6735−1/A1 Operation Scavenge Air Waste Gate Operation During usual operation conditions, scavenge air flows through the non-return valve (15, Fig. 2) into the pressure space (PS). This pressure, and the pressure from the compression spring (5), keep the piston (4) (and thus the waste gate valve) in the closed position.
Page 419 6735−1/A1 Operation Scavenge Air Waste Gate Open and Close Phases When the outside air temperature decreases below the values given in Table 1, the solenoid valve (8, Fig. 2) energizes. The scavenge air pressure flows through the pressure reducing valve (9), then through the non-return valve (16) to the pressure space (PS).
Page 420 6735−1/A1 Operation Scavenge Air Waste Gate Pressure Check You use the pressure reducing valve (9, Fig. 2) to adjust the pressure that opens the waste gate valve. Operate the engine at approximately 50% load (when the scavenge air pressure is more than 1.0 bar). Note: For the pressure that opens the valve, see Table 1.
Page 421 Group7 Operation Cylinder Lubrication Group 7 Cylinder Lubrication ..............7218−1/A1 Cylinder Lubrication Oil Consumption −...
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Page 423 7218−1/A1 Operation Cylinder Lubrication General ............Cylinder Lubricating Oil .
Page 424: 7218-1/A1
7218−1/A1 Operation Cylinder Lubrication Description The diagrams in Fig. 1 show the complete cylinder lubricating system, which has the components that follow: Lube oil tank for cylinder lubricating oil (plant side). Duplex filter 8.17 (one). Lubricating pumps 8.06 (one for each cylinder) with Advanced Lubrication Module−20 (ALM−20), 4/2-way solenoid valve and pressure transmitter.
Page 425 7218−1/A1 Operation Cylinder Lubrication DATA FOR 6-CYLINDERS TO 8-CYLINDERS WCH01117 DATA FOR 9-CYLINDERS WCH01117 Fig. 1: Schematic Diagram − Cylinder Lubrication System 2014-09 3/ 19 Winterthur Gas & Diesel Ltd.
Page 426 7218−1/A1 Operation Cylinder Lubrication Location of the Cylinder Lubricating Pump Each cylinder has a lubricating pump (1, Fig. 2) installed on a support on the cylinder block (11) on the fuel side of the engine. Servo oil, from the servo oil rail at the free end, operates the lubricating pumps (see 8016−1, paragraph 4 Servo oil system).
Page 427 7218−1/A1 Operation Cylinder Lubrication Duplex Filter and Measurement Tube The duplex filter (1, Fig. 3) and the measurement tube (4) are installed between the lube oil tank and the lubricating pumps. The differential pressure sensor (6) monitors the quantity of dirt in the duplex filter (1). If the filter is clogged, the differential pressure sensor transmits a signal with a failure message to the alarm and monitoring system.
Page 428 7218−1/A1 Operation Cylinder Lubrication Oil Consumption Measurement The integrated magnetic indicator and scale (7, Fig. 3) are used to measure the lubricating oil consumption. The specified, theoretic feed rate is set in the WECS−9520. To change the parameters use the operator interface (see 4002−3, paragraph 1.1). Note: Make sure that the lubricating oil level is always above the mark (1) on the scale (7).
Page 429 7218−1/A1 Operation Cylinder Lubrication Lubricating Pump General The lubricating pumps are attached to the cylinder block (see Fig. 4). The components of the lubricating pump can be replaced easily during operation, because of the interchangeable modules. The lubricating pumps have the parts that follow: Pump body (1, Fig.
Page 430 7218−1/A1 Operation Cylinder Lubrication WCH01118 WCH01118 WCH01121 Fig. 4: Lubricating Pump 1 Pump body 10 Vent screw (lubricating oil) 2 Baseplate 11 Test port and fill connection 3 4/2-way solenoid valve ZV7131−39C 12 Control box E41.01−09 4 Accumulator 5 Pressure transmitter PT3131−39C 6 Shut-off valve (servo oil) OQ Oil to lubricating quill 7 Lubricating oil outlet port...
Page 431 7218−1/A1 Operation Cylinder Lubrication Function The WECS−9520 operates the 4/2-way solenoid valve (3, Fig. 4) and servo oil flows through the valve to the bottom of the central piston. The pressure of the servo oil pushes the central piston to the top end position. The servo oil from the top of the central piston flows through the 4/2-way solenoid valve into the servo oil return pipe.
Page 432 7218−1/A1 Operation Cylinder Lubrication 4.3.2 Servo oil WARNING Injury Hazard: Always wear safety goggles and gloves when you do work on high pressure systems. The servo oil system operates at high pressure. When you loosen the vent screws, oil can come out as a spray.
Page 433 7218−1/A1 Operation Cylinder Lubrication I - I 019.037/09 Fig. 5: Last Lubricating Pump 1 Pump body 7 Screw plug 2 Baseplate 8 Screw plug 3 4/2-way solenoid valve ZV7131−39C 9 Vent screw (servo oil) 4 Accumulator 10 Vent screw (lubricating oil) 5 Blind flange 11 Assembly pin (max.
Page 434 7218−1/A1 Operation Cylinder Lubrication Bleed the Lubricating Oil System Release the air in the pipes to the lubricating quills after you have released the air in: The filter The measurement tube The lubricating pumps. Do the steps that follow: Loosen all union nuts on the pipes approximately two turns (see 2138−1, Fig 2). In the operator interface, select the related cylinder number in the menu MANUAL LUBRICATION ON CYL.
