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WinGD X72 Operation Manual

WinGD X72 Operation Manual

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Operation Manual

"Marine"

Vessel:

Type:

Engine No.:

Document ID:

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: 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 2017-11 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 3 Operation Manual “Marine” Vessel: Type: Engine No.: Document ID: 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 2017-11 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
Bulletin RT-138 Date of publication 2014-08-19 OM_2015-03 2015-03 Cover Page and New Layout WinGD; Disclaimer Disclaimer updated (WinGD and WSCH added); 0000-1/A1 2015-03 For Your Attention Data updated (WinGD and WSCH added); 0010-1/A1 2015-03 Preface Minor text changes; Data about Wärtsilä Service Switzerland Ltd added;...
Page 6 Fig. 1: Viscosity/Temperature Diagram updated; 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 Switerland Ltd and WinGD added; 0720-1/A1 2015-03 EAAD085468 Operating Media - Fuel Fig.
Page 7 Modification Service Engine Documentation Summary for Operation Manual (OM) Page No. Modification Title Subject Page or Date Manual new exch. 4003-1/A1 2015-03 Engine Control Updated with latest data, general minor changes; paragraphs 4.1 and 4.6: data about hydraulic pump unit Tool 94845 removed;...
Page 8 Modification Service Engine Documentation Summary for Operation Manual (OM) Page No. Modification Title Subject Page or Date Manual new exch. 0250-2/A1 2015-12 EAAD086282 Operating Data Sheet - Crosshead bearing oil (high pressure): see also Alarms and Safeguards New data for PT2021A added for different CMCR speed Circular to ranges (additional crosshead lubricating pump);...
Page 9 Service Bulletin; Structure of the document changed; 161_Issue2 Date of publication 2016-01-12 Operation 2016-11 General All documents New engine brand WinGD X72 added Manual Update 0020-1/A1 2016-11 Update SCR Table of Contents New documents 4002-4/A1; 4003-10/A2; 9270-1/A1 added...
Page 10 Modification Service Engine Documentation Summary for Operation Manual (OM) Page No. Modification Title Subject Page or Date Manual new exch. 0710-1/A1 2016-11 General Diesel Engine Fuels -minor text changes; Update -para 3.4: maximum permitted sulphur value changed from 4.5% m/m to 3.5% m/m; 0750-1/A1 2016-11 RT-138 Issue5 Operating Media - -Fig.
Page 11 New document added; integration Reduction System (SCR) Date of publication 2016-11-30 All pages 2017-10 Update All documents Engine brand changed from Wärtsilä to WinGD X72 WinGD 0250-1/A1 2017-04 Update Operating Data Sheet Torisional vibration damper (damper inlet): WinGD; Pressure and Min.
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Page 13 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 15: 0250-1/A1
........0460−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
Page 16: 0710-1/A1
..........0840−1/A1 X72 / OM / 2014 2/ 1 Winterthur Gas &...
Page 17 The data, instructions, graphics and illustrations etc. in this manual are related to drawings from WinGD. These data relate to the date of issue of the manual (the year of the issue is shown on the title page). All instructions, graphics and illustrations etc can change because of continuous new development and modifications.
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Page 19 0010−1/A1 Operation General Preface Technical Documentation Set The technical documentation set for this diesel engine type includes the following publications: Operation Manual The operation manual contains data about engine operation, the necessary operating media (oil, water and fuel) and descriptions of the components and systems. The manual also gives troubleshooting procedures.
Page 20 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-X72 Title Variant Subtitle − − − − − description Year of issue 2015 Winterthur Gas & Diesel Ltd.
Page 21 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 23: 0000-1/A1
0020−1/A1 Operation Table of Contents Table of Contents Operating Descriptions Group 0 For Your Attention ..............0000−1/A1 General Preface...
Page 24 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 25 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 26 0020−1/A1 Operation Table of Contents Scavenge Air System Group 6 Scavenge Air Receiver ..............6420−1/A1 Turbocharging .
Page 27 0030−1/A1 Operation Subject Index Alphabetical Table of Contents Abbreviations ............... 0035−1/A1 Adjustment −...
Page 28 0030−1/A1 Operation Alphabetical Table of Contents ECS Modules–Replacement ............4002−4/A1 ELBA −...
Page 29 0030−1/A1 Operation Alphabetical Table of Contents Leakage and wash-water piping system ..........8345−1/A1 Leakage check of pressure control valve .
Page 30 0030−1/A1 Operation Alphabetical Table of Contents Pick-up for speed measurement ............4628−1/A1 Pipe diagram −...
Page 31: 0010-1/A1
0030−1/A1 Operation Alphabetical Table of Contents Safety measures and warnings (general information) ........0210−1/A1 Scavenge air .
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Page 33: 0035-1/A1
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 Crank Angle Determination Algorithm Ahead Alarm Alarm and Monitoring System Astern ASTM American Society for Testing and Materials Bottom Dead Center Base Number...
Page 34 0035−1/A1 Operation Abbreviations Abbreviation Word(s) in Full Operator Interface (user interface in the control room) PMCC Pensky Martens Closed Cup method Remote Control System Society of Automotive Engineers Speed Control System Shut Down Slow Down Start of Injection Top Dead Center UNIC Unified Controls Variable Exhaust valve Closing...
Page 35 0040−1/A1 Operation General How to Use the Operation Manual Contents The Operation Manual, 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 36 0040−1/A1 Operation How to Use the Operation Manual Cross section 8135−1 5562−1 6500−1 6510−1 8019−1 8017−1 4325−1 8345−1 6420−1 8018−1 6606−1 2303−1 6545−1 3603−1 5556−1 8016−1 5552−1 5551−1 4104−1 WCH02248 Fig. 1: Cross Section 2014 2/ 3 Winterthur Gas & Diesel Ltd.
Page 37 0040−1/A1 Operation How to Use the Operation Manual Longitudinal section 2728−1 2751−1 2722−1 2124−1 2138−1 7218−1 1903−1 3403−1 4002−2 2303−1 3326−1 4104−1 3140−1 3303−1 1132−1 1203−1 WCH02249 Fig. 2: Longitudinal Section 2014 3/ 3 Winterthur Gas & Diesel Ltd.
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Page 39 The engine is reversible and is directly connected to the propeller. The X concept is based on the WinGD Common Rail, with full electronic control of the fuel injection system and the exhaust valve operation.
Page 40 0050−1/A1 Operation Short Description of the Engine The exhaust gases flow from the cylinders through the exhaust valves into an exhaust gas manifold. The turbocharger constantly charges the gas pressure from the manifold. The scavenge air from the turbocharger flows through the air cooler and water separator into the air receiver.
Page 41 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. 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 43 0070−1/A1 Operation General The Relation between Engine and Propeller General ............Fixed Pitch Propeller (FPP) .
Page 44 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 45 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 46 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 47 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 49 0080−1/A1 Operation General Basic Engine Data General Turbocharger Auxiliary Auxiliary Blower 2 Blower 1 Cylinder Number DRIVING END FREE END Main Bearing Number WCH01191 Thrust Bearing Pads Rail Unit FUEL SIDE EXHAUST SIDE Supply Unit WCH01191 Fig. 1: Outline View 2014 1/ 2 Winterthur Gas &...
Page 50 0080−1/A1 Operation Engine Numbering and Designations Flex Parts Fuel Pump 1 Fuel Pump 2 Fuel Pump 3 Servo Oil Pump 2 Servo Oil Pump 1 DRIVING EXHAUST WCH01192 SIDE II-II ST5131C ZS5123C ST5133C ST5134C ST5131C ZS5124C Proximity Crank Angle Sensors Sensor Unit Crankshaft gearwheel...
Page 51 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 52: 0110-1/A1
0110−1/A1 Operation Prepare for Engine Start after a Short Shut-down Period (One or More Days) 21) 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. Obey the data given in 0210−1 Safety Precautions and Warnings.
Page 53 0110−1/A1 Operation Prepare for Engine Start after a Short Shut-down Period (One or More Days) 40) Close the ball valve. 41) In the LDU−20 MAIN page (on the local control panel), get the USER PARAMETERS page. 42) Select the tab SLOW TURN. The engine will slowly turn one time (see Slow Turning 0220−1, paragraph 3).
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Page 55 0120−1/A1 Operation Prepare the Engine for Operation Prepare the Fuel System for Operation Prepare the Fuel System Diesel Operation See 0720−1, Fig. 2. Set the three-way valve 4 in the suction line of the low pressure pump 7. This lets diesel oil flow from the daily tank 3 to the pump and to the mixing unit 8.
Page 56 0120−1/A1 Operation Prepare the Fuel Oil System for Operation High pressure circuit 8019−1 Fuel System Fig. Make sure that the ball valve 43 is open. 2014 2/ 2 Winterthur Gas & Diesel Ltd.
Page 57 0130−1/A1 Operation Prepare the Engine for Operation Prepare the Servo Oil System Servo Oil System − Checks 8016−1 Lubricating oil system, Fig. 2 Fig. Do the checks that follow: Make sure that the ball valve 20-8423_E0_2 (26, Fig. 2) upstream of the injector valve is closed (see 4003-2).
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Page 59 0140−1/A1 Operation Prepare the Engine for Operation Prepare the Cylinder Lubricating System 7218−1 Cylinder Lubrication Fig. Make sure that the engine is in the condition that follows: The engine control system (ECS) and remote control systems (RCS) are set to on. The primary switches in the control box E44 (engine room) are set to on and the ECS has selected cylinder lubrication.
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Page 61 0200−1/A1 Operation Operation during Usual Conditions General 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: 0210/1-A1
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 ECS 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: 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 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.
Page 70: 0220-1/A1
0220−1/A1 Operation Slow Turning Conditions Note: The numbers e.g. 30-4325_E_01 refer to items in 4003−2 Control Diagram. Before you start the SLOW TURNING operation, do the steps that follow: Make sure that the turning gear is disengaged. Make sure that the ECS is set on. Make sure that the oil pumps operate (bearing oil and crosshead oil).
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 In the LDU, MAIN page push the button ON/OFF to start the auxiliary blowers. Make sure that Running shows in the Auxiliary Blowers field (see 4002−2, paragraph MAIN page). Use the rotary button to select the Fuel command button. Turn the rotary button to set the fuel injection quantity to approximately 30%.
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 − −...
Page 78 0250−1/A1 Operation Operating Data Sheet Medium System Location of Gage Pressure Temperature [bar] [_C] Measurement Min. Max. Min. Max. Diff. Exhaust Gas Receiver Downstream of − − − Tolerance each cylinder ±50 Note (4) Turbocharger inlet − − − − Manifold downsteam of turbocharger max.
Page 79: 0250-2/A1
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] ( 3) Cylinder Cooling Water Pressure Engine inlet PT1101A 4.0 bar 3.8 bar PS1101S 3.5 bar...
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] ( 3) Oil mist Concentration Crankcase AS2401A − AS2401S − Failure Detection unit XS2411A −...
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) Exhaust Gas Temperature Downstream of TE3701−08A 515_C each cylinder ±50_C 530_C ±70_C Upstream of each TE3721-22A...
Page 82 0250−2/A1 Operation Alarms and Safeguards at Continuous Service Power Notes: Signal number shows the interface to the remote control (see 4003−2). Function: SLD = Slow down SHD = Shut down ALM = Alarm. Type of signal: Difference in value Failure High Low.
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 In the LDU−20, get the MAIN page. Turn the rotary button to select 30% fuel injection quantity. Push the button START AHD or START AST until the engine operates 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 0270−1/A1 Operation Operation Change-over from Diesel Oil to Heavy Fuel Oil and Back General Continuous operation with heavy fuel oil (HFO) is recommended for engines and plants. You must only change from HFO to marine diesel oil (MDO) if necessary, for example when: The engine is flushed before maintenance The heating plant is set to off in the dry dock...
Page 88: 0270-1/A1
0270−1/A1 Operation Change-over from Diesel Oil to Heavy Fuel Oil and Back Change-over from HFO to MDO 0720−1 Fuel Treatment and Fuel System, Fig. 1 Schematic Diagram − Fuel System. Plant Side To change from HFO to MDO, you must first change the position of the automatic change-over unit (16).
Page 89 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 91: General
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 93 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 95 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 engine control system (ECS) must stay set to on. All the pumps for coolant water, lubricating oil and fuel must operate.
Page 96 0320−1/A1 Operation Procedures after Engine Stop Post-lubrication of the Cylinders Post-lubrication starts automatically during the slow-down of the engine. Close the shut-off valve on the control air supply (supply of air from the board system). Note: Make sure that the lubricating oil pump is set to off before you bleed the air spring system.
Page 97 0410−1/A1 Operation Operation − Special Procedures Running-in New Cylinder Liners and Piston Rings General It is not necessary to do a special running-in procedure after new components of the piston running system are installed. But, you must obey the data given in paragraph 2.
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Page 99 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 100 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 LDU−20, get the USER Example B PARAMETERS page (see 4002−2, paragraph 3.10).
Page 101 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 103 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 104 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 105 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 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 107 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 109 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 111 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 In the LDU−20, get the FUEL INJECTION page (see 4002−2, paragraph 3.7 Fuel Injection).
Page 112 0510−1/A1 Operation Operation with Injection Cut Out (One or More Cylinders) WCH01194 Fig. 1: High Pressure Pipes 1 Injection valve 3 Plug to control valve 2 High pressure pipe 2014 2/ 2 Winterthur Gas & Diesel Ltd.
Page 113 0515−1/A1 Operation Operation during Unusual Conditions Faults in High Pressure Fuel System Defective Fuel Pump ..........Fault Identification .
Page 114: 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. A failure message shows in the ECS (see 4002−2, paragraph 3.15 Log Messages).
Page 115 0515−1/A1 Operation Faults in High Pressure Fuel System 2.3.1 One Actuator is Defective Do a check of the control signals from the ECS and the electrical cables. If necessary, replace the electrical cables. Make sure that the toothed rack (3) moves freely (see Fig.
