WinGD X35-B User manual

Operation Manual
X35-B
Issue 001 2019-10
Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. [phone]
Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax [phone]
Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com

© 2019 Winterthur Gas & Diesel Ltd. – All rights reserved
No part of this publication may be reproduced or copied in any form or by any means (electronic,
mechanical, graphic, photocopying, recording, taping or other information retrieval systems)
without the prior written permission of the copyright holder. Winterthur Gas & Diesel Ltd. makes
no representation, warranty (express or implied) in this publication and assumes no responsibility
for the correctness, errors or omissions of information contained herein. Information in this
publication is subject to change without notice.
NO LIABILITY, WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS
ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS
INTENDED FOR INFORMATION PURPOSES ONLY.
www.wingd.com

Table of contents
1 Introduction
1.1 Operation Manual - change record.......................................... 18
1.2 Preface..................................................................20
1.3 Technical documentation set................................................22
1.4 Data module codes (descriptive data)........................................24
1.5 Data module codes (procedural data)........................................26
1.6 About this book...........................................................28
1.7 About the engine..........................................................30
1.8 List of abbreviations.......................................................36
2 Safety
2.1 Safety precautions and safety rules..........................................42
2.2 Contamination and fire in the scavenge air spaces............................ 46
2.3 Fire-fighting in the scavenge air space.......................................48
2.4 Explosions in the crankcase................................................50
2.5 Prevent explosions in the crankcase.........................................52
2.6 Access to engine spaces...................................................54
3 Design and function of the engine
3.1 Short description of the engine..............................................58
3.2 Use of the engine.........................................................60
3.3 The relation between engine and propeller................................... 64
4 Design and function of systems
4.1 General for systems.......................................................70
4.2 Cooling water system......................................................72
4.3 Wash-water system....................................................... 74
4.4 System oil system.........................................................76
4.5 Servo oil system..........................................................78
4.6 Cylinder oil system........................................................80
4.7 Starting air system........................................................ 82
4.8 Scavenge air system......................................................84
4.9 Control air system.........................................................86
4.10 Exhaust gas system.......................................................88
4.11 Fuel system..............................................................90
4.12 HP Selective catalytic reduction system......................................94
4.13 LP Selective catalytic reduction system..................................... 114
4.14 Steam production control system...........................................128
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5 Design and function of components
5.1 Group 1 - Engine frame and bearings
5.1.1 Bedplate........................................................... 134
5.1.2 Main bearing........................................................136
5.1.3 Thrust bearing...................................................... 138
5.1.4 Monoblock column...................................................140
5.1.5 Tie rod.............................................................142
5.2 Group 2 - Cylinder
5.2.1 Cylinder liner........................................................144
5.2.2 Lubricating quill..................................................... 146
5.2.3 Piston rod gland.....................................................148
5.2.4 Direct controlled injection valve........................................150
5.2.5 Starting valve.......................................................152
5.2.6 Exhaust valve.......................................................154
5.3 Group 3 - Crankshaft, connecting rod and piston
5.3.1 Crankshaft..........................................................156
5.3.2 Torsional vibration damper............................................158
5.3.3 Axial vibration damper............................................... 162
5.3.4 Turning gear........................................................164
5.3.5 Connecting rod and connecting rod bearing.............................166
5.3.6 Crosshead and guide shoe........................................... 168
5.3.7 Piston..............................................................170
5.4 Group 4 - Supply unit drive and control components
5.4.1 Supply unit drive.................................................... 172
5.4.2 Starting air shut-off valve.............................................174
5.4.3 Control air supply....................................................176
5.4.4 Local maneuvering stand.............................................178
5.4.5 Pick-up for speed measurement.......................................180
5.5 Group 5 - Supply unit, pumps and control valves
5.5.1 Servo oil pump......................................................182
5.5.2 Supply unit......................................................... 184
5.5.3 Fuel pump..........................................................186
5.5.4 Pressure control valve............................................... 188
5.5.5 Flow limiting valve...................................................190
5.5.6 Exhaust valve control unit............................................ 192
5.6 Group 6 - Scavenge air components
