Wingd W-x82 User manual

Operation Manual

“Marine”

Vessel:

Type:

Engine No.:

Document ID: DBAC753771

Winterthur Gas & Diesel Ltd. 24hrs Support:

Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd.

CH-8400 Winterthur Zürcherstrasse 12

Switzerland CH 8400 Winterthur

Switzerland

+41 52 262 80 10

[email protected]

No part of this publication may be reproduced or copied in any form or by any means

(electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval

systems) without the prior written permission of the copyright holder.

Winterthur Gas & Diesel Ltd. makes no representation, warranty (express or implied) in this

publication and assumes no responsibility for the correctness, errors or omissions of informa-

tion contained herein. Information in this publication is subject to change without notice.

NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUEN-

TIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS

PUBLICATION IS INTENDED FOR INFORMATION PURPOSES ONLY.

Operation Manual

“Marine”

Vessel:

Type:

Engine No.:

Document ID: DBAC753771

Winterthur Gas & Diesel Ltd. 24hrs Support:

Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd.

CH-8400 Winterthur Zürcherstrasse 12

Switzerland CH 8400 Winterthur

Switzerland

+41 52 262 80 10

[email protected]

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.

Winterthur Gas & Diesel Ltd. or Wärtsilä Services Switzerland Ltd. make no representation,

warranty (express or implied) in this publication and assumes no responsibility for the correct-

ness, errors or omissions for information contained herein. Information in this publication is

subject to change without notice.

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUEN-

TIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS

PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

1/4 16/10/2017

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new exch.

2014 Operation Manual, Issue 2014 x

Date of publication 2014-08-19

0020-1/A1 TOC New chapter 9314-2/A1 added x

0030-1/A1 Subject Index New chapter 9314-2/A1 added x

0080-1/A1 Basic Engine Data Additional illustrations added; x

0590-1/A1

Operation during Unusual

Conditions - Defective

Turbocharger

Additional data for three turbocharger configuration and

Table 1 added

0710-1/A1 Diesel Engine Fuels Latest data, minor text changes x

4104-1/A1 Supply Drive Unit

Additional illustration for 9-cylinder engines added;

illustrations updated

7218-1/A1 Cylinder Lubrication

page 2: Illustration schematic diagram for 9-cylinder

engines added

page 13, 14: pressure transmitter PT3139C added

8016-1/A2

Lubricating Oil System - 9-

cylinders

page 4: New illustration added

page 5: Key to Fig. 1 updated

page 8: New illustration added

page 9: New illustration added; Key to Fig. 3 updated

Group 9 Group TOC New chapter 9314-2/A1 added x

9314-1/A1

Oil Mist Detector -

6-cylinder to 8-cylinder

Schematic diagram updated; terminology updated x

9314-2/A1

Oil Mist Detector -

9-cylinder

New chapter for 9-cylinder engines added x

Date of publication 2014-09-16

OM_2015-05 2015-05

Cover page, Disclaimer

and all related pages

Data about Winterthur Gas & Diesel (WinGD) and Wärtsilä

Services Switzerland (WSCH) added;

New Layout WinGD;

Disclaimer updated (WinGD and WSCH added);

8019-1/A1 2015-05

Fuel System - 6-cylinders

to 8-cylinders

Fig. 5: Illustration updated;

para 4.3 and 4.4: reference changed;

para 4.4: procedure changed; alternative procedure added;

para 4.5: procedure changed; data about spare part kit

added;

8019-1/A2 2015-05 Fuel System - 9-cylinders

Fig. 5: Illustration updated;

para 4.3 and 4.4: reference changed;

para 4.4: procedure changed; alternative procedure added;

para 4.5: procedure changed; data about spare part kit

added;

all paragraphs: minor text changes and updates (e.g.

position numbers);

Date of publication 2015-06-09

0210-1/A1 2015-07

Safety Precautions and

Warnings (General Data)

paragraph 2: Warning about oil mist detector added;

paragraph 8: Warning about hot parts added;

paragraph 9: Warning about injury hazards added;

paragraph 13: Warning about air run added;

0270-1/A1 2015-07

Service

Bulletin RT-82

Changing Over from

Diesel Oil to Heavy Fuel

Oil and Vice Versa

Temperature gradient changed from 15°C/min to 2°C/min

related to the Service Bulletin;

2014-09

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

2/4 16/10/2017

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new exch.