Page 435 7218−1/A1 Operation Cylinder Lubrication ALM-20 The function of the ALM-20 (see Fig. 6) is to operate the 4/2-way solenoid valve and to measure the metering pressure. The ALM-20 monitors the lubricating quills for blockages, airlocks, a decrease of lubricating oil and operation problems. PART NO : SER.
Page 436 7218−1/A1 Operation Cylinder Lubrication Table 2: LED Indications Indication Status LED 8, LED 9 Shows yellow Active CAN Bus (CAN2, CAN1) Shows red Defective CAN Bus (failure) LED 10 Flashes yellow Shows a released lube pulse (VLV) and LED 11 (FAIL) shows red: Indicates an Shows red electrical short-circuit of the 4/2-way solenoid valve...
Page 437 7218−1/A1 Operation Cylinder Lubrication Resistor in Plug X1 Each ALM-20 has a built-in resistor in the plug X1 (at terminals 16 and 17). The value of each resistor is related to the cylinder number. Note: Before you install a new resistor, make sure that the replacement has the correct resistance.
Page 438 7218−1/A1 Operation Cylinder Lubrication Lubricating Quill Lubricating oil is injected on to the cylinder liner wall through the lubricating quills installed on the circumference of the cylinder liner. For more data about the lubricating quills, see 2138−1. Lubricating of the Exhaust Valve Spindle The lubricating pump (1, Fig.
Page 439 7218−1/A1 Operation Cylinder Lubrication Cylinder Lubricating System − Control Control System The WECS−9520 controls the cylinder lubricating system. The control system includes a row of ALM-20, one ALM-20 for each cylinder (see Fig. 8). The CAN Bus transmits the signals. To prevent faults one more CAN Bus is installed and gives redundancy.
Page 440 7218−1/A1 Operation Cylinder Lubrication Radial Oil Supply The nozzle tip in the lubricating quill has holes in specified positions (see Fig. 9). The lubricating oil flows out of these holes at high pressure to give equal lubrication on the cylinder liner wall (see also 2138−1 Lubricating Quills on Cylinder Liner).
Page 441 7218−1/A1 Operation Cylinder Lubrication Lubricating Oil Feed Rate − Adjustment It is possible to adjust the lubricating oil feed rate in steps of 0.1 g/kWh. Use the user parameters in the columns Supply Rate and Adjustment for one cylinder, or for all cylinders (see 4002−3, paragraph 1.1).
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Page 443 7218−2/A1 Operation Measurement of Cylinder Lubricating Oil Consumption Calculate the Cylinder Lubricating Oil Consumption You can measure the cylinder lubricating oil consumption at all engine power outputs. The engine has a load-related cylinder lubricating system. To get a correct result, make sure that the engine speed and power are kept as constant as possible.
Page 444 7218−2/A1 Operation Measurement of Cylinder Lubricating Oil Consumption Calculate the Cylinder Lubricating Oil Consumption of a Consumption Measurement You use a a consumption measurement (parallel measurement) to do a check of the parameter settings and function of the cylinder lubricating system. For data about the measurement procedure, see 7218−1 paragraph 3.3.
Page 445 7218−3/A1 Operation Feed Rate − Adjustment Feed Rate − Adjustment General ............Feed Rate Adjustment .
Page 446 Start to collect the empirical data after the first running-in period of the engine. For the procedure, WinGD recommends to use lubricating oil with the highest available BN in relation to the used fuel. Use a baseline feed rate of 0.9 g/kWh. For more data, refer to 0750−1 Lubricating Oils.
Page 447 40 (BN ≥ 40). You can use the WinGD PU Drain Oil Analysis Tool to collect your data. You can see examples of its analysis in Fig. 2 and Fig. 3.
Page 448 7218−3/A1 Operation Feed Rate − Adjustment WCH037457 Fig. 2: PU Drain Oil Analysis Tool − Residual BN in Relation to the Engine Load WCH037458 Fig. 3: PU Drain Oil Analysis Tool − Iron Content in Relation to the Engine Load Note: If the engine operates with fuel that has a sulphur content less than 0.1% m/m (and a cylinder lubricating oil with a base number (BN) between 15 and 25) the minimum value of the residual BN value is 10 mg KOH/g.
Page 449 0.05 g/kWh to get the iron content value to approximately 200 mg/kg. You must get PU drain oil samples regularly to make sure that the feed rate used is applicable. WinGD recommends that you do a check of the coating thickness of the piston rings each 1500 to 2000 running hours.
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Page 451 Group8 Operation Piping Systems Group 8 Lubricating Oil System − 6-cylinders to 8-cylinders ........8016−1/A1 Lubricating Oil System −...
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Page 453 8016−1/A1 Operation Lubricating Oil System − 6-cylinders to 8-cylinders General ............Bearing and Turbocharger Oil System / Lubricating Oil System .
Page 454 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Bearing and Turbocharger Oil System / Lubricating Oil System Bearing oil is supplied through the inlet pipe (4, Fig. 1) on the exhaust side to the oil supply pipe (6) and main bearings (8) through bores in the bearing covers. Bearing oil is also used to cool the pistons through the supply pipe (5) to the toggle levers (13), to lubricate the crosshead pins (12) and the bottom end bearings.