5.6.1 Scavenge air receiver................................................194
5.6.2 Turbocharger....................................................... 196
5.6.3 Auxiliary blower..................................................... 198
5.6.4 Auxiliary blower switch box........................................... 200
5.6.5 Scavenge air cooler..................................................202
5.6.6 Water separator.....................................................204
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5.7 Group 7 - Cylinder lubrication
5.7.1 Cylinder lubrication.................................................. 206
5.8 Group 8 - Pipes
5.8.1 Exhaust waste gate..................................................208
5.9 Group 9 - Monitoring instruments
5.9.1 Crank angle sensor unit..............................................210
5.9.2 Oil mist detector.....................................................212
6 Control system
6.1 Engine control system....................................................216
6.2 Intelligent combustion control..............................................222
6.3 Local display unit (LDU-20) - general.......................................226
6.4 Local display unit (LDU-20) - pages
6.4.1 LDU-20 pages - general..............................................228
6.4.2 LDU-20 page - MAIN.................................................230
6.4.3 LDU-20 page - CONTROL LOCATIONS................................234
6.4.4 LDU-20 page - CA SENSOR STATUS..................................236
6.4.5 LDU-20 page - FUEL SYSTEM........................................238
6.4.6 LDU-20 page - CYLINDER BALANCING DIESEL........................240
6.4.7 LDU-20 page - MAIN FUEL INJECTION................................242
6.4.8 LDU-20 page - PAGE INDEX......................................... 244
6.4.9 LDU-20 page - EXHAUST VALVES....................................246
6.4.10 LDU-20 page - FAILURE LIST........................................ 248
6.4.11 LDU-20 page - CYLINDER LUBRICATION..............................250
6.4.12 LDU-20 page - USER PARAMETERS..................................252
6.4.13 LDU-20 page - PERFORMANCE DATA DIESEL.........................254
6.4.14 LDU-20 page - TEMPERATURES..................................... 256
6.4.15 LDU-20 page - SOFTWARE INFO.....................................258
6.4.16 LDU-20 page - LOG MESSAGES......................................260
6.4.17 LDU-20 page - LOG ENTRY DATA.................................... 262
6.4.18 LDU-20 page - SYSTEM STATUS..................................... 264
6.4.19 LDU-20 page - SOFTWARE TOOLS...................................266
6.4.20 LDU-20 page - SYSTEM SETTINGS...................................268
6.4.21 LDU-20 page - ETHERNET...........................................270
6.4.22 LDU-20 page - DATE................................................ 272
6.4.23 LDU-20 page - SCAVENGE AIR - EWG (optional)....................... 274
6.4.24 LDU-20 page - SCREENSHOT........................................276
6.5 Operate the local display unit (LDU-20).....................................278
7 Installation
7.1 Installation..............................................................284
8 Operation
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8.1 Prepare the engine before start - general....................................286
8.2 Prepare the engine before start............................................288
8.3 Start the engine - general.................................................296
8.4 Start the engine..........................................................298
8.5 Do checks during operation - general.......................................300
8.6 Do checks during operation............................................... 302
8.7 Do regular safety checks..................................................306
8.8 Maneuver the ship - general...............................................310
8.9 Maneuver the ship.......................................................312
8.10 Change-over the diesel fuel - general.......................................314
8.11 Change-over the diesel fuel automatically...................................318
8.12 Change-over from HFO to MDO manually...................................320
8.13 Change-over from MDO to HFO manually...................................322
8.14 Stop the engine - general.................................................324
8.15 Stop the engine..........................................................326
8.16 Emergency stop the engine - general.......................................328
8.17 Emergency stop the engine............................................... 330
8.18 Prepare the engine after stop - general..................................... 332
8.19 Prepare the engine for a short service break.................................334
8.20 Prepare the engine for a long shutdown period...............................336
9 Service during operation
9.1 Do an analysis of the system oil............................................342
9.2 Do an analysis of the cylinder oil...........................................344
9.3 Replace the filter element of the duplex filter.................................348
9.4 Clean the turbocharger during operation....................................350
9.5 Clean the scavenge air cooler during operation..............................352
9.6 Do a test of the exhaust waste valve........................................356
9.7 Running-in of new components - general....................................358
9.8 Running-in of new components............................................360
10 Troubleshooting
10.1 Troubleshooting - general data............................................ 364
10.2 Malfunctions of systems and components...................................366
10.3 Failures and defects of UNIC-flex components...............................386
10.4 Examine the supply unit for servo oil leakage................................388
10.5 Examine the supply unit for fuel leakage....................................392
10.6 Examine the rail unit for leakage...........................................396
10.7 Examine the FLV or fuel pipes for fuel leakage...............................398
10.8 Temporary cut out a defective injection valve................................ 402