Page 116: Defective Injection Valve
0515−1/A1 Operation Faults in High Pressure Fuel System 2.3.2 All Actuators are Defective To install the distance pieces (6, Fig. 1) to the toothed racks (3), see steps a) and For engines with two fuel pumps, install the distance pieces (6) to get: One fuel pump in the 0% fuel position and the other fuel pump in the 100% position.
Page 117: Procedures
0515−1/A1 Operation Faults in High Pressure Fuel System Procedures 3.3.1 Injection Valve The fuel injection must be cut out immediately (if not automatically cut-out). See 0510−1, paragraph Cut Out the Injection. Note: When the injection is cut out (Inj. CUT OFF) the engine can only be operated at decreased load.
Page 118: Defective Pressure Control Valve
0515−1/A1 Operation Faults in High Pressure Fuel System Defective Pressure Control Valve Fault Identification Fault identification of a defective pressure control valve (PCV) is as follows: The engine load decreases or the engine stops. The fuel system pressure is too low (alarm). The fuel pump supply is higher than usual or at maximum.
Page 119 0515−1/A1 Operation Faults in High Pressure Fuel System WCH02237 WCH03718 FREE Fig. 2: Location of Pressure Control Valve 1 Pressure control valve 10-5562_E0_5 6 Fuel supply pipe 2 Solenoid valve (ZV7061S) 7 Valve block 3 Rail unit 8 Fuel return pipe 4 Fuel rail 9 Drain screw 5 Drain pipe...
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Page 121 0520−1/A1 Operation Operation during Unusual Conditions Operation with Exhaust Valve Control Unit Cut Out General ............Emergency Operation with Exhaust Valve Closed .
Page 122 0520−1/A1 Operation Operation with Exhaust Valve Control Unit Cut Out Connect the electrical connection (7, Fig. 1) to the 4/2-way valve (8). 10) Start the injection (see 0510−1). 11) Do a visual check for leaks. DRIVING END WCH02525 WCH02525 WCH02585 Fig.
Page 123 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 124 0520−1/A1 Operation Operation with Exhaust Valve Control Unit Cut Out WCH01217 WCH02257 Fig. 2: Exhaust Valve / Pressure Element 1 Damper 3 Shim 2 Pressure element (tool 94259) 4 Top housing VS Maximum exhaust valve stroke 2014 4/ 4 Winterthur Gas & Diesel Ltd.
Page 125 0525−1/A1 Operation Operation during Unusual Conditions Faults in Servo Oil System Defective Servo Oil Pump Identification The flow sensors FS2061A and FS2062A show that a servo oil pump does not supply oil, i.e. an alarm is activated in the alarm and monitoring system (Servo oil pump No.
Page 126 0525−1/A1 Operation Faults in Servo Oil System In the new 4/2−way valve (6, Fig. 1), make sure that the correct new O-rings are installed. Make sure that the mating surfaces of the 4/2-way valve (6) and the VCU (1) are clean.
Page 127 0525−1/A1 Operation Faults in Servo Oil System 2.2.2 Defective Exhaust Valve Control Unit If the piston, or the slide rod in the VCU cannot move, shut off the VCU immediately. See 0520−1, paragraph 2 Emergency Operation with Exhaust Valve Closed. Note: With one or more VCU cut-out, you can operate the engine only at decreased load.
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Page 129: 0530-1/A1
0530−1/A1 Operation Operation during Unusual Conditions CCM-20 Failure CCM-20 Failure Identification The alarm Module Fail CCM#X shows in the engine control system (ECS). Fig. 1 shows a schematic diagram of the CCM-20 in usual configuration. Cause The CCM-20 of cylinder X is defective, thus the related cylinder has no lubrication. CYLINDER Y CYLINDER X Usual Cylinder Lubrication...
Page 130 0530−1/A1 Operation CCM−20 Failure Socket B Socket C Terminal Box Socket A WCH01087 (Tool 94929) CYLINDER Y CYLINDER X Usual Cylinder Lubrication Emergency Cylinder Lubrication CYL. LUB. CYL. LUB. CYL. LUB. CYL. LUB. CYL. LUB. CYL. LUB. CYL. LUB. CYL. LUB. VALVE VALVE VALVE...
Page 131 0540−1/A1 Operation Operation during Unusual Conditions Operation with Running Gear Partially or Fully Removed General If the engine must operate with a defect in the running gear, which cannot be immediately repaired, do the procedures given in paragraph to paragraph 7. Note: You can operate the engine only at decreased load.
Page 132 0540−1/A1 Operation Operation with Running Gear Partially or Fully Removed Piston, Crosshead and Connecting Rod Removed Problems The crosshead or guide shoes are defective. WCH02356 The connecting rod bearing is damaged. The crosshead pin or the connecting rod is defective. Preparation Cut out the injection to the related cylinder (see...
Page 133 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 135 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 137 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 139 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. If this is not possible, you can control the engine from the local control panel. If the fuel command signal from the speed control system is missing during engine operation, the speed control system will continue to operate.
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Page 141 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 procedure below is completed.
Page 142 0590−1/A1 Operation Defective Turbocharger Condition Two All turbochargers are defective. 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 143 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 145 0620−1/A1 Operation Special Procedures Before and After Operation Prepare the Engine for a Long Shutdown Period General When you prepare the engine for a long shutdown period, make sure that you know the correct precautions to protect the engine from corrosion. There are two conditions as follows: Condition One has the procedures for when there is less crew on board for a period of some weeks.
Page 146: 0620-1/A1
0620−1/A1 Operation Prepare the Engine for a Long Shutdown Period 13) Repair all the damage and leaks found during the previous operation period and the checks made after shut-down. 14) Do all scheduled overhauls and obey the general guidelines for maintenance (see the Maintenance Manual 0011−1 and 0012−1).
Page 147 0710−1/A1 Operation Operating Media Diesel Engine Fuels General ............Heavy Fuel Oil .
Page 148: 0710-1/A1
0710−1/A1 Operation Diesel Engine Fuels Heavy fuel oil must have treatment 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 149 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 150 0710−1/A1 Operation Diesel Engine Fuels The notes that follow are related to the data in Table /s=1cSt (Centistoke) You can get ISO standards from the ISO Central Secretariat, Geneva, Switzerland (www.iso.ch). For W−X engines the fuel viscosity at the fuel pump inlet can be in the range of between 13 mm /s (cSt) and 20 mm /s (cSt).
Page 151: 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 152: Density
0710−1/A1 Operation Diesel Engine Fuels The maximum permitted viscosity of the fuel that can be used in an installation is related to the heating and fuel preparation facilities available. The flow rate and the temperature of the fuel that flows through the centrifuges must be adjusted in relation to the viscosity to get good separation.
Page 153: 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 154: 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 155 0710−1/A1 Operation Diesel Engine Fuels Distillate Fuel Specifications Note: For data about the parameters given in Table 2, see to paragraph 5.12. Table 3: Fuel Specifications Parameter Unit Bunker Limit Test Method Applicable Fuel Quality at the Engine Inlet Kinematic viscosity at 40_C /s [cSt] Maximum 11.0 ISO 3104...
Page 156: Data About Distillate Fuel Specifications
0710−1/A1 Operation Diesel Engine Fuels Distillate fuels are used more in 2-stroke engines to meet area specified emission standards. They are easier to operate than residual fuel, but caution is necessary for some problems. Refer to Service Bulletin RT−82: Distillate Fuel Use. ISO 8217: 2010 specifies DMX, DMA, DMZ and DMB categories.
Page 157: 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 vapor.
Page 158: Bio-Derived Products And Fatty Acid Methyl Esters
0710−1/A1 Operation Diesel Engine Fuels Bio-derived Products and Fatty Acid Methyl Esters Such components can be found in diesel engine fuels and can cause a decrease of greenhouse gases and SOx emissions. Most bio-fuel components in the diesel pool are Fatty Acid Methyl Esters (FAME), which come from a special chemical treatment of natural plant oils.
Page 159: General
0720−1/A1 Operation Operating Media Fuel Treatment and Fuel System General ............Treatment of HFO and Treatment Plant .
Page 160: 0720-1/A1
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 161 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 162 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 163 0720−1/A1 Operation Fuel Treatment and Fuel System WCH03261 Fig. 1: Schematic Diagram − Fuel System 2015-12 5 / 5 Winterthur Gas & Diesel Ltd.
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Page 165 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 167: System
0750−1/A1 Operation Operating Media Lubricating Oils General ............System Oil .
Page 168: 0750/1A1
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. The self-cleaning, centrifugal separator is used as a purifier in by-pass mode. The oil flows from the oil tank through the centrifugal separator.
Page 169 0750−1/A1 Operation Lubricating Oils If one of the limits of the system oil is at a value given in the table above, applicable procedures must be done to correct the problem. Such procedures can be purification (decrease of the flow rate, adjustment of temperatures), treatment in a renovating tank (settling tank) or partial exchange of the oil charge.
Page 170: Particle Size And Count
0750−1/A1 Operation Lubricating Oils If the system oil is used for more than one year, the FZG performance of the oil must be done to make sure that the performance is sufficient for the new or polished gear(s). You must do regular on-board checks of the BN and water content to get an early indication of a lower oil quality.
Page 171 0750−1/A1 Operation Lubricating Oils Table 3: 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 172 0750−1/A1 Operation Lubricating Oils 2.3.1 Recommended Limits for ISO 4406 Particle Count The specification for a 100 ml oil sample is ISO 4406 --/20/17 maximum in the system oil downstream of the filter, which means: It is not necessary to count particles of size equal to or more than 4 mm A maximum of 1 000 000 particles of size equal to or less than 6 mm A maximum of 130 000 particles of size equal to or more than 14 mm.
Page 173: Oil Samples
0750−1/A1 Operation Lubricating Oils Oil Samples At regular intervals, (i.e. at approximately each 3000 operating hours), it is recommended to get a sample of the system oil. Send 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 174: 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 175 0750−1/A1 Operation Lubricating Oils Worn metals, the residual BN, viscosity, fuel components and water are measured. The quantity of system oil additive metals in the sample gives an indication about the piston rod gland box condition. It is important to monitor trends and not full values, and to think about the quantity of drained oil relative to the analysis results.
Page 176 0750−1/A1 Operation Lubricating Oils WCH03457 Fig. 1: Piston Underside, Scrape-down or Drip Oil Analysis Interpretation Note: There are smooth transitions between the different areas shown in Fig. 1. For engines with chrome ceramic piston rings installed the chromium content of the piston underside oil shows if there is corrosion or if the engine is worn.
Page 177: Fuel Sulphur Content And Cylinder Lubricating Oil Base Number
0750−1/A1 Operation Lubricating Oils Fuel Sulphur Content and Cylinder Lubricating Oil Base Number Fig. 2 shows recommendations of applicable cylinder lubricating oils related to the sulphur content of the used fuel. Also shown is the data for fuel with a sulphur content in the range of 1.5% m/m to 3.5% m/m and cylinder lubricating oil with a base number between BN 50 to BN 100.
Page 178 0750−1/A1 Operation Lubricating Oils Range 3 (see Fig. 2): When the fuel sulphur content is more than 0.5% m/m and less than 1.0% m/m during operation with BN 70 to BN 80 cylinder lubricating oil, operation is permitted only, when you do an analysis of the piston underside drain oil from the on-board monitoring system.
Page 179: General Recommendations
0750−1/A1 Operation Lubricating Oils The BN 40 products can also be used safely with HFO that has a sulphur content in the range 0.5% m/m to 1.5% m/m. It is possible that the feed rate must be increased in relation to the remaining BN measured in the piston underside drain oil or scrape-down samples.
Page 180: Intermediate Bn Lubricating Oils
0750−1/A1 Operation Lubricating Oils Intermediate BN Lubricating Oils CAUTION Damage Hazard: Intermediate BN lubricating oils (between BN 50 and BN 60) are applicable only, if the sulphur content of the used HFO is in the range of 0.5% m/m to 2.5% m/m. Damage to the engine can occur.
Page 181: Applicable Lubricating Oils
0750−1/A1 Operation Lubricating Oils Applicable Lubricating Oils Lubricating Oil Instruction and Liability The handling of lubricating oils must be in compliance with the Wärtsilä general lubricating oil requirements and recommendations given in the Operation Manual (this manual) and the Maintenance Manual. Also, refer to the Service Bulletins RT-138, RT-138 Appendix 1, RT-138 Appendix 2 and RT-161.
Page 182: Cylinder Lubricating Oils
0750−1/A1 Operation Lubricating Oils Cylinder Lubricating Oils Table 4: List of Applicable Lubricating Oils and Blending on Board Additives (Last Update: January 25, 2016) Oil Supplier 15 ≤ BN ≤ 25 BN 40 50 ≤ BN ≤ 60 70 ≤ BN ≤ 80 BN 100 Aegean Alfacylo 525 DF...
Page 183 0750−1/A1 Operation Lubricating Oils Oil Supplier 15 ≤ BN ≤ 25 BN 40 50 ≤ BN ≤ 60 70 ≤ BN ≤ 80 BN 100 SINOPEC Cylinder Oil 5025 Cylinder Oil − Cylinder Oil 5070 Cylinder Oil (BN 25) 5040 (BN 70) 50100 Cylinder Oil 5070S...
Page 184: System Oils
0750−1/A1 Operation Lubricating Oils System Oils Table 5: List of Applicable System Oils (Last Update: January 25, 2016) Oil Supplier Brand Aegean Alfasys 305 Energol OE−HT 30 Castrol CDX 30 Chevron Veritas 800 Marine 30 Marilube Oil AC−30 Cladium 50 ExxonMobil Mobilgard 300 Mobilgard 300 HD...
Page 185 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. Raw Water −...
Page 186 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 187 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 188 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 Engine Control System (ECS) Failures Major failures Minor failures Info logs. 2014 2/ 2 Winterthur Gas & Diesel Ltd.
Page 189 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 during the start sequence are closed...