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

0710-1/A1 2015-07

EAAD085468

Service

Bulletin

RT-126

Diesel Engine Fuels

Latest data from fuel specification added;

Table 1: maximum sulfur value changed from 4.5 to 3.5

m/m[%];

Fig. 1: Viscosity/Temperature Diagram updated;

Note 2) to Fig. 1: min. value for fuel viscosity changed from

13 cSt to 10 cSt;

Table 2: Pour point (upper) winter max. value changed

from 0 to -6; Carbon residue max. value removed;

minor changes in the text;

Data about Wärtsilä Service Switzerland Ltd and WinGD

added;

0720-1/A1 2015-07

EAAD085468

EAAD085894

Operating Media - Fuel

Treatment and Fuel

System

Fig. 1: Schematic Diagram - Fuel System updated;

Key to Fig. 1: Items 31, 32, 33 added;

para 3: minor text changes;

para 4: text changed; data about additional leakage

collection tank added;

Structure of the document changed;

0750-1/A1 2015-07

Service

Bulletins

RT-138

(Version 4)

RT-138_1

(Version 4)

RT-161

Operating Media

paragraph 2.1: additional data added

Table 1: data FZG gear machine test added

Table 2: data FZG gear machine test added

paragraph 2.4: Sample point added

paragraph 3.1: updated

Fig. 1: illustration updated

paragraph 3.2: new data and Fig. 2 added

paragraph 3.3: new paragraph added

paragraph 3.4: new paragraph added

paragraph 7: new paragraph added

paragraph 8.1: new paragraph added

paragraph 8.2: list of approved lubricating oils updated

paragraph 8.3: new table added added

Chapter updated (latest data from Revision 4 of the

Service Bulletin RT-138);

Fig. 1 and Fig. 2: new illustration with latest data;

Table 4: List of Validated Lubricating Oils updated (latest

data from January 2015);

Table 5: List of Validated System Oils updated (latest data

from January 2015);

4003-2/A1 2015-07 EAAD085118 Engine Control Diagram

Document updated with latest data:

-At servo oil rail new group with PT2041A, PI2041L, 8.11-1,

4.23 and accumulator added;

-Check point 3.17 top of ICU removed.

4003-2/A2 2015-07 EAAD085118 Engine Control Diagram

Document updated with latest data:

-At servo oil rail new group with PT2041A, PI2041L, 8.11-1,

4.23 and accumulator added and connection L2 with

PT2042A, PI2042L, 8.11-2 removed;

-At cylinder lubrication connection L2 removed and

connected the two servo oil pipes to one pipe.

3/4 16/10/2017

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new exch.

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

4003-3/A1 2015-01 EAAD085118

Control and Auxiliary

Systems

Document updated with latest data:

-Page 11: PT2041A, PI2041L, 8.11-1 have been removed.

Address 313 has been changed to 314;

-Page 12: PT2041A, PI2041L, 8.11-1, PT2042A, PI2042L,

8.11-2 and connection 319 have been removed. Address

313 has been changed to 314. Only one servo oil pipe;

-Page 13: All signals related to the turbocharger updated;

-Page 14: All signals related to the turbocharger updated;

-Page 15,16: New group with PT2041A, PI2041L, 8.11-1,

4.23 added;

-Page 17,18: New group with PT2041A, PI2041L, 8.11-1,

4.23 added. Connection 319 has been removed;

-Page 19,20: Check point 3.17 top of ICU has been

removed;

-Page 22: Oil mist detection MK6 has been replaced by

MK7.