10.9 Temporary cut out a defective exhaust valve drive............................404
10.10 Temporary isolate a cylinder with cooling water leakage.......................406
10.11 Temporary isolate a defective turbocharger..................................410
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10.12 Temporary isolate the exhaust waste gate...................................414
10.13 Isolate a defective engine at twin engine installation..........................418
10.14 Temporary isolate the HP SCR system......................................420
10.15 Connect the HP SCR system after isolation................................. 424
11 Technical data
11.1 Engine data.............................................................428
11.2 List of usual values and safeguard settings - general......................... 430
11.3 List of usual values and safeguard settings..................................434
11.4 Section views........................................................... 446
12 Operating media
12.1 General for operating media...............................................450
12.2 Compressed air..........................................................452
12.3 Scavenge air............................................................454
13 Schematic diagrams
13.1 Schematic diagrams - general.............................................456
13.2 List of diagrams..........................................................462
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List of tables
1 Introduction
1-1 Change record ............................................................................................. 18
1-2 Data module codes (descriptive data) ......................................................... 24
1-3 Data module codes (procedural data) ......................................................... 26
1-4 List of abbreviations and acronyms ............................................................. 36
4 Design and function of systems
4-1 Operation limits of exhaust gas temperature after exhaust gas manifold ... 96
4-2 HP SCR SYSTEM STATUS (MAIN PAGE) ................................................. 107
4-3 HP SCR SYSTEM OVERVIEW ................................................................... 108
4-4 HP SCR INTERFACES ............................................................................... 109
4-5 HP SCR MANUAL VALVE CONTROL ........................................................ 110
4-6 HP SCR SOFTWARE INFO ........................................................................ 111
4-7 HP SCR PAGE INDEX ................................................................................ 112
4-8 LP SCR SYSTEM STATUS (MAIN PAGE) .................................................. 123
4-9 LP SCR SYSTEM OVERVIEW ................................................................... 124
4-10 LP SCR INTERFACES ................................................................................ 125
4-11 LP SCR SOFTWARE INFO ......................................................................... 126
4-12 LP SCR PAGE INDEX ................................................................................. 127
4-13 STEAM PRODUCTION CONTROL (SPC) ................................................. 129
6 Control system
6-1 MAIN ........................................................................................................... 231
6-2 CONTROL LOCATIONS ............................................................................. 235
6-3 CA SENSOR STATUS ................................................................................. 237
6-4 FUEL SYSTEM ........................................................................................... 239
6-5 CYLINDER BALANCING DIESEL ............................................................... 241
6-6 MAIN FUEL INJECTION ............................................................................. 243
6-7 PAGE INDEX ............................................................................................... 245
6-8 EXHAUST VALVES ..................................................................................... 247
6-9 FAILURE LIST ............................................................................................. 249
6-10 CYLINDER LUBRICATION ......................................................................... 251
6-11 USER PARAMETERS ................................................................................. 253
6-12 PERFORMANCE DATA DIESEL ................................................................. 255
6-13 TEMPERATURES ....................................................................................... 257
6-14 SOFTWARE INFO ....................................................................................... 259
6-15 LOG MESSAGES ........................................................................................ 261
6-16 LOG ENTRY DATA ...................................................................................... 263
6-17 SYSTEM STATUS ....................................................................................... 265
6-18 SOFTWARE TOOLS ................................................................................... 267
6-19 SYSTEM SETTINGS ................................................................................... 269
6-20 ETHERNET ................................................................................................. 271
6-21 DATE ........................................................................................................... 273
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6-22 SCAVENGE AIR - EWG (optional) .............................................................. 275
10 Troubleshooting
10-1 Supply pressure of the cylinder cooling water is too low ............................. 369
10-2 Supply temperature of the cylinder cooling water is too low ....................... 369
10-3 Cylinder cooling water temperature downstream of a cylinder is too high .. 369
10-4 Supply pressure of the cooling water to the SAC is too low ........................ 369
10-5 Supply temperature of the cooling water to the SAC is too low .................. 370
10-6 Temperature of the cooling water downstream of the SAC is too high ........ 370