Page 190 0810−1/A1 Operation Problems during Engine Start and Stop Problem Possible Cause Procedure No air spring pressure, or pressure is too low Open the 3/2-way valve 35-36HA, adjust the pressure to 6 bar in control air supply unit A The non-return valve on the exhaust valve (air Do a check and install inlet to air spring) is incorrectly installed.
Page 191 0810−1/A1 Operation Problems during Engine Start and Stop Problem Possible Cause Procedure No ignition during engine start The high pressure circuit has leaks (fuel Find the cause and repair the (continued) pumps, HP pipes, fuel rail) leaks. The heating of the high pressure pipe to the Set the heating lines to on.
Page 192 0810−1/A1 Operation Problems during Engine Start and Stop Problem Possible Cause Procedure Violent firing during engine Fuel rail pressure is too high, fuel control Do a check of the power start does not operate correctly. supply and wiring. Cylinders were lubricated too much before Decrease the speed setting starting.
Page 193 0820−1/A1 Operation Operating Problems Irregular Operation Load Indications ..........Cylinder Lubrication .
Page 194 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 dirty...
Page 195 0820−1/A1 Operation Irregular Operation Problem Possible Causes Procedure There is smoke from the Air supply is not sufficient. Unwanted material See 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 The engine has too much load...
Page 196 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 decreases quickly inlet to the cooling water pump because of a...
Page 197 0820−1/A1 Operation Irregular Operation Problem Possible Causes Procedure Cylinder lubrication is The daily tank is empty. The filter element in Fill the daily tank. Clean, or defective. No lubricating oil the filter unit is clogged replace the filter element There is air in the cylinder lubricating system Bleed the cylinder lubricating system (the filter, the pump and the pipes to the lubricat-...
Page 198 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 199 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 posi- Adjust the screw for manual thermal load...
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Page 201 0840−1/A1 Operation Operation Problems Problems and Damage to Engine Parts 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 203 ................. 1903−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
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Page 205 1132−1/A1 Operation Main Bearing General The main bearing has a bottom bearing shell (7, Fig. 1) and a top bearing shell (5). The bottom main bearing shell (7) is is installed in the bearing girder (9) of the bedplate and the top main bearing shell (5) in the bearing cover (4). The screws (6) engage and hold the top bearing shell and bottom bearing shell in position.
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Page 207 1203−1/A1 Operation Thrust Bearing General The thrust bearing is installed at the driving end of the engine. The thrust bearing flange transmits the force from the propeller through the thrust pads into the bedplate. The arbor supports (4, Fig. 1) prevent axial movement of the thrust pads. There are six thrust pads (5 and 9) on each side of the thrust bearing flange (10, Fig.
Page 208 1203−1/A1 Operation Thrust Bearing Lubrication During operation, bearing oil flows through the oil pipe (2) to the two nozzles Fig. 1). The oil flows out of the two nozzles as a spray, which becomes an oil layer between the thrust bearing flange (10) and the thrust pads (5 and 9, Fig.
Page 209 1903−1/A1 Operation Tie Rod General The tie rods (1, Fig. 1) keep the cylinder block (3), column (4) and bedplate (5) together at four locations around the cylinders. WCH01211 WCH01211 FOR 6-CYLINDER ENGINES Fig. 1: Tie Rod Configuration and Locations 1 Tie rod 4 Column 2 Protection cover...
Page 210 1903−1/A1 Operation Tie Rod A two-part bush (8, Fig. 2) is welded on the tie rod (4). At the bottom of the cylinder block, two set screws (7) keep the two-part bush in position to prevent vibration of the tie rods. If a tie rod breaks in the bottom area, the holders (11) and screws (12) make sure that the nut (10) does not fall into the crankcase.
Page 211 ................2751−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
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Page 213 2124−1/A1 Operation Cylinder Liner General The screws (7, Fig. 1) and holders (6) hold the cylinder liner (4) in the cylinder jacket (5). The nuts of the elastic bolts attach the cylinder cover (1), cylinder liner (4) and the top and bottom water guide jacket (2) and (3), to the cylinder jacket (5). The surfaces of the cylinder liner (4) and the cylinder jacket (5) make the metallic seal MS.
Page 214 2124−1/A1 Operation Cylinder Liner FUEL SIDE WCH01203 WCH01201 WCH01200 EXHAUST SIDE Fig. 1: Cylinder Liner 1 Cylinder cover 11 Tube 2 Top water guide jacket 12 O-ring 3 Bottom water guide jacket 4 Cylinder liner OG Oil grooves 5 Cylinder jacket CI Cooling water inlet (water guide jacket) 6 Holder MS Metallic seal...
Page 215 2124−1/A1 Operation Cylinder Liner EXHAUST SIDE WCH01204 Fig. 2: Cooling Water Outlet 1 Exhaust valve cage 3 Cooling water outlet 2 Cylinder cover 2014 3/ 3 Winterthur Gas & Diesel Ltd.
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Page 217 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 (4) installed on the rail unit, supplies lubricating oil through pipes to each lubricating quill. WCH02268 FREE END Fig.
Page 218 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. The non-return valve (8) opens and the lubricating oil comes out of the the nozzle tip and the lubricating point (LP) as a spray.
Page 219 2303−1/A1 Operation Piston Rod Gland General The piston rod gland (4, Fig. 1) keeps the dirty oil in the scavenge space (SS) and prevents contamination of the bearing oil. Also, the piston rod gland seals the scavenge air from the crankcase (1). Damaged gaskets cause an increase in the quantity of oil in the leakage oil drain.
Page 220: 2303-1/A1
2303−1/A1 Operation Piston Rod Gland WCH02292 Fig. 2: Piston Rod Gland 1 Oil bore 10 Gasket (4-part) 2 Relief passage 11 Tension spring 3 Neutral space 12 Scraper ring (4-part) 4 Ring support (3-part) 13 Housing (2-part) 5 Support 6 Cylinder jacket 7 Scraper ring (3-part) 8 Tension spring BD Bearing oil drain...
Page 221: General
2722−1/A1 Operation Injection Valve (FAST Nozzle) General Three injection valves (1, Fig. 1) are installed in each cylinder cover. Fuel is used to operate the injection valves (1). When the injection valve operates and the needle opens, a small quantity of fuel leaks out of the injection valve. This fuel flows back through the control fuel return pipe (2).
Page 222 2722−1/A1 Operation Injection Valve (FAST Nozzle) Function Fuel flows through the high pressure (HP) fuel pipes (9, Fig. 1) to the three injection valves (1). The control valve for the injection valves is activated, which moves the needle to the open position.
Page 223 2728−1/A1 Operation Starting Valve General A starting valve is installed in each cylinder cover (6, Fig. 1). The starting valves start the engine, or decrease the engine speed for reversing. The engine control system (ECS) monitors and controls the starting valve operation (see 4002−1, paragraph 3.1).
Page 224 2728−1/A1 Operation Starting Valve WCH01215 Fig. 1: Starting Valve 1 Cover 7 Pipe 2 Piston 8 3/2-way solenoid valve 3 Housing 4 Compression spring 5 Valve spindle Air chamber 6 Cylinder cover Air chamber 2014 2/ 2 Winterthur Gas & Diesel Ltd.
Page 225 2751−1/A1 Operation Exhaust Valve General ............Function .
Page 226 2751−1/A1 Operation Exhaust Valve The air spring (AS) is below the air spring piston (9, Fig. The valve stroke sensor (19) monitors and transmits the open and closed positions of the valve spindle (16) to the engine control system (ECS). 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 227 2751−1/A1 Operation Exhaust Valve II - II WCH01217 WCH01217 Fig. 2: Exhaust Valve and Leakage Oil Drain 2014 3/ 5 Winterthur Gas & Diesel Ltd.
Page 228 2751−1/A1 Operation Exhaust Valve Key to Fig. 2: Exhaust Valve and Leakage Oil Drain 1 Damper 16 Valve spindle 2 Top housing 17 Leakage oil collection space 3 Orifice 18 Hydraulic oil connection 4 Outer piston 19 Valve stroke sensor 5 Inner piston 20 Non-return valve 6 Thrust piece...
Page 229 2751−1/A1 Operation Exhaust Valve Lubrication Leakage oil from the outer piston (4, Fig. 2) and inner piston (5) lubricates the air spring piston (9). Oil in the leakage oil collection space (17) drains to the leakage oil drain (LD). While the exhaust valve closes, oil flows through the air spring piston (9) and into the air spring (AS).
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Page 231 ..........3603−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
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Page 233 3140−1/A1 Operation Axial Damper General The engine has a built-in axial damper. The function of the axial damper is to decrease the axial vibrations. The axial damper includes a top cylinder half (3, Fig. 1) and a bottom cylinder half (4) attached with bolts to the last bearing girder.
Page 234 3140−1/A1 Operation Axial Damper Axial Damper Monitor The engine has a system that monitors the axial damper, installed at the free end above the end casing (see Fig. 2). This system monitors the oil pressure in the front and rear spaces of the axial damper. If the oil pressure decreases below a set value, an alarm is activated (for more data about the setting values, see 0250−2...
Page 235 3303−1/A1 Operation Connecting Rod and Connecting Rod Bearing General The connecting rod connects the crosshead with the crankshaft and converts the linear movement of the piston into a circular movement. The bearing shells (4, 7, and 9, Fig. 1) (that you can replace) are installed on the connecting rod (1) for the bottom end bearing and top end bearing.
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Page 237: 3326-1/A1
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 Fig. 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 238 3326−1/A1 Operation Crosshead and Guide Shoe FUEL SIDE EXHAUST WCH01219 SIDE Fig. 2: Crosshead and Guide Shoe (Top View) 3 Guide shoe 11 Groove (in connecting rod) 4 Connecting rod 12 Guide rail 6 Crosshead pin 13 Groove (in crosshead pin) 7 Compression shim 9 Holding plate CO Crosshead lubricating oil inlet...
Page 239 3403−1/A1 Operation Piston General The piston has the parts that follow: Piston crown (1, Fig. Piston rings (2) Piston skirt (3) Piston rod (4) Oil pipe (5) Compression shim (6). Nine elastic bolts (8) and round nuts (9) attach the piston crown (1) and the piston rod (4) together.
Page 240 3403−1/A1 Operation Piston WCH01222 Fig. 1: Piston 1 Piston crown 9 Round nut 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 crown) 7 Crosshead pin CO Piston cooling oil 8 Elastic bolt...
Page 241 3603−1/A1 Operation Crosshead Lubrication and Piston Cooling General Lubricating oil keeps the pistons cool. 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, Fig.
Page 242 3603−1/A1 Operation Crosshead Lubrication and Piston Cooling Key to Fig. 1: Articulated Lever − Location 1 Column 9 Top end bearing shell 2 Support 10 Connecting rod 3 Oil inlet (crosshead lubrication) 11 Guide shoe 4 Bottom lever 12 Piston rod 5 Top lever OB Oil bore (crosshead lubricating oil to 6 Connection piece...
Page 243: Group 4
............4628−1/A1 X72 / OM / 2016−11 Winterthur Gas & Diesel Ltd.
Page 244 Intentionally blank...
Page 245 Some parts and functions in the ECS configuration are optional and are related to the application. Note: The name of the WinGD engine control system is Unified Controls Flex (UNIC−flex) The system uses modern bus technologies for the transmission of signals.
Page 246: 4002-1/A1
4002−1/A1 Operation Engine Control System System Description The engine control system on the X-engine is a modular system that has the items that follow: Two local display units (LDU-20) (1, Fig. 1). One LDU-20 is installed at the local maneuvering stand at the free end. The other LDU-20 is installed in the engine control room (ECR).
Page 247 4002−1/A1 Operation Engine Control System UNIC Color Codes: Power Speed To PCS Modbus Diesel To AMS Modbus PT2021C X-Head Brng. Oil Press. Supply XS3411C HFO Supply CV7003C Inj. Lub Shut-off Vlv PT4043C Scav Air Press #1 in Air Rec. #1 CV7013C Common Start Vlv #1 LDU-20...
Page 248 4002−1/A1 Operation Engine Control System Intentionally blank 2015-12 4/ 22 Winterthur Gas & Diesel Ltd.
Page 249 4002−1/A1 Operation Engine Control System WCH03159 Fig. 3 CCM-20 − Overview Connections Diesel 2015-12 5/ 20 Winterthur Gas & Diesel Ltd.
Page 250 4002−1/A1 Operation Engine Control System Intentionally blank 2015-12 6/ 22 Winterthur Gas & Diesel Ltd.
Page 251: Power Supplies
4002−1/A1 Operation Engine Control System Power Supplies Two 230 VAC supplies from the ship installation supply electrical power to E85.1 to E85.n. The two 230 VAC supplies are isolated (see Fig. 2). WARNING Injury Hazard: The power supplies have redundancy. If it is necessary to isolate the ECS, make sure that each of the two 230 VAC power supplies are set to off.
Page 252: Engine Control System − Functions
4002−1/A1 Operation Engine Control System Engine Control System − Functions The functions of the engine control system (ECS) are as follows: Starting valve control (see paragraph 3.1) Servo oil pressure control (see paragraph 3.2) Exhaust valve control (see paragraph 3.3) Cylinder lubricating control (see paragraph 3.4) Engine speed and crank angle sensor (see paragraph 3.5) Diesel fuel pressure control (see paragraph 3.6)
Page 253: Servo Oil Pressure Control
4002−1/A1 Operation Engine Control System Servo Oil Pressure Control 3.2.1 Pressure Setpoint The internal controller of the servo oil pumps keeps the basic servo oil pressure. The load dependent changes in servo oil pressure is controlled by the CCM-20 Cyl. 3 (with the signal CV7221C to servo oil pump #1) and CCM-20 Cyl.
Page 254: Exhaust Valve Control
4002−1/A1 Operation Engine Control System Exhaust Valve Control 3.3.1 Exhaust Valve − Function When the engine operates, the exhaust valve opens and closes once during each full turn of the crankshaft related to the defined crank angle position (see Fig. 5). The control valves CV7401−08C are installed on the exhaust valve control unit.