Date of publication 2015-07-28

0050-1/A1 2017-08

Update

WinGD

Short Description of the

Engine

Minor text changes x

0120-1/A1 2017-08

Update

WinGD

Prepare the Fuel System

for Operation

Correction of References to Fig 1; Chapter 3.2 Leak Test

deleted

0120-1/A2 2017-08

Update

WinGD

Prepare the Fuel System

for Operation

Correction of References to Fig 1; Chapter 3.2 Leak Test

deleted

0250-1/A1 2017-04

Update

WinGD

Operating Data Sheet

Pressure and

Temperature Ranges

Torisional vibration damper (damper inlet):

Min. pressure value changed from 1.0 bar to

2.8 bar; max. pressure 5.0 bar (value added);

Note added;

0250-2/A1 2017-04

Update

WinGD

Operating Data Sheet

Alarms and Safeguards

PT2711A: ALM value changed from 1.5 bar to 2.2 bar;

Medium name changed to 'Torsional vibration damper oil

(steel spring damper)';

Note 5 changed

0270-1/A1 2017-08

Update

WinGD

Change-over from HFO

to MDO and back

Changed description and changed procedure x

0410-1/A1 2017-08

Update

WinGD

Running in of New

Cylinder Liners and

Piston Rings

Changed procedure for running-in x

0710-1/A1 2017-08

Update

WinGD

Diesel Engine Fuels Text changed for Fuel additives x

0750-1/A1 2017-08

Update

WinGD

Lubricating Oil

Update according to Service Bulletin (Text changes,

Particle Count; new Tables 4 and 5, updated Figures 1 and

2, updated Tables 6 and 7)

1203-1/A1 2017-08

Update

WinGD

Thrust Bearing Minor text changes, Section 1.1 deleted x

2722-1/A1 2017-08 EAAD086283 Injection Valve Updated section drawing x

3326-1/A1 2017-08 EAAD086618

Crosshead and Guide

Shoe

Text changed; Fig. 1 updated with shorter Guide rails x

4003-1/A1 2017-08

Update

WinGD

Engine Control

Table 4: Text changed; Table 5: Note deleted; Para 4.7:

step 2 deleted; Para 4.11: step 2 changed, step 3 added;

Para 4.12.1: step 4 changed

4325-1/A1 2017-08

Update

WinGD

Starting Air Shut-off

Valve

Steps 2 to 6 deleted x

5556-2/A1 2017-08

Update

WinGD

Fuel Pump - Cutting Out

and Cutting In

Procedures updated (2.1: step 10 and step 12 to 16; 2.2:

step 6 to 10)

5583-1/A1 2017-08

Update

WinGD

Fuel Pump Actuator Update drawing x

4/4 16/10/2017

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new exch.

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

6510-1/A1 2017-08

Update

WinGD

Cleaning the

Turbocharger during

Operation

Minor text changes (only cleaning of compressor) x

6606-1/A1 2017-08

Update

WinGD

Operating Instructions

and Cleaning

Fig. 1 FW line changed x

6735-1/A1 2017-08

Update

WinGD

Scavenge Air Waste

Gate

Text corrections: First paragraph -5°C replaced with related

value; Table 1 Corrections; In paragraph 2.1 last two

sentences deleted.

7218-3/A1 2017-08

Update

WinGD

Feed Rate - Adjustment Updates according to Service Bulletin x

Date of publication 2017-10-16

OM / X82 / Register

Engine Control and Control Elements

Crankshaft, Connecting Rod and Piston

Cylinder Liner and Cylinder Cover

Bedplate and Tie Rod

Operating Descriptions

Supply Unit, Servo Oil Pump and Fuel Pump

Scavenge Air System

Cylinder Lubrication

Piping Systems

Engine Monitoring

Intentionally blank

Operation Group0

Winterthur Gas & Diesel Ltd. 1/ 1

Operating Descriptions Group 0

For Your Attention 0000−1/A1......................................................................

General

Preface 0010−1/A1.............................................................................

Table of Contents 0020−1/A1....................................................................

Subject Index 0030−1/A1.......................................................................

Abbreviations 0035−1/A1.......................................................................