10-7 Lubricating oil supply pressure at the engine inlet is too low ...................... 371
10-8 Lubricating oil supply pressure upstream of the injectors is too low ........... 371
10-9 Lubricating oil supply temperature at the engine inlet is too high ................ 371
10-10 Lubricating oil supply pressure upstream of the crossheads is too low ...... 371
10-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted
range ........................................................................................................... 371
10-12 Servo oil leakage flow from the servo oil supply unit is too high ................. 372
10-13 Servo oil flow at a servo oil pump inlet is too low ........................................ 372
10-14 Bearing oil temperature at a bearing outlet is too high ................................ 372
10-15 Oil mist concentration is too high ................................................................ 372
10-16 Piston cooling oil temperature downstream of a piston is too high ............. 373
10-17 Piston cooling oil flow to a piston is not in the permitted range ................... 373
10-18 TC bearing oil temperature at a turbocharger outlet is too high .................. 373
10-19 TC bearing oil supply pressure upstream of a turbocharger is too low ....... 373
10-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil
supply) ......................................................................................................... 373
10-21 Damper oil supply pressure upstream of the torsional vibration damper is
too low ......................................................................................................... 374
10-22 Damper oil supply pressure upstream of the axial vibration damper is too
low ............................................................................................................... 374
10-23 Cylinder oil supply pressure is too low ........................................................ 374
10-24 Cylinder oil flow is too low ........................................................................... 374
10-25 Fuel supply temperature is not in the permitted range ................................ 375
10-26 Fuel supply pressure at the engine inlet is too low ...................................... 375
10-27 Fuel leakage flow from the fuel supply unit is too high ................................ 375
10-28 Temperature difference of the fuel outlet of the two fuel pumps is too high
(for X35 or X40 engine) ............................................................................... 375
10-29 Leakage flow from the rail unit is too high ................................................... 375
10-30 Fuel leakage flow from fuel rail items is too high (engine with FLV) ............ 375
10-31 Fuel leakage flow from fuel rail items is too high (engine with ICU) ............ 376
10-32 Fuel pressure in the fuel rail is too high (for X35 or X40 engine) ................ 376
10-33 Fuel pressure in the fuel rail is too low (for X35 or X40 engine) .................. 376
10-34 Gas concentration in piston underside is too high ....................................... 377
10-35 Difference pressure of pilot fuel filter is too high ......................................... 377
10-36 Gas supply pressure is too low ................................................................... 377
10-37 Exhaust gas temperature downstream of a cylinder is too high .................. 378
10-38 Exhaust gas temperature difference downstream of all cylinders is too
high .............................................................................................................. 378
10-39 Exhaust gas temperature upstream of a turbocharger is too high .............. 378
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10-40 Exhaust gas temperature downstream of a turbocharger is too high .......... 379
10-41 Exhaust valve does not operate, unwanted noise ....................................... 379
10-42 Smoke is too dark ........................................................................................ 379
10-43 Scavenge air temperature in the receiver is too high .................................. 380
10-44 Scavenge air temperature in the receiver is too low ................................... 380
10-45 Scavenge air pressure is too high ............................................................... 380
10-46 Scavenge air pressure is too low ................................................................ 380
10-47 Condensation flow at a water separator is too high .................................... 381
10-48 Condensation flow upstream of a water separator is too high .................... 381
10-49 Scavenge air temperature in the piston underside is too high .................... 381
10-50 Starting air supply pressure is too low ......................................................... 381
10-51 Pressure of the air spring air supply is too high .......................................... 381
10-52 Pressure of the air spring air supply is too low ............................................ 382
10-53 Oil leakage flow in the collector for leakage oil from the air spring is too
high .............................................................................................................. 382
10-54 Control air supply pressure is too low (usual supply) .................................. 382
10-55 Control air supply pressure is too low (stand-by supply) ............................. 382
10-56 Control air supply pressure is too low (safety supply) ................................. 382
10-57 Temperature of a thrust bearing pad is too high .......................................... 383
10-58 Cylinder liner wall temperature is too high .................................................. 383
10-59 A fuel pump actuator has a failure ............................................................... 383
10-60 Power supply to the power supply box E85 has a failure ............................ 384
10-61 Unwanted engine speed decrease .............................................................. 384
10-62 Unwanted engine stop ................................................................................. 384
10-63 Examples of failure messages .................................................................... 386