Page 255: Cylinder Lubricating Control
4002−1/A1 Operation Engine Control System Cylinder Lubricating Control 3.4.1 General The cylinder lubricating system (see Fig. 6) is a time-based system, that supplies lubricating oil on to the cylinder liner wall. Each CCM-20 controls the solenoid valves CV7131−38C that activate an oil pulse on the related cylinder.
Page 256 4002−1/A1 Operation Engine Control System Cylinder Lubricating Oil Tank PT3124A Duplex Filter PT3131C PT3136C CCM-20 CCM-20 CCM-20 CCM-20 CCM-20 CCM-20 Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. 5 Cyl. 6 DATA FOR CANBus 6 CYLINDERS Fig. 6: Cylinder Lubricating System 2015-12 12/ 22 Winterthur Gas &...
Page 257: Engine Speed And Crank Angle Sensor
4002−1/A1 Operation Engine Control System Engine Speed and Crank Angle Sensor Four proximity sensors (A and B, C and D) are installed near the crankshaft gear wheel (see Fig. 7). As the crankshaft gear wheel turns, the proximity sensors sense the movement of the teeth and calculate the crankshaft position (see also 9223−1 Crank Angle Sensor Unit).
Page 258: Crank Angle Determination Algorithm (Ada)
4002−1/A1 Operation Engine Control System Crank Angle Determination Algorithm (ADA) WARNING Injury Hazard: After an air run, the crankshaft can turn suddenly when the pressurized air in the cylinder releases. There is a risk of death, serious injury or damage to components. Note: Before you do maintenance on the engine, engage the turning gear, or start the Crank Angle Determination Algorithm (ADA) a second time: Make sure that there is no pressurized air in the cylinder and the...
Page 259 4002−1/A1 Operation Engine Control System 3.6.4 ADA Start from the LDU-20 Local Control Panel or LDU-20 ECR If you manually start the ADA from the LDU-20 Local Control Panel or the LDU-20 ECR, do step 1) step Note: It is possible to do the ADA procedure with open or closed indicator valves.
Page 260: Diesel Fuel Pressure Control
4002−1/A1 Operation Engine Control System Diesel Fuel Pressure Control 3.7.1 Engine Start At engine start, the fuel pump actuators are set to the start position (see Fig. 3.7.2 Engine Operation The fuel pressure is related to the engine load. The control loop for the fuel rail pressure is given as follows: The engine control system (ECS) activates a control signal, which is related to the engine speed or estimated power.
Page 261 4002−1/A1 Operation Engine Control System Fuel Injectors Fuel Rail Flow Limiter Supply Pressure Valves Fuel Unit Drive Control Pumps Valve CV7233C Lube Oil Supply CV7232C Control Valve to keep the Injectors cool CV7231C CCM-20 CCM-20 CCM-20 CCM-20 Cyl. 1 Cyl. 2 Cyl.
Page 262: Diesel Fuel Injection Control
4002−1/A1 Operation Engine Control System Diesel Fuel Injection Control 3.8.1 Injection Valve Control Each injection valve, related to the solenoid valve in each cylinder, is controlled independently (see Fig. Usually, the three injection valves on each cylinder operate at the same time. Special operation modes enable fuel injection with one, or the two injection valves, or with multi-shot spray patterns.
Page 263 4002−1/A1 Operation Engine Control System Control Fuel out Solenoid Valve Outlet Throttle Outlet Throttle Control Space Injection Injection Needle Valve Valve Fuel Rail All components are shown in the NO INJECTION position Fuel Fig. 9: Fuel Injection Control 2015-12 19/ 22 Winterthur Gas &...
Page 264: External Control Systems
4002−1/A1 Operation Engine Control System External Control Systems Communication between ECS and External Systems The Diesel Engine CoNtrol and OptImizing Specification (DENIS) and the engine control system (ECS) are designed so that different remote controls can be used. All nodes are fully specified. The terminal boxes are installed on the engine, to which the cable ends from the control room or from the bridge can be connected.
Page 265: Alarm And Monitoring System
4002−1/A1 Operation Engine Control System 4.2.1 Remote Control System The remote control system (RCS) has the primary functions that follow: Start, stop and reverse Automatic slow turning. Data about the engine control system (ECS) status is available in the RCS. This includes measured values of sensors, defects and other indications (see the documentation of the remote control manufacturer).
Page 266: Unic
UNIC Shipyard Interface Box Alarm Terminal Boxes Starter Units Control Panel Sensors and Actuators Alarm Sensors UNIC Local Indications UNIC Sensors and Actuators W−X72 diesel engine WCH03158 Fig. 10: Signal Flow Diagram 2015-12 22/ 22 Winterthur Gas & Diesel Ltd.
Page 267 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) General ............Installed Components .
Page 268: 4002-2/A1
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Installed Components Electronic Components The local control panel has the electronic components that follow: LDU−20 ME tachometer Emergency stop button Telegraph system. LDU−20 There are two LDU-20 (2, Fig. 1). One LDU-20 is installed in the local control panel. The other LDU-20 is installed in the engine control room.
Page 269 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) FREE END WCH02226 POWER STATUS PUSH SELECT AST. AHD. EMERG. STOP Fig. 1: Local Control Panel − Location 1 Local control panel 4 Emergency stop button 2 LDU−20 5 Telegraph receiver 3 ME tachometer 2015-03 3/ 37...
Page 270: General
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) LDU−20 General The LDU-20 is a multi-purpose module that has an LCD color display (1, Fig. 2), ten multi-function buttons (3) and a rotary button (2). You can also push the rotary button to select a function.
Page 271: User Guide
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) User Guide The LDU-20 shows different pages for each application. After boot-up, or when you push the HOME button, the MAIN page is shown. To show other pages, push and hold the rotary button for 3 seconds. The navigation menu shows on the display.
Page 272: Main Page
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) MAIN Page The MAIN page (Fig. 5) shows: After you start the LDU-20, or When the HOME button is pushed during LDU-20 operation. 16 17 3 WCH03164 Fig. 5: MAIN Page Item Function Effect / Procedure...
Page 273 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Different sensor indications Necessary to operate the engine locally Speed Setpoint button Arrow shows the selected mode: Speed control mode or Fuel control mode Indication of active manual Use the rotary button to change to manual speed control mode control mode.
Page 274: Control Locations
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Control Locations WCH03165 Fig. 6: Control Locations Page Item Function Effect / Procedure START AST button Start the engine in astern direction STOP button Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 275 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.4.1 Procedure − Change the LDU-20 Control Location Push the CTRL. TR. button (4, Fig. 6) to accept control to the LDU-20 at your location. To get / accept control to / from a different location, select the related on-screen button, then push the CHECK button (see Fig.
Page 276: Fuel System
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Fuel System WCH03476 Fig. 7: Fuel System Page Item Function Effect / Procedure START AST button Start the engine in astern direction STOP tab Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 277 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Shutdown active indicator Shows the shutdown mode status. When the shutdown mode is active, the green indicator is on. Control position fuel pump #1 Shows the setpoint of fuel pump #1 in percent (%) Control position fuel pump #2 Shows the setpoint of fuel pump #2 in percent (%) Control position fuel pump #3...
Page 278: Cylinder Balancing
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Cylinder Balancing The cylinder balancing page shows data about the combustion process for each cylinder and related sensor indications (see Fig. 7). For more data about the cylinder balancing, see 9308−1 Intelligent Combustion Control.
Page 279 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Compression pressure Shows the compression pressure for each cylinder in bar Exhaust valve offset Shows the exhaust valve closing time offset for each cylinder in degree Firing pressure Shows the firing pressure for each cylinder in bar Injection begin offset...
Page 280: Fuel Injection
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Fuel Injection WCH03167 Fig. 9: Fuel Injection Page Item Function Effect / Procedure START AST button Start the engine in astern direction STOP tab Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 281 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.7.1 Procedure − Adjust the Diesel Fuel Injection Parameters To adjust the diesel fuel injection parameters, turn the rotary button to move the cursor to the related text field (see Fig.
Page 282: Exhaust Valve
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Exhaust Valve The manual exhaust valve operation is only available on the local LDU−20 (at the local control stand), while the engine is stopped. WCH03168 Fig. 10: Exhaust Valve Page Item Function Effect / Procedure...
Page 283 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.8.1 Procedure − Open the Exhaust Valve for Inspections To open the exhaust valve for inspection, do steps 1) to 4). Move the cursor to the related text field (6, Fig.
Page 284: Cylinder Lubrication
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Cylinder Lubrication Manual lubrication can be used to inject a specified number of lubricating oil pulses to the cylinders before engine start (see Fig. 10). WCH03169 Fig. 11: Cylinder Lubrication Item Function Effect / Procedure...
Page 285 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Manual lubrication start Move the cursor to the related button, then push the rotary button to start manual lubrication. To select a specified cylinder, see item 13. Manual lubrication to The operator can select a cylinder (1 to 6) or set the specified cylinder...
Page 286: User Parameters
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.10 User Parameters WCH03171 Fig. 12: User Parameters Item Function Effect / Procedure START AST button Start the engine in astern direction STOP button Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 287 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Fuel Quality Setting (FQS) Adjustable parameter range from −5_ to +5_ The FQS can be set to adjust maximum firing pressure to nominal value. A negative correction angle will advance the injection start and increase maximum pressure.
Page 288 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Angle detection / Angle Shows the angle determination status. When the determination failure indication crank angle determination algorithm (ADA) mode is active, the related indicator is on. When there is a crank angle determination failure, the related indicator is on.
Page 289: Performance Data
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.11 Performance Data WCH03170 Fig. 13: Performance Data Page Item Function Effect / Procedure START AST button Start the engine in astern direction STOP tab Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 290 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Fuel rail pressure Shows the fuel rail pressure in bar Scavenge air pressure at Shows the scavenge air pressure at CMCR in bar CMCR Scavenge air pressure Shows the scavenge air pressure in bar Active nozzles Shows the number of active injection nozzles...
Page 291: Temperatures − Cylinder Liner Wall And Exhaust Gas
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.12 Temperatures − Cylinder Liner Wall and Exhaust Gas WCH03172 Fig. 14: Temperature − Cylinder Liner Wall and Exhaust Gas Item Function Effect / Procedure START AST button Start the engine in astern direction STOP button Stop the engine START AHD button...
Page 292: Crank Angle
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.13 Crank Angle WCH03480 Fig. 15: Crank Angle Page Item Function Effect / Procedure START AST button Start the engine in astern direction STOP tab Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 293 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) Item Function Effect / Procedure Approximate CA Shows the set approximate crank angle (CA) value (see also item 7). CA synchronized (No ADA Shows the crank angle synchronization status, i.e. if the needed) angle determination algorithm (ADA) process is necessary/on.
Page 294: Software Info
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.14 Software Info WCH03173 Fig. 16: Software Info Item Function Effect / Procedure START AST button Start the engine in astern direction STOP button Stop the engine START AHD button Start the engine in ahead direction CTRL.
Page 295: Log Messages
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.15 Log Messages You can use the Filters field (7, Fig. 15) to filter the list of log messages to only show specified types of messages. Fig. 17: Log Messages Item Function Effect / Procedure...
Page 296 Recommended action that the operator can do to solve the problem Note: Some data on this screen are only applicable to WinGD SW developers, i.e. the ID and status flag numbers. 3.15.1 Procedure − Export a Screenshot of the Log Entry Page...
Page 297: System Status
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.16 System Status The LDU-20 have a full backup of all application and configuration files for all modules in the system (5, Fig. 17). When a module starts, all files are compared to the backup files in the LDU-20.
Page 298 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.16.1 Procedure − Download Backup Files Use the rotary switch (turn then push) to select the Download button. A dialog box is shown. This dialog box gives an option to download, or not to download the backup files to the selected modules.
Page 299: Usb Page
You use the partial upgrade wizard to adjust software parameters, which the user does not usually have access. A file (from WinGD stored on a USB drive is necessary. To apply the partial upgrade, connect the USB drive to the USB port on the back of the LDU.
Page 300 4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) A screen shows you the available upgrade packages on the USB drive and helps you through the upgrade process (see Fig. 19). Fig. 21: Choose Upgrade Page 2015-03 34/ 37 Winterthur Gas &...
Page 301: System Settings
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.18 System Settings This page contains three sub-pages to adjust the LDU-20 system settings (see Fig. 20). Fig. 22: System Settings Page Item Function Effect / Procedure Display luminance setting Adjusts the brightness of the display: 1% to 100% Turn off display Adjusts the time period to turn off the display after...
Page 302: Ethernet
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.19 Ethernet Fig. 23: Ethernet Page Item Function Effect / Procedure Enable/Disable ethernet ports eth0 = plug X31 eth1 = plug X32 The two ports must be enabled by default Address field Configure TCP/IP address for each ethernet port Default settings:...
Page 303: Date
4002−2/A1 Operation Local Control Panel / Local Display Unit (LDU−20) 3.20 Date Fig. 24: Date Page Item Function Effect / Procedure Local time Includes time offset from UTC UTC time Coordinated universal time Select time zone Use the rotary button to get a list with all available time zones Set Date field Use the rotary button to adjust the date setting...
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Page 305 4002−4/A1 Operation ECS Modules − Replacement Local Control Panel ..........Replace Defective LDU-20 .
Page 306 4002−4/A1 Operation ECS Modules − Replacement Record the positions of the plugs and cables that follow: The plug X21 (7, Fig. 2) and plug X22 (5). The cables of the service connection (2). The cables to the Ethernet connection (3). WCH02715 Fig.
Page 307 4002−4/A1 Operation ECS Modules − Replacement 18) If installed, connect the USB cable (6). Note: Use your notes to identify the correct connections in step 18) to step 20). 19) Connect the cables to the service connection (2, Fig. 20) Connect the cables to the Ethernet connection (3). 21) Connect the plugs X21 (7) and X22 (5) to the connections on the LDU−20.