Page 455 10) Open the ball valve (2) to drain the oil that collected in the dirty oil pipe (3). 11) Do the steps 1) to 10) again on each cylinder. Note: WinGD recommends that you also get an oil sample of the cylinder lubricating oil downstream of the duplex filter. Send the oil sample to the laboratory to make an analysis to make sure the initial cylinder lubricating oil had the correct quality and no contamination.
Page 456 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders PLANT ENGINE PLANT ENGINE Lubricating oil Oil drains and outlets Fig. 1: Lubricating Oil System 2014 4/ 12 Winterthur Gas & Diesel Ltd.
Page 457 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Key to Fig. 1 1 Oil pump 26 Flushing oil drain (automatic filter) 2 Oil filter 27 Vibration damper 3 Oil cooler 28 Crankcase vent pipe 4 Oil inlet pipe (exhaust side) 29 Oil inlet pipe 5 Oil supply pipe 30 Turbocharger...
Page 458 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders PLANT ENGINE ENGINE PLANT 30 5 30 4 Fig. 2: Leakage Oil Pipes − Exhaust Valves 1 Oil pump 17 Turbocharger oil return 2 Oil filter 18 Servo oil return pipe 4.63 3 Oil cooler 19 Leakage oil pipe from actuator pipe 4.66 4 Oil inlet pipe on exhaust side...
Page 459 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Servo Oil System The servo oil system controls the exhaust valve movement and the injection control units. The necessary oil flows off from the bearing oil system. For more data see Fig. 3 and Fig. 4. Servo Oil Service Pump The electrically-driven servo oil service pump (3) must be manually set to on and off.
Page 460 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Fig. 3: Servo Oil System 2014 8/ 12 Winterthur Gas & Diesel Ltd.
Page 461 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Key to Fig. 3: Servo Oil System 1 Automatic filter 4.20 29 Fuel shut-down pilot valve 3.08 2 Servo pump unit 30 Servo oil return pipe 4.63 3 Servo oil service pump 4.88 31 Drain screw 4.82 4 Servo oil pump 4.15 32 Leakage oil pipe (from HP servo oil pipes)
Page 462 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Servo Oil Leakage System The level switches (LS) monitor all important leakages in the servo oil system. If there is a large quantity of leakage oil, the related alarm is activated. See the table below: Level switch Monitored components...
Page 463 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Hydraulic Pipe − Leakage If the level switch (24, Fig. 3) (LS2076A) activates an alarm, the leakage inspection point on the hydraulic pipes (9) lets you find the location of the leakage. You can then do the applicable procedure (see paragraph 5.4).
Page 464 8016−1/A1 Operation Lubricating Oil System 6-cylinders to 8-cylinders Servo Oil Rail − Fill and Drain Fill and Vent Make sure that the stop valves (14, Fig. 3) and (15) (upstream and downstream of the automatic filter (1) are open. Make sure that the drain screw (2, Fig. 6) (in the servo oil rail (1)) has a torque of 200 Nm.
Page 465 8016−1/A2 Operation Lubricating Oil System − 9-cylinders General ............Bearing and Turbocharger Oil System / Lubricating Oil System .
Page 466 8016−1/A2 Operation Lubricating Oil System 9-cylinders Bearing and Turbocharger Oil System / Lubricating Oil System Bearing oil is supplied through the inlet pipe (4, Fig. 1) on the exhaust side to the oil supply pipe (6) and main bearings (8) through bores in the bearing covers. Bearing oil is also used to cool the pistons through the supply pipe (5) to the toggle levers (13), to lubricate the crosshead pins (12) and the bottom end bearings.
Page 467 10) Open the ball valve (2) to drain the oil that collected in the dirty oil pipe (3). 11) Do the steps 1) to 10) again on each cylinder. Note: WinGD recommends that you also get an oil sample of the cylinder lubricating oil downstream of the duplex filter. Send the oil sample to the laboratory to make an analysis to make sure the initial cylinder lubricating oil had the correct quality and no contamination.
Page 468: 8016-1/A2
8016−1/A2 Operation Lubricating Oil System 9-cylinders PLANT ENGINE PLANT ENGINE Lubricating oil Oil drains and outlets Fig. 1: Lubricating Oil System 2014-09 4/ 13 Winterthur Gas & Diesel Ltd.
Page 469 8016−1/A2 Operation Lubricating Oil System 9-cylinders Key to Fig. 1 1 Oil pump 26 Flushing oil drain (automatic filter) 2 Oil filter 27 Vibration damper 3 Oil cooler 28 Crankcase vent pipe 4 Oil inlet pipe (exhaust side) 29 Oil inlet pipe 5 Oil supply pipe 30 Turbocharger 6 Oil supply pipe (main bearing)
Page 470 8016−1/A2 Operation Lubricating Oil System 9-cylinders ENGINE PLANT PLANT ENGINE 30 4 Fig. 2: Leakage Oil Pipes− Exhaust Valves 1 Oil pump 17 Turbocharger oil return 2 Oil filter 18 Servo oil return piping 4.63 3 Oil cooler 19 Leakage oil pipe from actuator pipe 4.66 4 Oil inlet pipe (exhaust side) 20 Return of servo oil service pump 4.88 5 Oil supply pipe...
Page 471 8016−1/A2 Operation Lubricating Oil System 9-cylinders Servo Oil System The servo oil system controls the exhaust valve movement and the injection control units. The necessary oil flows off from the bearing oil system. For more data see Fig. 3 and Fig. 4. Servo Oil Service Pump The electrically-driven servo oil service pump (3) must be manually set to on and off.
Page 472 8016−1/A2 Operation Lubricating Oil System 9-cylinders Fig. 3: Servo Oil System 2014-09 8/ 13 Winterthur Gas & Diesel Ltd.