How to Use the Operation Manual 0040−1/A1.....................................................

Short Description of the Engine 0050−1/A1........................................................

Two-stroke Diesel Engine −Operation 0060−1/A1..................................................

The Relation between Engine and Propeller 0070−1/A1.............................................

Basic Engine Data 0080−1/A1...................................................................

Prepare the Engine for Operation

Prepare for Engine Start after a Short Shutdown Period (One or More Days) 0110−1/A1................

Prepare the Fuel System for Operation 0120−1/A1.................................................

Prepare the Servo Oil System 0130−1/A1.........................................................

Prepare the Cylinder Lubricating System 0140−1/A1................................................

Operation during Usual Conditions

General Data 0200−1/A1........................................................................

Safety Precautions and Warnings (General Data) 0210−1/A1........................................

Slow Turning 0220−1/A1........................................................................

Engine Start 0230−1/A1........................................................................

Usual Operation 0240−1/A1.....................................................................

Operating Data Sheet

Pressure and Temperature Ranges at Continuous Service Power MCR 0250−1/A1.....................

Alarms and Safeguards at Continuous Service Power 0250−2/A1....................................

Operation

Manoeuvring 0260−1/A1........................................................................

Change-over from Diesel Oil to Heavy Fuel Oil and Back 0270−1/A1.................................

Operation at Low Load 0280−1/A1...............................................................

Operation at Overload 0290−1/A1................................................................

Engine Shutdown

General 0310−1/A1............................................................................

Procedures after Engine Stop 0320−1/A1.........................................................

Special Procedures

Running-in New Cylinder Liners and Piston Rings 0410−1/A1........................................

Indicator Diagrams 0420−1/A1...................................................................

Procedures to Prevent Contamination and Fire in the Scavenge Air Spaces 0450−1/A1.................

Prevention of Crankcase Explosions −Instructions 0460−1/A1.......................................

Winterthur Gas & Diesel Ltd. X82 / OM / 2014

OperationGroup0

Winterthur Gas & Diesel Ltd.

2/ 1

Operation during Unusual Conditions

General Data 0500−1/A1........................................................................

Operation with Injection Cut Out (One or More Cylinders) 0510−1/A1.................................

Faults in High Pressure Fuel System 0515−1/A1...................................................

Operation with Exhaust Valve Control Unit Cut Out 0520−1/A1.......................................

Faults in Servo Oil System 0525−1/A1............................................................

Operation with Running Gear Partially or Fully Removed 0540−1/A1..................................

Operation with Water Leakage into the Combustion Chamber 0545−1/A1.............................

Defective Scavenge Air Cooler / Defective Auxiliary Blowers 0550−1/A1..............................

Defective Remote Control 0560−1/A1.............................................................

Defective Speed Control System 0570−1/A1.......................................................

Defective Turbocharger 0590−1/A1...............................................................

Special Procedures Before and After Operation

Prepare for Engine Start after a Long Shutdown Period or an Overhaul 0610−1/A1.....................

Prepare the Engine for a Long Shutdown Period 0620−1/A1.........................................

Operation Media

Diesel Engine Fuels 0710−1/A1..................................................................

Fuel Treatment and Fuel System 0720−1/A1......................................................

Scavenge Air and Starting Air 0740−1/A1.........................................................

Lubricating Oils 0750−1/A1......................................................................

Cooling Water / Cooling Water Treatment 0760−1/A1...............................................

Problems during Operation

General 0800−1/A1............................................................................

Problems During Engine Start and Stop 0810−1/A1................................................

Irregular Operation 0820−1/A1...................................................................

Problems and Damage to Engine Parts 0840−1/A1.................................................

Failure and Defects of WECS Components 0850−1/A1.............................................

X82 / OM / 2014 Winterthur Gas & Diesel Ltd.

Operation 0000−1/A1

Winterthur Gas & Diesel Ltd. 1/ 1

For Your Attention

1. General

This manual is for the operator and is for use only for the related type of diesel engine

(the engine described in this manual). The data in this manual is confidential.