Page 308 4002−4/A1 Operation ECS Modules − Replacement Replace Defective CCM-20 Note: It is recommended to make a software back-up from the LDU-20. This will make sure that the correct configuration is loaded. For more data, speak to or send a message to Winterthur Gas & Diesel Ltd. Stop the engine.
Page 309 4003−1/A1 Operation Engine Control General ............Engine Control Functions .
Page 310: 4003-1/A1
4003−1/A1 Operation Engine Control Engine Local Control You can operate the engine from the local control panel (see 4002−2, Local Control Panel/ Local Display Unit (LDU-20). The speed controller is part of the ECS. If the MCM-11 becomes defective, the fuel command mode is selected automatically.
Page 311: Control Transfer
4003−1/A1 Operation Engine Control Control Transfer There are different steps necessary to successfully transfer the signal from one control panel to another. Not all four different transfer modes are always applicable. For more details, refer to the schematic diagram shown in Fig. 1. The list that follows shows the four possible transfer modes (with the related steps): Target request Origin agreement...
Page 312: Engine Control System Checks
4003−1/A1 Operation Engine Control Engine Control System Checks If parts of the pneumatic control system were disassembled, removed or replaced during an overhaul, you must do a general check before commissioning. CAUTION Equipment Hazard: Leaks can cause faults in the engine control systems and damage to engine components.
Page 313: Ecs Start
4003−1/A1 Operation Engine Control ECS Start In the power supply boxes E85.1 to E85.x, set all the knife switches to on. On all the CCM-20, MCM-11, IOM-10 and the two LDU-20, make sure that all green LED indications come on. Safety and Alarm System Make sure that the remote control system (RCS), engine safety system (ESS), alarm and monitoring system (AMS) are set to on.
Page 314 4003−1/A1 Operation Engine Control To monitor the passive failures, connect an applicable resistor (see Table 3) 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 2.
Page 315: Auxiliary Blowers
4003−1/A1 Operation Engine Control Auxiliary Blowers CAUTION Equipment Hazard: Without applicable lubrication, damage can occur to components. Before you operate the auxiliary blowers make sure that the main lubrication oil and the turbocharger lubricating oil supply are set to on. Note: Do a check of the necessary lubrication oil pressure, refer to 0250−1 Operating Data Sheet.
Page 316: Servo Oil System
4003−1/A1 Operation Engine Control 4.5.2 Test of Auxiliary Blower from LDU20 Local On the MCM-11, disconnect terminal X33. Start the auxiliary blowers. Note: Command and feedback of auxiliary blowers must continue to operate. If the auxiliary blowers do not operate, do a check of the wiring to the starter box. On the MCM-11, connect terminal X33.
Page 317: Cylinder Lubrication
4003−1/A1 Operation Engine Control Cylinder Lubrication Release the air in all cylinder lubrication pumps 25-7206_C1_1 to 25-7206_C#_1 (see the Maintenance Manual, 7218−1). Release the air in the pipes to the lubricating quills (see the Maintenance Manual, 7218−1). In the LDU−20 get the CYL. LUBRICATION page (see 4002−2, paragraph Cylinder lubrication).
Page 318 4003−1/A1 Operation Engine Control 4.10.2 Starting Air Shut-off Valve On the valve unit E, remove the check valve 35-115HA. Make sure that the three O-rings do not fall out of the valve. In the LDU−20, get the CONTROL LOC. Page, then select the button CTRL. TR. to get control.
Page 319: Overspeed Limit
4003−1/A1 Operation Engine Control 4.10.3 Turning Gear Interlocks Make sure that the turning gear is engaged. Make sure that the pressure transmitter PT5017C and the switch ZS5016C do not operate (open contacts). Note: The pressure transmitter PT5017C operates at 2.0 bar. Make sure that the indication Turning Gear Engaged shows on each LDU−20 (at the control room console and local maneuvering stand).
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Page 321 4003−2/A0 Operation Identification of Parts Control Diagram General ............Area Codes in the Control Diagram .
Page 322: Designations
4003−2/A0 Operation Designations Process Codes − Description The process codes and their descriptions are shown in Fig. 1 and Table 3. 10-5556_E0_1 System Running Number Design Group 0 = for all Cylinders Cylinder e.g. E5 = Engines with five or more cylinders Code to identify the function Signal from / to engine Code for systems...
Page 323 4003−2/A0 Operation Designations Process Code Description 20−8445_E01 Servo oil service pump 20−8445_E0_2 Pressure safety vale 20−8445_E0_3 Pressure retaining vale 20−5610_E0_1 Non-return valve 20−5610_E0_2 Non-return valve 20−5610_E0_3 2-way shut-off valve 20−5610_E0_4 Pressure safety valve 20−5614_E0_1 Pressure reducing valve 20−5614_E0_4 Cylinder lubrication mini−rail 20−5614_E0_6 Pressure safety valve 20−8406_E0_5...
Page 324 4003−2/A0 Operation Designations Process Code Description 35−36HA 3/2-way valve 35−36HB 3/2-way valve 35−36HC 3/2-way valve 35−4325_E0_2 3/2-way valve 35−4325_E0_3 3/2-way valve 35−4325_E0_5 2/2-way valve 35−4605_E0_6 2-way shut-off valve 35−4605_E0_8 2-way shut-off valve 35−4605_E0_9 Restrictor 35−4606_E0_2 2-way shut-off valve 35−4606_E0_4 Needle valve 35−8353_E0_2 Ball valve 35−8606_E0_4...
Page 325 4003−2/A0 Operation Designations Sensors and Transmitters The sensors, transmitters and their descriptions are shown in Table 4. Table 4: Sensors and Transmitters − Descriptions Sensors − Control and Safety Sensors − Alarm PS1101S Cylinder cooling water inlet PS3121A Cyl. lube oil filter diff. pres. PS1101S Main bearing oil supply PS5017C...
Page 326 4003−2/A0 Operation Designations Sensors − Control and Safety Sensors − Alarm ST5133−34C Crank angle pick−up 3−4 (C−D) TE1111A Cylinder cooling water inlet ST5201C Turbocharger speed TE1121−28A Cylinder cooling water outlet each cyl. TE1371A Scav. air cool. water inlet cooler ZS5016C Turning gear disengaged TE1381A Scav.
Page 327 4003−2/A0 Operation Designations Actuators Local Indications TI3721L Exhaust gas temp. upstream of TC TI3731L Exhaust gas temp. downstream of TC TI4031L Scav. air temp. downstream of air cooler TI4521L Thrust bearing oil temp. − front SI5101M Engine speed 2016-01 7/ 7 Winterthur Gas &...
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Page 329: 4003-2/A1
930−B001 930−B002 35−2751_CX_2 30−4325_E0_1 30 bar 30 bar RAIL UNIT 25.8475_E0_2 3/3-WAY VALVE 30.8605_CX_1 6 OUTLETS FOR X52/X62 7131−38C 3131−38C 8 OUTLETS FOR X72 5018C STARTING AIR 50−2751_CX_1 10−5562_E0_6 4301C CONTROL AIR 4341S 4341A 4341C BOARD SUPPLY 7−9 BAR 10−5562_E0_1 1000 bar 20−5614_E0_4...
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Page 331 4003−3/A1 Operation Pipe Diagram − Water Systems (Cylinder Cooling) 8611_E0_5 8611_E0_3 8611_E0_4 8611−E0_2 / DN12 8611−E0_3 / DN12 8611−E0_1 / DN40 8310−E6_1/ DN200 1121A 1122A 1123A 1124A 1125A 1126A 1121L 1122L 1123L 1124L 1125L 1126L Cylinder Cylinder Cylinder Cylinder Cylinder Cylinder 4801C 4841C...
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Page 333 4003−4/A1 Operation Pipe Diagram − Water Systems (Scavenge Air Receiver and T/C) PLANT ENGINE 8338−E0_1 / DN20 8338−E0_3 / DN15 8338−E0_4 / DN15 8347−E0_3 / DN20 Turbocharger Turbocharger 1371A 1361A Washing Plant SAC 1361L 8347_E0_7 8347_E0_8 8347−E0_5 / DN20 8347−E0_6 / DN20 8335−E0_7 / DN15 8335−E0_8 / DN15 1381L...
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Page 335 4003−5/A1 Operation Pipe Diagram − Oil Systems (System Oil, Internal T/C Oil Supply) PLANT ENGINE 2601A 2601L Turbocharger 2611S 2611L 2611A Adjustable orifice integrated in ABB TCs only! Adjustable orifice required in systems with MHI TCs only! Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5...
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Page 337 4003−6/A1 Operation Pipe Diagram − Oil Systems (System Oil, External T/C Oil Supply) PLANT ENGINE 2621A 2601A 2601L 2621L Turbocharger 2611S 2611L 2611A Adjustable orifice integrated in ABB TCs only! Adjustable orifice required in systems with MHI TCs only! Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4...
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Page 339 4003−7/A1 Operation Pipe Diagram − Oil Systems (Servo Oil and Supply Unit Pipes) 2003C DG 5560 Rail Unit 2003A 8423_E0_1 8423−E0_6 / DN20 5560−E0_1 / DN25 8423_E0_2 8423−E0_7 / DN20 5560−E0_2 / DN25 5560−C1_3 / DN9 5560−C2_3 / DN9 5560−C3_3 / DN9 5560−C4_3 / DN9 5560−C5_3 / DN9 5560−C6_3 / DN9...
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Page 341 4003−8/A1 Operation Pipe Diagram − Oil Systems (Cylinder Lubrication) Cylinder 1 Cylinder 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 flexLube flexLube flexLube flexLube flexLube flexLube DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 DOC.006 5614−C1_1 Page 6 5614−C2_1 Page 6...
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Page 343 4003−9/A1 Operation Pipe Diagram − Air Systems (Starting Air and Control Air) 4341A 35−274HD Only required if 8606−E0_1 / DN50 4341C Waste Gate for Low Load or delta T Bypass 4341S 4351A 4352A Tuning is used 8606−E0_2 / DN20 DOC.009 8607−E0_2 Page 9 (041.1−B)−8607−E0_2...
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Page 345 4003−10/A1 Operation Pipe Diagram − Air Systems (Exhaust Gas and Scavenge Air), Two Turbochargers Bypass for Low Load Tuning PLANT optional only ENGINE 7076C 8607−E0_2 Page 8 8135_E0_2 Turbocharger− type 8135_E0_1 2x ABB Ax65 DN65 2x ABB Ax70 DN65 5372C 3721L 3722L 2x ABB Ax75...
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Page 347 DG 6547 Starter Unit for Starter Unit for Auxilliary Blower Auxilliary Blower Blower Blower 5031C 7031C 5031C 7031C *) Sensor Measurements shall be available for WinGD 5032C 7032C 5032C 7032C **) Optional WCH03764 2016−11 1/ 1 Winterthur Gas & Diesel Ltd.
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Page 349 4003−11/A1 Operation Pipe Diagram − Fuel, Drain and Extinguishing Systems DG 5560 Rail Unit 5562_E0_9 Fuel Oil Rail 3461C 5562_E0_8 3462C 5562_E0_7 7061S 3446A 8744_E0_5 8744_E0_4 7441C 7461C 7481C 7442C 7462C 7482C 7443C 7463C 7483C 7444C 7464C 7484C 7445C 7465C 7485C 7446C 7466C...
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Page 351 4104−1/A1 Operation Supply Unit Drive General The supply unit drive is installed at the driving end of the engine on the fuel side. The crankshaft gear wheel (2, Fig. 1) moves the intermediate wheel (3) and the intermediate wheel (4). You must do regular checks of the tooth profile condition.
Page 352 4104−1/A1 Operation Supply Unit Drive Lubrication The intermediate wheel (3, Fig. 2) operates the gear wheels (1) and (2) for the servo oil pumps. The camshaft of the intermediate wheel (3) also operates the fuel pumps. The bearings of the gear wheels (1) and (2) are lubricated through an oil inlet. Oil flows through the nozzles (4) in the bearing housing to lubricate the teeth of the gear wheels (1), (2) and the intermediate wheel (3).
Page 353 4325−1/A1 Operation Starting Air Shut-off Valve General The starting air shut-off valve (shut-off valve) stops or releases the starting air to the engine. You use the handwheel (3, Fig. 1) to put the shut-off valve in the positions that follow: CLOSED AUTOMAT OPENED.
Page 354: 4325-1/A1
4325−1/A1 Operation Shut-off Valve Starting Air WCH02229 Fig. 1: Starting Air Shut-off Valve 1 Control valve 12 Double check valve 35-115HA 2 Spindle 13 Solenoid Valve CV7013C 3 Handwheel 14 Lever 4 Spring 15 Proximity sensor ZS5018C 5 Valve 6 Balance bore 7 Non-return valve IP Inlet pipe 8 Inlet chamber...
Page 355: 4605-1/A1
4605−1/A1 Operation Control Air Supply General The compressed air necessary for the air springs in the 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 356 4605−1/A1 Operation Control Air Supply WCH02555 Fig. 2: Schematic Diagram − Control Air Supply Unit 1 2-way shut-off valve 35-4605_E0_8 A1 Control air from board system A2 Starting air from starting air system A3 Connection to air tank 287HA A6 Air supply to air spring 2015-03 2/ 3 Winterthur Gas &...
Page 357 4605−1/A1 Operation Control Air Supply WCH00538 Fig. 3: Control Air Supply Unit 1 Pressure transmitter PT4411A 7 Non-return valve 35-342HA 2 Pressure transmitter PT4401A 8 Pressure reducing valve 35-23HA 3 Pressure gauge PI4401L 9 Pressure reducing valve 35-19HA 4 3/2-way valve 35-36HB 10 Non-return valve 35-342HB 5 3/2-way valve 35-36HC 11 Filter 35-351HA...
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Page 359: 4605-1/A2
4605−1/A2 Operation Control Air Supply (for Engines with Built-in ELBA) General The compressed air necessary for the air springs in the 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.