Page 473 8016−1/A2 Operation Lubricating Oil System 9-cylinders Key to Fig. 3: Servo Oil System 1 Automatic filter 4.20 32 Flow sensors FS2061 − FS2063A 2 Servo pump unit 33 Stop valve 3.40 3 Servo oil service pump 4.88 34 Safety valve 4.23 4 Servo oil pump 4.15 35 Fuel shut-down pilot valve 3.08 5 Supply pipe 4.51...
Page 474 8016−1/A2 Operation Lubricating Oil System 9-cylinders Servo Oil Leakage System The level switches (LS) monitor all important leakages in the servo oil system. If there is a large quantity of leakage oil, the related alarm is activated. See the table below: Level switch Location...
Page 475 8016−1/A2 Operation Lubricating Oil System 9-cylinders Do a check for oil. If oil flows from the leakage inspection point, do as follows: On the servo oil pump (6) of the related HP servo oil pipe (1), use the pressure controller to adjust the pressure to minimum. Note: You can operate the engine until the defective HP servo oil pipe is replaced.
Page 476 8016−1/A2 Operation Lubricating Oil System 9-cylinders Procedure WARNING Injury Hazard: Always use gloves and safety goggles when you do work on hot components. Oil can come out as a spray when you open the drain screws. On the flange (3, Fig. 6) of the connection pipe (1), carefully loosen the drain screw (2) a maximum of one turn.
Page 477 8016−1/A2 Operation Lubricating Oil System 9-cylinders Servo Oil Rail − Fill and Drain Fill and Vent Make sure that the stop valves (14, Fig. 3) and (15) (upstream and downstream of the automatic filter (1) are open. Make sure that the drain screw (2, Fig. 7) (in the servo oil rail (1)) has a torque of 200 Nm.
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Page 479: Cooling Water System
8017−1/A1 Operation Cooling Water System General The schematic diagram (see Fig. 1) shows the cylinder cooling water system on the engine. Fig. 2 shows a schematic diagram of the Scavenge Air Cooler (SAC) cooling water. The location of pumps, coolers, fresh water generator, heater, expansion tank, valves and throttling discs for flow control etc.
Page 480 8017−1/A1 Operation Cooling Water System Function The cooling water pump supplies cooling water, through the supply pipe (1) on the exhaust side, to the cylinders. The cooling water flows through the cylinder liner (2), water guide jacket (3), cylinder cover (4) and exhaust valve cage (5). The vent unit (16) and ball cock (19) stay open during operation, which makes sure that the system continuously releases air.
Page 481 8017−1/A1 Operation Cooling Water System ENGINE PLANT 30 8 30 9 30 1 SAC Cooling Water Drain See Fig. 2 VENT ENGINE PLANT WCH01152 Fig. 1: Cylinder Cooling Water 1 Inlet pipe 15 Ball cock 2 Cylinder liner 16 Vent unit 3 Water guide jacket 17 Condensate drain pipe 4 Cylinder cover...
Page 482 8017−1/A1 Operation Cooling Water System VENT PRE-STAGE From Fig. 1 LT SAC 30 2 WCH01153 Fig. 2: Scavenge Air Cooler − Cooling Water 1 Safety valve WD Drain outlet (cylinder cooling water) 2 Cooling water drain pipe SO Steam outlet (from safety valve) 3 Vent unit WO Cooling water outlet (from pre-stage SAC) WI Cooling water inlet (to pre-stage SAC)
Page 483 8018−1/A1 Operation Starting Air Diagram General The starting air system is shown in the schematic diagram below. The control air supply unit (6, Fig. 1) and the air bottle (5) supply the air necessary for engine control. For more data about the control air system, see 4003−2 Control Diagram and 4003−3...
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Page 485 8019−1/A1 Operation Fuel System − 6-cylinders to 8-cylinders General ............Low Pressure Circuit .
Page 486 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders High Pressure Circuit Before the first commissioning or after maintenance on the high pressure circuit, the tool 94583 (pipe) can be connected between the fuel rail (13, Fig. 1) and the servo oil rail (4.11).
Page 487 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders ENGINE PLANT 30 4 30 1 WCH01154 High pressure circuit Fuel pipe system Leakage fuel pipe Steam heating pipe Fig. 1: Fuel System 2015-05 3/ 12 Winterthur Gas & Diesel Ltd.
Page 488 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders Key to Fig. 1 1 Fuel inlet pipe 3.24 25 Fuel shut-down pilot valve 3.08 2 Shut-off valve 26 Leakage fuel collection pipe 3 Fuel pump 3.14 of HP fuel pipes and fuel pumps 4 Fuel outlet pipe 27 Leakage fuel (from fuel pumps) 5 Shut-off valve...
Page 489 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders WCH02335 Fig. 3: Drain Valves 1 Level switch (LS3426A) 4 Fuel pump 3.14 2 Drain valve (fuel inlet) 5 HP fuel pipe 3.29 3 Drain valve (fuel outlet) 2015-05 5/ 12 Winterthur Gas & Diesel Ltd.
Page 490 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders Fuel Leakage System Leakage Inspection Points You use the leakage inspection points to help you find possible leakages from the HP fuel pipes. The level switches (LS) (18, Fig. 1), (19) and (20) monitor all important leakages in the fuel system.
Page 491 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders HP Fuel Pipes 3.29 − Leakage WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components. When you open the screw plugs, fuel can come out as a spray and cause injury. If the level switch (18) (LS3426A) has activated an alarm, do the procedure that follows (see Fig.