Make sure that you read carefully the Operation Manual before you operate the

engine.

Make sure that you know the Inspection and Overhaul intervals in the Maintenance

Manual before you operate the engine.

Make sure that you read the data in Group 0 in the Maintenance Manual before you

do maintenance work on the engine.

2. Spare Parts

Use only original spare parts and components to make sure that the engine will

continue to operate satisfactorily. All equipment and tools for maintenance and

operation must be serviceable and in good condition.

The extent of all supplies and services is set exclusively to the related supply

contract.

3. Data

The specifications and recommendations of the classification societies, which are

essential for the design, are included in this manual.

The data, instructions, graphics and illustrations etc. in this manual are related to

drawings from Winterthur Gas & Diesel Ltd. (WinGD). These data relate to the date of

issue of the manual (the year of the issue is shown on the title page). All instructions,

graphics and illustrations etc can change because of continuous new development

and modifications.

4. Personnel

Only qualified personnel that have the applicable knowledge and training must do

work on the engine, its systems and related auxiliary equipment.

Data related to protection against danger and damage to equipment are specified in

this manual as Warnings and Cautions.

2014

Intentionally blank

Operation 0010−1/A1

Winterthur Gas & Diesel Ltd. 1/ 3

Preface

5. Technical Documentation Set

The technical documentation set for this diesel engine type includes the following

publications:

5.1 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.

5.2 Maintenance Manual

The maintenance manual contains data about disassembly / assembly procedures

that are necessary for the engine maintenance and the maintenance schedule. This

manual gives more data about the masses (weight) of components, a clearance table,

tightening values for important screw connections and a tool list.

5.3 Code Book (spare parts catalogue)

In the code book all parts of the engine are marked with a unique code number. The

code number is necessary to order spare parts from Winterthur Gas & Diesel Ltd.

(WinGD) or the engine supplier. The spare parts can only be ordered with the code

number from the code book.

5.4 External Supplier Documentation

The documentation from external suppliers gives data about the parts of the engine

that are not supplied by Winterthur Gas & Diesel Ltd (WinGD), such as turbocharger,

automatic filter, torsional or vibration damper. Most of this documentation also

contains data about spare parts.

5.5 Records and Drawings

The setting tables, shop trial documents, schematic diagrams and survey certificates

of the related engine are given with the first supply of the documentation.

6. Manual Structure

The manual is divided into different groups. Each group contains data about

components or systems referred to in the design groups.

The manuals give data about the standard engine with all cylinder numbers,

alternative designs and special equipment.

The documentation for alternative engine designs are separated into different

chapters with the related design name.

General

2014

Operation0010−1/A1

Winterthur Gas & Diesel Ltd.

2/ 3

6.1 Structure of the Manual

The groups with their illustrations are divided into the design groups.

0peration 1132−1/A1

Title

Subtitle −−−−−

Winterthur Gas & Diesel Ltd 1 / 4 2015

2015-05

Year of issue

(or)

Modification date

Page number

Total pages of group

Engine type

Manual type

Group No.

Design variant

Variant

description

(Version)

W-X62

2014

Preface

Operation 0010−1/A1

Winterthur Gas & Diesel Ltd. 3/ 3

6.2 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. If

ignored, these conditions could cause minor injury to personnel,

or damage to engine components.

Note: Notes give more data to help you do a task, or give you data about the

engine. Notes come immediately before or after the related paragraph.

7. Technical Documentation

Because of the continuous development of the engine, the technical documentation

also changes and is regularly updated. The modification service leaflet on the first

page of the manual shows all changes.

Important data and changes are given directly to the customer in the service bulletins.

To order more technical documents, the data that follows is necessary:

DEngine type, year of manufacture and engine manufacturer

DName of vessel or site of installation

DCylinder or engine number

DSpecial equipment

DDocument type (printed manuals or CD).

2014

Preface

Intentionally blank

Operation 0020−1/A1

Table of Contents

Winterthur Gas & Diesel Ltd. 1/ 4 2014-09