Page 360 4605−1/A2 Operation Control Air Supply WCH02555 Fig. 2: Schematic Diagram − Control Air Supply Unit 1 2-way shut-off valve 35-4605_E0_8 A1 Control air from board system A2 Starting air from starting air system A3 Connection to air tank 287HA A6 Air supply to air spring 2015-03 2/ 3 Winterthur Gas &...
Page 361 4605−1/A2 Operation Control Air Supply WCH00538 Fig. 3: Control Air Supply Unit 1 Pressure transmitter PT4411A 7 Non-return valve 35-342HA 2 Pressure transmitter PT4401A 8 Pressure reducing valve 35-23HA 3 Pressure gauge PI4401L 9 Pressure reducing valve 35-19HA 4 3/2-way valve 35-36HB 10 Non-return valve 35-342HB 5 3/2-way valve 35-36HC 11 Filter 35-351HA...
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Page 363 4628−1/A1 Operation Pick-up for Speed Measurement General To measure the engine speed (rpm), six proximity sensors are installed in a speed pick-up unit, attached to the support of the fuel pump unit. 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 364 4628−1/A1 Operation Pick-up for Speed Measurement DRIVING END WCH02579 WCH02579 5111−12S 4521L 4521S 4521A 5123C 5124C 5101−04C WCH02556 WCH02579 Fig. 1: Location of Proximity Sensors 1 Flywheel 7 Proximity sensor ST5102C 2 Bedplate 8 Pick-up holder 3 Crank angle mark 9 Proximity sensor ST5101C 4 Cover 10 Proximity sensor ST5103C...
Page 365 ..............5562−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
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Page 367 5551−1/A1 Operation Servo Oil Pump General The servo oil pumps (3 and 5, Fig. 1) are attached to, and part of, the supply unit (6). These pumps supply servo oil to open the exhaust valves. For more data about the supply unit, see 5552-1. The flow sensors (1 and 4), monitor the oil supply in each inlet pipe (2) of the servo oil pumps.
Page 368 5551−1/A1 Operation Servo Oil Pump WCH02235 WCH02234 WCH02234 Fig. 2: Servo Oil Pumps − Operation 1 Servo oil pump (20-5551_E0_1) 5 Pinion 2 Servo oil pump (20-5551_E0_2) 6 Intermediate wheel (supply unit) 3 Supply unit 7 Shaft 4 Safety device (waisted part) 2014 2/ 2 Winterthur Gas &...
Page 369 5552−1/A1 Operation Supply Unit General The supply unit is installed on the column at the driving end (see 4104-1 Supply Unit Drive). The supply unit has the servo oil supply, fuel supply, gear wheels and drive wheels. The components in paragraph and paragraph are part of, or attached to the housing.
Page 370 5552−1/A1 Operation Supply Unit Lubrication Oil flows through bores in the casing (8, Fig. 2) to lubricate the bearings and fuel pumps. Oil also flows through the nozzles (6) to lubricate the intermediate wheel (7) and the gear wheel (5). WCH02232 Fig.
Page 371 5556−1/A1 Operation Fuel Pump General The fuel pumps (1, Fig. 1) are part of the supply unit (2). The fuel pumps supply fuel through high pressure pipes to the fuel rail (see 8019-1, Fuel System). The fuel pumps are controlled to supply the necessary load-related fuel pressure (up to 1000 bar) in the fuel rail.
Page 372 5556−1/A1 Operation Fuel Pump WCH00832 Fig. 2: Fuel Pump 1 Oil pipe 16 Roller pin 2 Bottom spring carrier 17 Regulating sleeve 3 Orifice 18 Pump plunger 4 Roller 19 Pump cylinder 5 Cam 6 Guide piston 7 Bottom housing AS Accumulation space 8 Top housing DB Leakage fuel...
Page 373 5556−1/A1 Operation Fuel Pump When the pump plunger passes BDC, fuel flows through the two inlet bores (5, Fig. and the two control grooves (2) into the plunger chamber (1). The quantity of fuel that enters the plunger chamber (1) is related to the control position (between 0 for zero supply and 10 for maximum supply).
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Page 375 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In General If a fuel pump is unserviceable (e.g. the pump plunger cannot move) or the HP fuel pipe is broken (between the fuel pump and the fuel rail) the fault must be repaired immediately.
Page 376 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.
Page 377 5556−2/A1 Operation Fuel Pump − Cutting Out and Cutting In 13) Adjust the tension on the elastic bolt (3, Fig. 3) to 1500 bar (see the procedure in the Maintenance Manual 9403−4). 14) Make sure that the roller (3) has moved up approximately 3.0 mm from the cam (1).
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Page 379 5562−1/A1 Operation Pressure Control Valve General Operation The engine software controls the fuel pressure. The pressure in the fuel rail is always less than that necessary to open the pressure control valve (PCV). The PCV (1, Fig. 1) is usually closed. The PCV can also operate as a pressure relief valve and will open if the fuel pressure is more than the specified pressure of approximately 1050 bar.
Page 380 5562−1/A1 Operation Pressure Control Valve Emergency Operation If the fuel pressure control system becomes defective, the PCV will control the pressure in the system when: There are missing or incorrect control signals A flow control valve of a fuel pump is unserviceable. When no control signal is received, the fuel pumps are set to the maximum supply position.
Page 381 ..............6735−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
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Page 383 6420−1/A1 Operation Scavenge Air Receiver General The scavenge air receiver (4, Fig. 1) is a welded assembly attached to the cylinder block on the exhaust side. The scavenge air receiver has the parts that follow: Receiver Turbocharger support Diffuser Scavenge air cooler casing Charging unit.
Page 384: 6420-1/A1
6420−1/A1 Operation Scavenge Air Receiver WCH02238 For View II II see Fig. B WCH02238 WCH02238 Fig. 1: Scavenge Air Receiver 1 Scavenge air cooler 7 Diffuser 2 Drain pipe (condensed water) 8 Cover (water separator behind cover) 3 Auxiliary blower 9 Cover 4 Scavenge air receiver 10 Scavenge air cooler inlet...
Page 385 6420−1/A1 Operation Scavenge Air Receiver II - II WCH02238 Fig. 2: Scavenge Air Receiver 1 Cover 6 Air space 2 Water drain (from water separator) 7 Longitudinal wall 3 Condensate drain from SAC 8 Flaps 4 Cover 9 Flaps 5 Receiver space 10 Piston underside 2015-03 3/ 3...
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Page 387 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. Data about operation, maintenance and servicing are given in the related documentation of the manufacturer (which is part of the Operating Instruction). CAUTION Damage Hazard: If you operate the engine with a turbocharger cut out, you must obey the operation limits given in the Service...
Page 388 6500−1/A1 Operation Turbocharging WCH00566 WD CD Fig. 1: Schematic Diagram − Turbocharger Operation 1 Expansion piece 15 Manifold 2 Compressor 16 Turbine 3 Scavenge air cooler 17 Receiver 4 Water separator 18 Flaps 5 Charging unit AS Air space 6 Air inlet duct CD Condensation drain from air cooler 7 Non-return valve EG Exhaust gas from cylinder...
Page 389 6510−1/A1 Operation Turbocharger All Types Cleaning the Turbocharger during Operation General The turbochargers have a system to clean the turbine and the compressor. It is possible to clean the turbine and the compressor while the turbocharger operates. Regular procedures to clean the turbine and the compressor prevent or decrease contamination and increase the time between overhauls.
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Page 391: 6545-1/A1
6545−1/A1 Operation Auxiliary Blower and Switch Box Auxiliary blower General The electric motors (4, Fig. 1) operate the two auxiliary blowers (2), which are installed on the scavenge air receiver (3). The auxiliary blowers supply air from the air space through the duct (1) into the receiver space during the engine start and operation at low load.
Page 392: Switch Box
6545−1/A1 Operation Auxiliary Blower and Switch Box Switch box General The engine builder supplies an electrical switch box (5, 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 393 6606−1/A1 Operation Operating Instructions and Cleaning Scavenge Air Cooler General ............Operating Instructions .
Page 394: 6606-1/A1
6606−1/A1 Operation Operating Instructions and Cleaning ENGINE PLANT Fig. 1: Location of Wash-water System Parts 1 Fresh water supply pipe 16 Receiver 2 Ball valve 17 Water separator 3 Ball valve 18 Scavenge air cooler (SAC) 4 Compressed air supply pipe 19 Shut-off valve (vent) 5 Shut-off valve 20 Shut-off valve...
Page 395 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 (np) through the SAC, the interval can be extended (e.g.
Page 396 6606−1/A1 Operation Operating Instructions and Cleaning Open the ball valves (2 and 10, Fig. Carefully open the ball valve (12) PLANT ENGINE sufficiently to prevent back-flow of water in the funnel (11). Fresh Water Fill the air tank (3) through the Control Air funnel (11) with fresh water and the specified quantity of cleaning fluid (max...
Page 397 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 399: 6735-1/A1
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 -5_C). The waste gate operates as a safety valve, i. e. the overpressure is blown off into the engine room.
Page 400 6735−1/A1 Operation Scavenge Air Waste Gate Operation During usual operation conditions, scavenge air flows through the non-return valve (4, 2) into the pressure space (13). This pressure, and the pressure from the compression spring (7), keep the piston (6), and thus the waste gate valve, in the closed position.
Page 401 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 (19, Fig. 2) energizes. The scavenge air pressure flows through the pressure control valve (1), then through the non-return valve (3) to the pressure space (13).
Page 402 6735−1/A1 Operation Scavenge Air Waste Gate Pressure Check You use the pressure control valve 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 Connect a pressure gauge to the test connections (12, 22) (scavenge air...
Page 403 ............. . 7722−1/A1 X72 / OM / 2015-12 Winterthur Gas & Diesel Ltd.
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Page 405 7218−1/A1 Operation Cylinder Lubrication General ............Cylinder Lubricating Oil .
Page 406 7218−1/A1 Operation Cylinder Lubrication Lubricating Oil System − Overview The diagram Fig. 1 shows the complete system, which has the components that follow: Cylinder lube oil tank (1) for cylinder lubricating oil (plant side) Duplex filter (10) with a lever to change filters Lubricating quills (2) with a non-return valve and an injection nozzle System control from the ECS (see 4002-1, paragraph 3.4 Cylinder Lubricating Control).
Page 407: Cylinder Lubricating Oil Supply
7218−1/A1 Operation Cylinder Lubrication Cylinder Lubricating Oil Supply Supply Pipe − Cylinder Lubricating Oil Cylinder lubricating oil from the tanks (1, Fig. 1) flows through the lubricating oil inlet pipe (5, see Fig. 3) to the duplex filter (6). The filtered cylinder lubricating oil flows through the lubricating oil inlet pipe (7) into the lubricating oil supply pipe (8) to the cylinder lubricating pumps (1).
Page 408: 7218-1/A1
7218−1/A1 Operation Cylinder Lubrication FREE END WCH03154 Fig. 2: Cylinder Lubricating Oil Supply 1 Cylinder lubricating pump 5 Lubricating oil inlet pipe 2 Lubricating oil inlet 6 Duplex filter 3 Servo oil rail 7 Lubricating oil inlet pipe 4 Ball valve 8 Lubricating oil supply pipe 2015-03 4/ 12...
Page 409: Servo Oil Supply
7218−1/A1 Operation Cylinder Lubrication Servo Oil Supply Servo oil from the servo oil rail (7, Fig. 3) flows through the exhaust valve control unit (8) to the servo oil inlet pipe (6). Servo oil then flows through the servo oil supply pipe (2) and the servo oil inlet (3) into the cylinder lubricating pumps (5).
Page 410: Cylinder Lubricating Pump
7218−1/A1 Operation Cylinder Lubrication Cylinder Lubricating Pump General Each cylinder has a self-contained cylinder lubricating pump (5, Fig. 2) installed on a support in the rail unit (2, Fig. 3). All of the cylinder lubricating pumps are connected to supply pipes in the rail unit. Servo oil flows into a collector pipe installed below the rail unit.
Page 411 7218−1/A1 Operation Cylinder Lubrication DRIVING END WCH02614 WCH02614 Fig. 4: Cylinder Lubricating Pump 1 4/2-way solenoid valve (CV7131−38C) 8 Servo oil supply pipe 2 Storage position for HFR bush 9 Pressure relief valve 3 Outlet port 10 Lubricating oil supply pipe 4 Oil pipes 11 Servo oil −...
Page 412: Cylinder Lubricating System − Bleed
7218−1/A1 Operation Cylinder Lubrication Cylinder Lubricating System − Bleed To bleed the lubrication oil supply pipe (10, Fig. 4), and the cylinder lubricating pumps, see the procedure given in the Maintenance Manual 7218−1. After you bleed the lubricating oil supply pipe (10), and the cylinder lubricating pumps (see paragraph 5.3), it is necessary to bleed the oil pipes (4) to the lubricating quills (5) as follows: See 4002-2, LDU-20, paragraph...
Page 413: Lubricating Quill
7218−1/A1 Operation Cylinder Lubrication Lubricating Quill Lubricating oil is injected on to the cylinder liner (3, Fig. 5) wall through the eight lubricating quills (2) installed on the circumference of the supporting ring (see also paragraph 8.2). For the function of the lubricating quill (2), see 2138-1 Lubricating Quills on Cylinder Liner.
Page 414: Cylinder Lubricating System − Control
7218−1/A1 Operation Cylinder Lubrication Cylinder Lubricating System − Control Control System The cylinder lubricating system (see Fig. 6) is a time−based system, which supplies lubricating oil on to the cylinder liner wall. For more data about the cylinder lubricating control, see 4002−1 Engine Control System, paragraph 3.4 Cylinder Lubricating Control.
Page 415: Radial Oil Supply
7218−1/A1 Operation Cylinder Lubrication Radial Oil Supply The nozzle tip in the lubricating quill has holes in specified positions. The lubricating oil flows out of these holes at high pressure. This gives equal lubrication on to the cylinder liner wall (see Fig.
Page 416: Lubricating Oil Feed Rate − Adjustment
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 parameters in the columns Feed Rate and Adjustment for one cylinder, or for all cylinders (see 4002−2, paragraph Cylinder lubrication, CYL.