Page 492 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders WCH02333 Fig. 4: Leakage Inspection Points − HP Fuel Pipes 3.29 1 HP fuel pipe 3.29 (top part) 7 Intermediate piece 2 Intermediate piece 8 Drain screw 3.17 3 Intermediate piece 9 Drain screw 3.17 4 HP fuel pipe 3.29 (bottom part) 10 Drain screw 3.17 5 HP fuel pipe 3.29 (bottom center part)
Page 493 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders HP Fuel Pipes 3.47 to Injection Valves − Leakage WCH01157 WCH01157 WCH01157 Fig. 5: Leakage Inspection Points − HP Fuel Pipes 3.47 to Injection Valves 1 HP fuel pipe 3.47 6 Plug (Inspection point 3.17) 2 Injection control unit 3.02 7 Sealing face 3 ICU fuel leakage pipe...
Page 494 Injury Hazard: The fuel system has high pressure. Replace a defective HP fuel pipe only when the engine has stopped. Note: If the HP fuel pipe cannot be replaced immediately, WinGD recommends to cut out the related injection control unit (see 0510−1...
Page 495 8019−1/A1 Operation Fuel System 6-cylinders to 8-cylinders As an alternative procedure to find the defective HP fuel pipe (1, Fig. 5) do the steps that follows: Note: Do the procedure that follows only when the estimated engine power in flexView is between 25% and 30% and when all three fuel injection valves of the ICU are activated.
Page 496 Remove the ICU (1) from the fuel rail (2). For the procedure, see the Maintenance Manual 5564−1. Send the defective ICU (1) to WinGD for an overhaul. As an alternative, you can use the fuel quantity piston kit CX55414 and do an overhaul on board.
Page 497 8019−1/A2 Operation Fuel System − 9-cylinders General ............Low Pressure Circuit .
Page 498 8019−1/A2 Operation Fuel System 9-cylinders High Pressure Circuit Before the first commissioning or after maintenance on the high pressure circuit, the tool 94583 (pipe) can be connected between the fuel rail (15, Fig. 1) and the servo oil rail 4.11. Note: The fuel rail system will be pressurized so that you can vent the injection control unit (ICU) and the pipes.
Page 499 8019−1/A2 Operation Fuel System 9-cylinders 30 1 30 4 ENGINE PLANT WCH01158 High pressure circuit Fuel pipe system Leakage fuel pipe Steam heating pipe Fig. 1: Fuel System 2015-05 3/ 13 Winterthur Gas & Diesel Ltd.
Page 500 8019−1/A2 Operation Fuel System 9-cylinders Key to Fig. 1 1 Fuel inlet pipe 3.24 30 Drain valve 3.65 (usually closed) 2 Shut-off valve (inlet) 31 Drain screw 3.82 3 Fuel pump 3.14 32 Fuel overpressure safety valves 3.52 4 Fuel outlet pipe 33 Fuel pressure control valve 3.06 5 Shut-off valve (outlet) 34 Fuel shut-down pilot valve 3.08...
Page 501 8019−1/A2 Operation Fuel System 9-cylinders 019.376/10 Fig. 3: Drain Valves 1 HP fuel pipe 4 Drain valve (fuel outlet) 2 Fuel pump 5 Drain valve (fuel inlet) 3 Level switch LS3427A 6 Level switch LS3426A 2015-05 5/ 13 Winterthur Gas & Diesel Ltd.
Page 502 8019−1/A2 Operation Fuel System 9-cylinders Fuel Leakage System Leakage Inspection Points You use the leakage inspection points to help you find possible leakages from the HP fuel pipes. The level switches (LS) (20, Fig. 1) to (25) monitor all important leakages in the fuel system.
Page 503 8019−1/A2 Operation Fuel System 9-cylinders On the HP fuel pipe (2), carefully loosen each of the drain screws (8) approximately two turns. Do a check to see if fuel flows out or not as follows: If fuel flows out, the related HP fuel pipe (2) is defective. If fuel does not flow out, tighten the drain screws (8).
Page 504 8019−1/A2 Operation Fuel System 9-cylinders WCH02334 V III Fig. 4: Leakage Inspection Points − HP Fuel Pipes 1 Intermediate piece 8 Drain screw 2 HP fuel pipe 9 HP fuel pipe 3 Intermediate piece Drain screw 4 HP fuel pipe 11 Drain screw 5 HP fuel pipe 12 Drain screw...
Page 505 8019−1/A2 Operation Fuel System 9-cylinders Connection Pipes − Leakage If the level switch (23, Fig. 1) (LS3447A) activates an alarm, do the procedure that follows: On the valve block (4, Fig. 5), carefully loosen the drain screw (5) approximately two turns Do a check to see if fuel flows out or not.
Page 506 8019−1/A2 Operation Fuel System 9-cylinders HP Fuel Pipes 3.47 to Injection Valves − Leakage WCH01157 WCH01157 WCH01157 Fig. 6: Leakage Inspection Points − HP Fuel Pipes 3.47 to Injection Valves 1 HP fuel pipe 3.47 6 Plug (Inspection point 3.17) 2 Injection control unit 3.02 7 Sealing face 3 ICU fuel leakage pipe...
Page 507 Injury Hazard: The fuel system has high pressure. Replace a defective HP fuel pipe only when the engine has stopped. Note: If the HP fuel pipe cannot be replaced immediately, WinGD recommends to cut out the related injection control unit (see 0510−1...
Page 508 8019−1/A2 Operation Fuel System 9-cylinders As an alternative procedure to find the defective HP fuel pipe (1, Fig. 6) do the steps that follows: Note: Do the procedure that follows only when the estimated engine power in flexView is between 25% and 30% and when all three fuel injection valves of the ICU are activated.
Page 509 Remove the ICU (1) from the fuel rail (2). For the procedure, see the Maintenance Manual 5564−1. Send the defective ICU (1) to WinGD for an overhaul. As an alternative, you can use the fuel quantity piston kit CX55414 and do an overhaul on board.
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Page 511 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) General The Low-load Tuning (LLT) gives the lowest possible Brake Specific Fuel Consumption (BSFC) in the range of 40% to 70% engine load (see Fig. 1 for the schematic diagram of the LLT function). With LLT, engines can operate continuously at all loads in the range of 30% to 100%.
Page 512 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) Function When the load is less than 85% (referred to in the ISO conditions), the force of the spring in the actuator (7, Fig. 2 and Fig. 3) keeps the butterfly valve (5) in the closed position.
Page 513 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) DRIVING END WCH02752 WCH02752 DRAWN FOR 6-CYLINDERS TO 8-CYLINDERS For view III, see Fig. 4 WCH02753 Fig. 2: Exhaust Waste Gate − 6-cylinders to 8-cylinders 1 Exhaust bypass line 7 Actuator (ZS5372C) 2 Exhaust gas manifold 8 Position Switch ZS5372C 3 Turbocharger 9 Control air supply unit...
Page 514 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) DRIVING END WCH02763 WCH02764 DRAWN FOR 9-CYLINDERS For view II, see Fig. 2 WCH02763 Fig. 3: Exhaust Waste Gate − 9-cylinders 1 Exhaust bypass line 5 Butterfly valve 2 Exhaust gas manifold 7 Actuator (ZS5372C) 3 Turbocharger 8 Position Switch ZS5372C 4 Orifice...
Page 515 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) WCH02753 Fig. 4: 3/2-way solenoid valve (CV7076C) 12 3/2-way solenoid valve (CV7076C) AS Air spring air 13 Screw AV Air Vent 14 Electrical connection CA Control air to actuator 15 Control air pipe 16 Air spring air pipe WCH02753 Fig.
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Page 517 8345−1/A1 Operation Drainage System and Wash-water Pipe System General You must do checks at regular intervals to make sure that all drain pipes are not blocked. The checks on the drain pipes (3, Fig. 1) , (8) and (10) from the turbocharger, piston rod glands and piston underside are important.
Page 518 8345−1/A1 Operation Drainage System and Wash-water Piping System PLANT ENGINE 30 1 30 2 30 3 30 8 30 4 SCAVENGE AIR USUAL 016.749/08 COOLER CLEANING OPERATION Fig. 1: Schematic diagram 2014 2/ 3 Winterthur Gas & Diesel Ltd.
Page 519 8345−1/A1 Operation Drainage System and Wash-water Piping System Key to Fig. 1 1 Wash-water supply pipe 19 Cleaning agent and wash-water 2 Compressed air supply pipe drain from scavenge air cooler 3 Wash-water drain from turbocharger 20 Condensate collector (for TPL type) (with sight glass and filter) 4 Cylinder cooling water and 21 Vent unit...
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Page 521: Group 9
Group9 Operation Engine Monitoring Group 9 Instrument Panel ............... . 9215-1/A1 Crank Angle Sensor Unit .
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Page 523: Instrument Panel
9215−1/A1 Operation Instrument Panel General The instrument panel (1, Fig. 1) is installed adjacent to the control box. To monitor important pressure values of the engine, the instrument panel contains the necessary pressure gages. Pressure indications for fuel and servo oil are given in the local control panel (see 4618−1 Local Control Panel).
Page 524 9215−1/A1 Operation Instrument Panel Schematic Diagram Fig. 2 shows the schematic diagram of the instrument panel H with the same indications also shown in the Control Diagram 4003−2. Data about the related pressure switches and pressure transmitters are given in 9258−1. WCH02754 Fig.
Page 525 9223−1/A1 Operation Crank Angle Sensor Unit General The crank angle sensor unit is installed at the free end. The connecting unit (2) is attached to the crankshaft (10) over the driving shaft (1). The connecting unit absorbs all unwanted radial and axial movements of the crankshaft. The toothed belt (8) operates the two crank angle sensors (7), which give indications of the crank angle positions.
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Page 527 9258−1/A1 Operation Pressure Switches and Pressure Transmitters General All of the pressure switches and transmitters are installed on the plate at the free end. The pressure switches and transmitters monitor the pressure systems. If there is a decrease in pressure or there is no pressure, the control signals have an effect on the commands that follow: Alarm (ALM) Slow down (SLD)
Page 528 9258−1/A1 Operation Pressure Switches and Pressure Transmitters WCH01139 Fig. 1: Schematic Diagram 1 Plate 7 Terminal box 2 Pressure transmitter 6 bar 8 Needle valve 3 Pressure transmitter 16 bar 9 Pipe connection terminal 4 Pressure transmitter 40 bar 10 Throttle piece 5 Pressure transmitter 10 bar 6 Pressure switch 6 bar EC Cable...
Page 529 9308−1/A1 Operation Intelligent Combustion Control General ............Safety .
Page 530 9308−1/A1 Operation Intelligent Combustion Control Safety User Qualification Note: The Intelligent Combustion Control system can only be installed, operated, serviced and repaired by qualified personnel. Qualified personnel are those who have been trained, appointed and instructed by the system’s user. The personnel are familiar with the relevant standards, provisions, accident-prevention regulations and plant conditions by virtue of their training, experience and instruction.