Page 417 7218−2/A1 Operation Cylinder Lubrication − LFR and HFR Bushes Description There are two bushes installed on each cylinder lubricating pump (1, Fig. The low feed rate (LFR) bush (3) is installed on the screw (2) at the bottom of the cylinder lubricating pump.
Page 418 7218−2/A1 Operation Cylinder Lubrication DRIVING END WCH02575 High Feedrate Bush 4 or 3 WCH02612 Low Feedrate Bush WCH03153 Pipes to lubrication WCH02613 3 or 4 quills not shown Fig. 1: Cylinder Lubricating Pump 1 Cylinder lubricating pump 4 High feed rate bush 2 Stroke adjustment screw 5 Screw 3 Low feed rate bush...
Page 419: General
7218−3/A1 Operation Feed Rate − Adjustment Feed Rate − Adjustment General ............Feed Rate Adjustment .
Page 420: 7218-3/A3
7218−3/A1 Operation Feed Rate − Adjustment Feed Rate Adjustment CAUTION Equipment Hazard: The results of the bunker analysis and the values given in the Bunker Delivery Note (BDN) can be different. Always use the higher sulfur content value to adjust the feed rate. This makes sure that the engine operates safely.
Page 421 7218−3/A1 Operation Feed Rate − Adjustment Fig 1. shows the relation between the residual BN and the total iron content of the PU drain oil. This data is only applicable when fuel with a sulphur content between 0.5% m/m and 3.5% m/m and cylinder lubricating oil with a BN between 40 and 100 is used.
Page 422 7218−3/A1 Operation Feed Rate − Adjustment CAUTION Equipment Hazard: The Wärtsilä PU Drain Oil Analysis Tool and its recommendations are only applicable for cylinder lubricating oils with a base number more than or equal to 40 (BN ≥ 40). You can use the Wärtsilä PU Drain Oil Analysis Tool to collect your data. You can see examples of its analysis in Fig.
Page 423 7218−3/A1 Operation Feed Rate − Adjustment How to Set the Best Applicable Feed Rate Use the empirical data (see paragraph 2.1) from the PU drain oil samples to adjust the feed rate to get the best applicable feed rate. Note: You must make sure that the feed rate is not less than the minimum permitted value of 0.6 g/kWh.
Page 424 7218−3/A1 Operation Feed Rate − Adjustment Blending on Board You can use the Wärtsilä Blending on Board (BoB) system to adjust the BN of the cylinder lubricating oil. The system oil is used as a base oil and the correct additive package is added to make an applicable cylinder lubricating oil.
Page 425 7722−1/A1 Operation Integrated Electric Balancer Description ............Operation .
Page 426 7722−1/A1 Operation Integrated Electric Balancer Operation Integrated Electrical Balancer The two shafts (6 and 7, 2) are installed in the housing (5). These shafts turn in opposite directions at two times the engine speed. When the gear wheels (1, 4) turn, the two balance weights (2, 3) cancel each effect of the horizontal centrifugal forces.
Page 427 7722−1/A1 Operation Integrated Electric Balancer Control System The control system has the functions that follow: At the driving end, the proximity sensor ZS5401C senses the tooth movement of the balance weight. The signals are then transmitted through the terminal box 38.1 (2, Fig. 3) to the control unit. At the free end, the proximity sensor ZS5405C senses the tooth movement of the balance weight.
Page 428 7722−1/A1 Operation Integrated Electric Balancer Lubrication The lubrication system of the ELBA is connected to the low-pressure oil system of the engine. In the housing (1, Fig. 4) lubricating oil (3) flows through the pipes (2) to the shafts to lubricate the gear wheels. Oil that is not used flows through the oil return to the crankcase.
Page 429 7722−1/A1 Operation Integrated Electric Balancer Table 2: Error Modes and Descriptions Error Mode Error Description 1 DC-bus under-voltage No voltage available for the drive in X100 (power input). 2 Engine maximum speed exceeded Diesel engine speed is more than permitted. 3 Balancer maximum speed exceeded Electric motor speed is more than permitted.
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Page 431 ............8825−1/A1 X72 / OM / 2014 Winterthur Gas & Diesel Ltd.
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Page 433 8016−1/A1 Operation Lubricating Oil System General ............Lubricating Oil System .
Page 434: 8016-1/A1
8016−1/A1 Operation Lubricating Oil System Dirty Oil Samples 2.1.1 Preparation Write the applicable data on the oil analysis form (e.g. operation conditions, fuel parameters, cylinder lubricating oil feed rate etc). Make sure that the labels on the sample bottles refer to the related cylinders. 2.1.2 Procedure Close the ball valve (2, Fig.
Page 435 8016−1/A1 Operation Lubricating Oil System PLANT ENGINE Turbocharger Turbocharger ENGINE PLANT PLANT ENGINE OD OD OD OD Horizontal Oil Drain Horizontal Oil Drain (Option) (Option) Lubricating oil Oil drains and outlets WCH02245 Fig. 2: Lubricating Oil System 2015-03 3/ 10 Winterthur Gas &...
Page 436: Servo Oil System
8016−1/A1 Operation Lubricating Oil System Key to Fig. 1 1 Oil pipe − TC outlet 17 Supply pipe − vibration damper 2 Oil pipe − TC inlet 18 Vibration damper − crankshaft 3 Main collector (dirty oil, piston 19 Axial damper underside) 20 Main bearing 4 Main collector (leak oil −...
Page 437 8016−1/A1 Operation Lubricating Oil System Rail Unit CYL. 1 CYL. # VCU − Valve Control Unit Oil drains and outlets Oil inlet WCH02529 Fig. 3: Servo Oil System 2015-03 5/ 10 Winterthur Gas & Diesel Ltd.
Page 438: Servo Oil Leakage
8016−1/A1 Operation Lubricating Oil System Key to Fig. 3 1 Oil pipe − bearing drive, supply 16 Supply unit unit, servo oil 17 Servo oil pump 2 Supply pipe − cooling oil, injectors 18 Leakage inspection points − 3 Supply pipe servo oil pipes 4 Cylinder lubrication drive 19 Level switch LS2055A...
Page 439: Leakage Inspection Points
8016−1/A1 Operation Lubricating Oil System Leakage Inspection Points 4.2.1 HP Servo Oil Pipes If there is a leak in the HP servo oil pipes, the leakage inspection points (18, Fig. are used to find the pipe that has the leakage. 4.2.2 Exhaust Valve Control Unit If oil flows from the leakage inspection point (3,...
Page 440 8016−1/A1 Operation Lubricating Oil System WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components. When you loosen the screw plugs, high pressure oil can come out as a spray and cause injury. Carefully loosen the screw plug (5, Fig.
Page 441: Servo Oil Rail
8016−1/A1 Operation Lubricating Oil System Servo Oil Rail Pressurization The servo oil pumps (17) (see Fig. 3) supply high pressure oil to the HP servo oil pipes (11). The oil pressure opens the non-return valves and oil flows into the servo oil rail.
Page 442 8016−1/A1 Operation Lubricating Oil System DRIVING END WCH02301 Fig. 6: Servo Oil Rail 1 Screw plug 3 Drain pipe (to square collector) 2 Servo oil rail 2015-03 10/ 10 Winterthur Gas & Diesel Ltd.
Page 443: General
8017−1/A1 Operation Cooling Water System General The schematic diagram (see Fig.1) shows the cylinder cooling water system on the engine. The location of pumps, coolers, fresh water generator, heater, expansion tank, valves and throttling discs for flow control etc. are found in the separate documentation for the plant layout (shipyard side).
Page 444 8017−1/A1 Operation Cooling Water System Function The cooling water pump supplies cooling water, through the supply pipe (18) on the exhaust side, to the cylinders. The cooling water flows through the cylinder liner (9), water guide jacket (10), cylinder cover (11) and exhaust valve cage (12). When the vent unit (1) and ball valve (2) are open, the system continuously vents.
Page 445 8017−1/A1 Operation Cooling Water System ENGINE PLANT WO − Cylinder Cooling CYL. 1 CYL. # Fig. 1: Lubricating Oil System 1 Vent unit 13 Throttle (cylinder outlet) 2 Ball valve 14 Ball valve 3 Butterfly valve (cylinder outlet) 15 Cylinder outlet 4 Butterfly valve (cylinder inlet) 16 Outlet pipe (cylinder cooling water) 5 Ball valve (to drain the system)
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Page 447 8018−1/A1 Operation Starting Air Diagram General The starting air system is shown in the schematic diagram below. The control air supply unit and air bottle 6 supply the necessary control air for the engine. For more data, see the Pipe Diagram − Air System 4003-9. You must make sure that the compressed air is clean and dry.
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Page 449 8019−1/A1 Operation Fuel System General ............Low Pressure Circuit .
Page 450 8019−1/A1 Operation Fuel System 4 19 WCH02559 Waste Pipes (Dirty Drain Pipes) Trace Heating Fuel Leakage Fuel Return Fuel Supply Fig. 1: Fuel System 2014 2/ 9 Winterthur Gas & Diesel Ltd.
Page 451 8019−1/A1 Operation Fuel System Key to Fig. 1 1 Fuel inlet pipe 24 Fuel leakage pipe (injection valves) 2 Shut-off valve (plant) 25 Fuel leakage outlet pipe (rail unit) 3 Fuel pump 26 Pressure transmitter PT3461C 4 Flow control valve 27 Pressure transmitter PT3462C 5 Fuel outlet pipe 28 Rail unit...
Page 452 8019−1/A1 Operation Fuel System Fuel Leakage System The level switches (LS) monitor all important leakages in the fuel system. If there is too much leakage, the related alarm is activated. Level switch Monitored components LS3444A Leakages (fuel and servo oil) from the rail unit LS3446A HP fuel pipes to injection valves (13, Fig.
Page 453 8019−1/A1 Operation Fuel System FUEL SIDE WCH02550 Fig. 2: Leakage Inspection Points 1 HP fuel pipes (top section) 6 Flange 2 HP fuel pipes (middle section) 7 Flange 3 HP fuel pipes (bottom section) 8 Screw plug 4 Fuel pumps 9 Screw plug 5 Flange 10 Screw plug...
Page 454 8019−1/A1 Operation Fuel System HP Fuel Pipes to Injection Valves − Leakage WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components. When drain screws and plugs are opened, fuel can come out as a spray and cause injury. If the level switch (17, Fig.
Page 455 8019−1/A1 Operation Fuel System WCH02552 WCH02552 WCH02552 Fig. 3: Leakage Inspection Point − HP Fuel Pipes to Injection Valves 1 HP fuel pipe to injection valve 5 Screw-in union 2 Flow limiter valve 6 Fuel leakage pipe 3 Fuel rail 7 Sealing face 4 Screw 2014...
Page 456 8019−1/A1 Operation Fuel System Leakage Check of Pressure Control Valve Do the following procedures after emergency operation or maintenance on the fuel oil system only. WARNING Injury Hazard: Always put on gloves and safety goggles when you do work on hot components. Fuel can come out as a spray and cause injury.
Page 457 8019−1/A1 Operation WCH02561 WCH02567 Fig. 4: Pressure Control Valve 1 Pressure control valve 7 Fuel return pipe (0 bar and monitored) 2 Button (for pressure release) 8 Fuel leakage pipe 3 Non-return valve 9 Flow limiter valve 4 Fuel rail 10 Pressure relief valve 5 Fuel return pipe (10 bar) 11 Cover...
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Page 459 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 460 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 (6, Fig. 2) keeps the butterfly valve (3) in the closed position. Open When the engine load is more than 85%, the charge air pressure increases to more than the set limit.
Page 461 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) FREE END Fig 3 WCH02239 Fig. 2: Exhaust Waste Gate 1 Exhaust gas manifold 5 Cardan rod 2 Exhaust bypass line 6 Actuator (ZS5372C) 3 Butterfly valve 7 3/2-way solenoid valve (CV7076C) 4 Orifice 8 Air spring air pipe 2014 3/ 4...
Page 462 8135−1/A1 Operation Exhaust Waste Gate (Low-load Tuning) WCH02331 Fig. 3: 3/2-way solenoid valve (CV7076C) 6 Actuator (ZS5372C) 12 Electrical connection 7 3/2-way solenoid valve (CV7076C) 13 Control air pipe 8 Air spring air pipe 9 Control air supply unit AS Air spring air 10 Ball valve AV Air Vent 11 Screw...
Page 463 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 from the piston rod gland box (20) and the piston underside (9) are important (see Fig.
Page 464 8345−1/A1 Operation Drainage System and Wash-water Piping System EXHAUST SIDE 21 20 WCH02323 DATA FOR ENGINES WITH ONE TURBOCHARGER Fig. 1: Schematic diagram 2014 2/ 3 Winterthur Gas & Diesel Ltd.
Page 465 8345−1/A1 Operation Drainage System and Wash-water Piping System Key to Fig. 1 1 Air vent manifold 18 Ball valve 2 Vent − turbocharger outlet 19 Ball valve 3 Main engine 20 Leak gland box − outlet 4 Cylinder cooling water drain − outlet 21 SAC wash water −...
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Page 467: 8825-1/A1
8825−1/A1 Operation Electrical Trace Heating System General ............Electrical Trace Heating .
Page 468 8825−1/A1 Operation Electrical Trace Heating System Power Consumption Values The table below gives an estimate for the power consumption values for the heating cables installed on the engine: Number of Cylinders Power Consumption (W) 2100 2600 3100 3600 4100 Worst Case T_Amb = 0_C Power Consumption (W) 1200 1500...
Page 469 8825−1/A1 Operation Electrical Trace Heating System Alarms from E88 to the Alarm and Monitoring System The control box E88 gives a digital output signal XS3463A to the alarm and monitoring system (AMS) as follows: No alarm: The contact is closed. Alarm on: The contact is open.
Page 470 8825−1/A1 Operation Electrical Trace Heating System: Cyl 1 Cyl N SUPPLY UNIT I - I WCH02294 Fig. 2: Electrical trace heating 1 Fuel injection pipes 6 Power supply cables (to next E89.0X) 2 Heating cables 7 Insulation 3 Power supply cable (to connection 8 Connection box E89.0X box E89.0X) 9 Fuel inlet pipe...
Page 471 8825−1/A1 Operation Electrical Trace Heating System TOP VIEW WCH03204 Cyl. 3 I - I WCH03204 Fig. 3: Connection box E89.03 1 Fuel injection pipes 3 Flow limiter valve 10-5560_CX_2 2 Heating cables 4 Connection box E89.03 (Cyl. 3) 2015−03 5/ 6 Winterthur Gas &...
Page 472 8825−1/A1 Operation Electrical Trace Heating System 24VDC OFF / HEATING HEATING ON HEATING OFF TEMP. SENS. SUPPLY WITH MDO WITH HFO (RED) (RED) (RED) (RED) SUPPLIED BY MAIN/EMRGY HEATING EMERGENCY CONNECT -H21 -H31 -H30 (GREEN) (YELLOW) (YELLOW) 0. OFF 1. AUTO 2.
Page 473 ..........9362-1/A1 X72 / OM / 2016−11 Winterthur Gas & Diesel Ltd.
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Page 475 9223−1/A1 Operation Crank Angle Sensor Unit General The crank angle sensor unit is installed on the supply unit drive (7) at the driving end (see Fig. There are two crank angle systems that monitor the teeth on the intermediate wheel. The two sets of proximity sensors (2, 3 and 4, 5) operate independently to sense the teeth on the intermediate wheel (1).
Page 476 9223−1/A1 Operation Crank Angle Sensor Unit DRIVING END WCH02520 2 to 5 WCH02522 WCH02523 Fig. 6: Crank angle sensor unit 1 Intermediate wheel 8 Flywheel 2 Proximity sensor ST5131C 9 Crank angle mark 3 Proximity sensor ST5132C 10 Proximity sensor ZS5123C 4 Proximity sensor ST5133C 11 Proximity sensor ZS5124C 5 Proximity sensor ST5134C...
Page 477 9270−1/A1 Operation Selective Catalytic Reduction System Selective Catalytic Reduction System General ............SCR System .
Page 478: Selective Catalytic Reduction System
The SCR system is installed between the exhaust gas manifold and the turbocharger. A typical configuration is shown in Fig. The system design and the supply of components is divided between the SCR system supplier, the shipyard and WinGD/engine builder. WCH03754 Fig. 1: SCR System 2016−11 2/ 28 Winterthur Gas &...
Page 479 9270−1/A1 Operation Selective Catalytic Reduction System WCH03754 Fig. 1: SCR System Configuration 2016−11 3/ 28 Winterthur Gas & Diesel Ltd.
Page 480 9270−1/A1 Operation Selective Catalytic Reduction System SCR Reactor Turbocharger Ambient air Engine Exhaust gas WCH03720 Fig. 2: SCR System − Schematic Diagram 2016−11 4/ 28 Winterthur Gas & Diesel Ltd.
Page 481 9270−1/A1 Operation Selective Catalytic Reduction System Table 1: SCR System Valves Data Valve No. Name Function SCR reactor inlet valve Lets the exhaust gas go into the the SCR reactor. (CV7821C) Usually open The positioner (XI7831C) transmits the position feedback signal of the valve V1.
Page 482: Function
9270−1/A1 Operation Selective Catalytic Reduction System Function SCR System Bypassed (Tier II) The engine operates in Tier II mode without SCR, see Fig. 3. The valve V3 is fully open and the valves V1 and V2 are fully closed. Urea solution is not injected.
Page 483: Scr Heating-Up With Exhaust Gas (Tier Ii)
9270−1/A1 Operation Selective Catalytic Reduction System SCR Heating-up with Exhaust gas (Tier II) For operation conditions, the SCR temperature must be equal to or more than (see Table 2). The SCR system uses hot exhaust gas to get the Minimum Exhaust Gas applicable operation temperature, see Fig.
Page 484: Scr Usual Operation (Tier Iii)
9270−1/A1 Operation Selective Catalytic Reduction System SCR Usual Operation (Tier III) While the SCR operates in the usual load range, the full exhaust mass flow goes through the SCR reactor. Valves V1 and V2 are fully open. Valve V3 is fully closed, see Fig.
Page 485: Scr Operation With Turbocharger Bypass (Tier Iii)
9270−1/A1 Operation Selective Catalytic Reduction System SCR Operation with Turbocharger Bypass (Tier III) During SCR operation with low engine load (and low exhaust gas temperature), the valve V4 can be operated to increase the temperature upstream of the SCR reactor, see Fig.
Page 486: Scr / Vcs Operation − Scavenge Air Pressure Too High (Tier Ii)
9270−1/A1 Operation Selective Catalytic Reduction System SCR / VCS Operation − Scavenge Air Pressure Too High (Tier II) The heat capacity of the SCR reactor can cause high scavenge air pressure during a fast load decrease of the engine. If the scavenge air pressure is too high, valve V3 is opened to let the the exhaust mass flow bypass the hot SCR reactor, see Fig.
Page 487: Scr System − Stop And Vent (Tier Ii)
9270−1/A1 Operation Selective Catalytic Reduction System SCR System − Stop and Vent (Tier II) If the operation conditions are not in the limits, the SCR system can be set to off while the engine operates. The SCR system automatically deactivates (see Fig. 8) When SCR operation stops, valve V3 opens.
Page 488: Install Covers / Disassemble Scr System
9270−1/A1 Operation Selective Catalytic Reduction System Install Covers / Disassemble SCR System 2 and 3, tool 94820 WCH03755 Fig. 9: SCR System − Install Covers For maintenance or when the SCR system becomes defective, you can install cover (2, Fig. 9) and cover (3). Do the procedure that follows: Stop the engine.
Page 489: Operation Modes
9270−1/A1 Operation Selective Catalytic Reduction System Operation Modes The operation modes that follow are available: Tier II without SCR operation, refer to paragraph SCR heating, refer to paragraph Tier III, refer to paragraph 3.3. Tier II without SCR Operation This operation mode lets you operate the engine without a urea injection. This keeps the engine in the NO limits of Tier II (the SCR system is bypassed).
Page 490: Tier
9270−1/A1 Operation Selective Catalytic Reduction System Tier III CAUTION Damage Hazard. The SCR is designed to operate with Marine Gas Oil (maximum sulphur content of 0.1%). Do not operate the engine with fuels that have a high sulphur content. Damage the the SCR will occur.
Page 491: Control And Automation System
9270−1/A1 Operation Selective Catalytic Reduction System Control and Automation System The SCR automation system is a common control system for the full SCR system. Each module is connected to this control system through bus connections or hard-wired connections. The plant/ship and engine automation is also connected to the SCR automation system.
Page 492 9270−1/A1 Operation Selective Catalytic Reduction System WCH03729 Fig. 11: SCR Control and Automation System 2016−11 16/ 28 Winterthur Gas & Diesel Ltd.
Page 493: User Interfaces
9270−1/A1 Operation Selective Catalytic Reduction System User Interfaces The Local Display Unit (LDU) is a multifunction module, which has an LCD color display, multifunction buttons and a rotary button. One LDU is installed in E50 near the local control stand (see Fig. 1). Oe more LDU is installed in E49 in the engine control room.
Page 494 9270−1/A1 Operation Selective Catalytic Reduction System POWER STATUS PUSH SELECT Fig. 13: Local Display Unit (LDU) 1 Color display 5 CHECK button (used to accept 2 Rotary button (16 steps in the action or enter data) one turn. Push to select) 6 BACK button (used to cancel 3 Multi-function buttons (function the action or delete data)
Page 495: Global Buttons And Status Indications
9270−1/A1 Operation Selective Catalytic Reduction System Global Buttons and Status Indications Fig. 14 and Fig. 15 show the global buttons and status indications that are available at the bottom of each LDU page. WCH03730 Fig. 14: LDU Global Buttons WCH03731 Fig.
Page 496: Ldu
9270−1/A1 Operation Selective Catalytic Reduction System LDU Pages 5.2.1 SCR System Overview Page WCH03732 Fig. 16: SCR System Overview Page Item Function Effect / Data Indication UREA injection setpoint Status Indication SCR condition check Indication Sensor signals according the drawings in the documentation Status Indication Engine status.
Page 497 9270−1/A1 Operation Selective Catalytic Reduction System 5.2.2 SCR System Status Page WCH03733 Fig. 17: SCR System Status Page Item Function Effect / Data Status Indication Shows the status of the SCR software (internal) Status Indication Shows the control location Status Indication Shows the status of the SCR condition Button Pre-selection and indication for Bypass, Preparation...
Page 498 9270−1/A1 Operation Selective Catalytic Reduction System 5.2.3 SCR Interface Page WCH03734 Fig. 18: SCR Interfaces Page Item Function Effect / Data Status Indication Operator input for use of a manual value Status Indication Shows the control location Status Indication Shows the auxiliary blower status. During preparation and TIER III mode the auxiliary blowers are controlled through the SCR Valve Control Cabinet E48.
Page 499 9270−1/A1 Operation Selective Catalytic Reduction System 5.2.4 SCR Manual Valve Control Page WCH03735 Fig. 19: SCR Manual Valve Control Page Item Function Effect / Data Status indication Operator input for use of manual value Status indication Shows the control location Button Push the button to set the automatic valve movement to on or off.
Page 500 9270−1/A1 Operation Selective Catalytic Reduction System 5.2.5 Software Info Page WCH03736 Fig. 20: Software Info Page Item Function Effect / Data Engine Type Shows the applicable engine Manufacturer number Shows the software manufacturer number DB number Shows the identification number of the installation Software version number [major][middle][minor] e.g.
Page 501 9270−1/A1 Operation Selective Catalytic Reduction System 5.2.6 Failure Log Page WCH03737 Fig. 21: Failure Log Page Item Function Effect / Data Scroll bar Scrolls through the failure list List of failure messages The latest message is at the top of the list Selected failure message The blue background shows that the failure message is selected...
Page 502: Scr Operation Mode − Change
9270−1/A1 Operation Selective Catalytic Reduction System SCR Operation Mode − Change 5.3.1 General You can select the SCR modes at the SCR Overview page. You can select the operation modes that follow: Tier II without SCR operation SCR Heating Tier III. 5.3.2 Procedure Set the control location to the LDU where you operate.
Page 503: Automatic Valve Movement − Procedure
9270−1/A1 Operation Selective Catalytic Reduction System Automatic Valve Movement − Procedure WCH03735 Fig. 23: SCR Manual Valve Control Page To start the automatic valve movement make sure that: The engine status shows Start interlock, Stop or Shutdown (refer to 4002−2, paragraph 3.3, Main Page) The SCR system is in Bypass mode (refer to paragraph 5.2.2, SCR System Status Page)
Page 504: Ams Alarms
9270−1/A1 Operation Selective Catalytic Reduction System AMS Alarms The SCR system gives three messages to the AMS: SCR ON. This message shows that the SCR system is activated SCR Minor Alarm. This message shows a failure that does not have an effect on the SCR system operation.
Page 505: General
9308−1/A1 Operation Intelligent Combustion Control General ............Function .
Page 506 9308−1/A1 Operation Intelligent Combustion Control Pressure Transducers The pressure transducer (1) (one for each cylinder) is installed on the cylinder cover (see Fig. ® The technology (Pressductor ) of the pressure transducers (1) uses a magneto-elastic measuring principle to measure the in-cylinder pressure. The permanently measured in-cylinder pressure of all cylinders gives the necessary data for the ICC system.
Page 507 9308−1/A1 Operation Intelligent Combustion Control In-cylinder Pressure Evaluation The compression pressure cannot be measured directly because of the combustion and fuel injection that can occur before TDC. In the ICC system, the compression pressure of each cycle is calculated with the polynomial formula and the data of the piston position.
Page 508 9308−1/A1 Operation The cylinder pressure data of each cylinder is taken as an analogue input signal from the pressure transducer into the ECS. For more data, see Fig. 3. CAN System Bus CCM−20 CCM−20 CCM−20 CCM−20 CCM−20 CCM−20 Barometric IOM-10 Cyl.
Page 509 9314−1/A1 Operation Oil Mist Detector General The engine has an oil mist detection system. The system includes the sensors (2) and the control unit (1) on the engine (see Fig. A display unit (8) is installed in the control room (Fig.
Page 510 9314−1/A1 Operation Oil Mist Detector FUEL SIDE WCH02315 DATA FOR SIX CYLINDERS I - I WCH02315 WCH02315 EXHAUST SIDE Fig. 1: Location of Sensors 1 Control unit E15.1 4 Supply unit 2 Sensor 5 Column 3 Cable guide 6 Test connection 2014 2/ 3 Winterthur Gas &...
Page 511 9314−1/A1 Operation Oil Mist Detector ENGINE ROOM CONTROL ROOM WCH02526 Fig. 2: Schematic Diagram 1 Control unit E15.1 9 Power cable 2 Sensor 10 Data cable 4 Supply unit PS Power supply 7 Crankcase and gear box AS to alarm system 8 Display unit SS to safety system 2014...
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Page 513 9362−1/A1 Operation Location of ECS Electronic Components General Most of the electronic components necessary for the engine control system (ECS) are installed on the engine. The power supply box E85 (not shown) is installed near the engine. Control boxes Data about the most important control boxes and power supply boxes are given as follows: The E85 has the two 230 VAC power supplies for the CCM-20, MCM-11 and the LDU-20.
Page 514 9362−1/A1 Operation Location of ECS Electronic Components DRIVING END FREE END FUEL SIDE 10, 11 DATA FOR SIX CYLINDERS WCH02527 Fig. 1: ECS electronic components 1 Rail unit 8 Terminal box E89 2 Terminal box E10 9 Terminal box E89.01 to E89.0x 3 Terminal box E20 10 Control box E90 4 Local control box E25...

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