Page 531 9308−1/A1 Operation Intelligent Combustion Control Function The ICC system is an optional part of the WECS−9520, which adjusts the peak firing pressure of the engine according to engine design criteria. The firing and the compression pressure of all cylinders are balanced by modifying the injection timing and exhaust valve timing within their permitted operation range.
Page 532 9308−1/A1 Operation Intelligent Combustion Control In-cylinder Pressure Evaluation The compression pressure cannot be measured directly because of combustion and fuel injection that can occur before TDC. In the ICC system, the compression pressure of each cycle is calculated using the polynomial formula based on the position of the piston.
Page 533 9308−1/A1 Operation The cylinder pressure raw data of each unit is taken as an analogue input signal from the pressure transducer into the WECS−9520 as shown in the ICC installation overview below (see Fig. 3). Barometric pressure TC compressor inlet temperatures Scavenge air temperatures Dynamic cylinder pressure signals Fig.
Page 534 9308−1/A1 Operation Operation Operation of ICC In the WECS−9520 it is possible to set to on or off each individual sub-function of the ICC system. The system adjusts the necessary average value of the firing pressure to its site-corrected set-point value. This balances the firing pressure of all units and balances the compression pressure.
Page 535 9308−1/A1 Operation When the compression pressure balancing function is set to ON (see Fig. 6) this offset is calculated by ICC system. Fig. 6: Compression Pressure Balancing − Set to ON When the compression pressure balancing function is set to OFF (see Fig. 7), this offset is the same as on the flexView Adjust card adjusted by the operator.
Page 536 9308−1/A1 Operation ICC-INJ Card This flexView card (see Fig. 9) shows the measured values of the cylinder firing (combustion) pressure in each cylinder unit. The yellow horizontal line shows the average firing pressure value and the green horizontal line shows the firing pressure set-point.
Page 537 9308−1/A1 Operation From the ICC-INJ card, the firing pressure balancing function can be set ON as follows: Select [Shift] + [Arrow UP] To confirm, select [Shift] + [Enter] (see the workflow in Fig. 12). Fig. 12: Firing Pressure Balancing − Set to ON Workflow When the firing pressure control function is set to ON (see Fig.
Page 538 9308−1/A1 Operation From the ICC-INJ card, the firing pressure control function can be set ON as follows: Select [Shift] + [Arrow UP] To confirm, select [Shift] + [Enter] (see the workflow in Fig.15). Fig. 15: Firing Pressure Control − Set to ON Workflow ICC-INDICATION Card The ICC-indication card (see Fig.
Page 539 9314−1/A1 Operation Oil Mist Detector − 6-cylinders to 8-cylinders General The engine has an oil mist detection system, which includes the sensors (3, Fig. 1) and a control unit E15.1 (2) on the engine. A control panel (8, Fig. 2) is installed in the control room. The oil mist detection system continuously monitors the concentration of oil mist in the crankcase, supply unit drive and the supply unit.
Page 540: 9314-1/A1
9314−1/A1 Operation Oil Mist Detector 6-cylinders to 8-cylinders FUEL SIDE WCH01142 I - I Fig. 1: Location of Sensors 1 Cable guide 4 Fuel pump unit 2 Control unit E15.1 5 Column 3 Sensor 2014-09 2/ 3 Winterthur Gas & Diesel Ltd.
Page 541 9314−1/A1 Operation Oil Mist Detector 6-cylinders to 8-cylinders ENGINE ROOM CONTROL ROOM WCH02858 Fig. 2: Schematic Diagram 2 Control unit E15.1 8 Control panel 3 Sensor 9 Communications cable (Modbus) 4 Fuel pump unit PS Power supply 6 Crankcase and gearbox AM to alarm and monitoring system 7 Power cable SS to safety system...
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Page 543 9314−2/A1 Operation Oil Mist Detector − 9-cylinders General The engine has an oil mist detection system, which includes the sensors (3, Fig. 1), the control unit E15.1 (2), the control unit E15.2 (10) and the terminal box E15.0 (11) on the engine. A control panel (8, Fig.
Page 544: 9314-2/A1
9314−2/A1 Operation Oil Mist Detector 9-cylinders FUEL SIDE WCH02857 I - I WCH02857 Fig. 1: Location of Sensors 1 Cable guide 5 Column 2 Control unit E15.1 10 Control unit E15.2 3 Sensor 11 Terminal box E15.0 4 Fuel pump unit 2014-09 2/ 3 Winterthur Gas &...
Page 545 9314−2/A1 Operation Oil Mist Detector 9-cylinders ENGINE ROOM CONTROL ROOM WCH02857 Fig. 2: Schematic Diagram 2 Control unit E15.1 9 Communications cable (Modbus) 3 Sensor 10 Control unit E15.2 4 Fuel pump unit 11 Terminal box E15.0 6 Crankcase and gearbox PS Power supply 7 Power cable AM to alarm and monitoring system...
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Page 547 9362−1/A1 Operation Location of Flex Electronic Components General Most of the electronic components necessary for the WECS−9520 are installed on the engine. The power supply box E85 (not shown in Fig. 1) is installed near the engine. Control boxes Data about the most important control boxes and power supply boxes are given as follows: The E90 control box (shipyard interface box) is attached to the middle of the rail unit (see Fig.
Page 548 9362−1/A1 Operation Location of Flex Electronic Components WCH01144 Fig. 1: Flex Electronic Components 1 Control box E90 3 Rail unit 2 Control box E95.01 (Cyl 1) 4 Control box E41.01 (Cyl 1) 2014 2/ 2 Winterthur Gas & Diesel Ltd.

WinGD W-X82 Operation Manual

Modification Service

Safety Precautions and Warnings (General Data)

Running-In New Cylinder Liners and Piston Rings

Faults in High Pressure Fuel System

Faults in High Pressure Fuel System

1 Defective Fuel Pump

2 Defective Fuel Pump Actuator

3 Defective Injection Control Unit

4 Defective Fuel Pressure Control Valve

Diesel Engine Fuels

Diesel Engine Fuels

Heavy Fuel Oil

Data about Heavy Fuel Oil Specifications

Data about Distillate Fuel Specifications

Bio-Derived Products and Fatty Acid Methyl Esters

Fuel Additives

General

Lubricating Oils

Lubricating Oils

System Oil

Cylinder Lubricating Oil

Turbocharger Oil

Lubricants − Flywheel and Pinion Gear Teeth

Environmentally Acceptable Lubricants

Turning Gear Oil

Validated Lubricating Oils

General

Failures and Defects of Wecs Components

Failures and Defects of WECS Components

Failure ID and LED Indications on FCM-20

LED Indication on ALM-20

Failure Indications

General

Exhaust Valve

Exhaust Valve

Function

Engine Control System Wecs-9520

Engine Control System WECS-9520

Components

Engine-Related Control Functions

Cylinder-Related Control Functions

Communication between WECS-9520 and External Systems

General

Engine Control

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Chapters

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