10-64 Special failures ............................................................................................ 387
11 Technical data
11-1 General data ................................................................................................ 428
11-2 Rated power ................................................................................................ 429
11-3 Function code .............................................................................................. 432
11-4 Function group ............................................................................................ 433
11-5 Applied system ............................................................................................ 433
11-6 Cooling water systems (XX10NN to XX19NN) ............................................ 435
11-7 Oil systems (XX2NNN, part 1) ..................................................................... 436
11-8 Oil systems (XX2NNN, part 2) ..................................................................... 437
11-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil)) ........................... 438
11-10 Oil systems (XX2NNN, part 4) ..................................................................... 439
11-11 Fuel system (XX34NN) ................................................................................ 440
11-12 Exhaust gas system (XX37NN) ................................................................... 441
11-13 Air systems (XX40NN to XX44NN) ............................................................. 442
11-14 Miscellaneous items (XX45NN to XX52NN) ................................................ 443
11-15 Failure messages ........................................................................................ 444
13 Schematic diagrams
13-1 Function code .............................................................................................. 458
13-2 Function group ............................................................................................ 459
13-3 Applied system ............................................................................................ 459
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13-4 List of diagrams ........................................................................................... 462
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List of illustrations
1 Introduction
1-1 Side view (generic) ...................................................................................... 31
1-2 End view (generic, seen from the driving end) ............................................ 32
1-3 Standard and LEFT engine (generic, seen from the driving end) ............... 33
1-4 Engine numbering (generic) ........................................................................ 34
3 Design and function of the engine
3-1 Pressure - volume diagram and schematic of the two-stroke diesel cycle .. 59
3-2 Operating range .......................................................................................... 60
3-3 Tuning options ............................................................................................. 62
3-4 Twin engine propulsion (generic example) .................................................. 63
3-5 Schematic diagram - Relation Speed/Power (FPP) .................................... 65
3-6 Schematic diagram - Relation Speed/ Power (CPP) ................................... 67
4 Design and function of systems
4-1 Line codes for systems ................................................................................ 70
4-2 Cooling water system (generic and simplified) ............................................ 73
4-3 Wash-water system (generic and simplified) ............................................... 75
4-4 System oil system (generic and simplified) ................................................. 77
4-5 Servo oil system (generic and simplified) .................................................... 79
4-6 Cylinder oil system (generic and simplified, with and without iCAT) ........... 81
4-7 Starting air system (generic and simplified) ................................................ 83
4-8 Scavenge air system ................................................................................... 85
4-9 Control air system (generic and simplified) ................................................. 87
4-10 Exhaust gas system (generic and simplified) .............................................. 89
4-11 Fuel system with FLV (generic and simplified) ............................................ 92
4-12 Fuel system with ICU (generic and simplified) ............................................ 93
4-13 HP SCR system - layout .............................................................................. 95
4-14 HP SCR system - emergency bypass ......................................................... 97
4-15 HP SCR system - change from Tier III to bypass ........................................ 98
4-16 HP SCR system - purging and venting ........................................................ 99
4-17 HP SCR system - emergency bypass ......................................................... 100
4-18 HP SCR system - preparation ..................................................................... 101
4-19 HP SCR system - Tier III ............................................................................. 102
4-20 HP SCR system - principal control configuration ........................................ 103
4-21 Control box E48 ........................................................................................... 104
4-22 Control box E49 ........................................................................................... 105
4-23 Control box E50 ........................................................................................... 106
4-24 LDU-20 page - HP SCR SYSTEM STATUS (MAIN PAGE) ......................... 107
4-25 LDU-20 page - HP SCR SYSTEM OVERVIEW .......................................... 108
4-26 LDU-20 page - HP SCR INTERFACES ....................................................... 109
4-27 LDU-20 page - HP SCR MANUAL VALVE CONTROL ................................ 110
4-28 LDU-20 page - HP SCR SOFTWARE INFO ............................................... 111
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4-29 LDU-20 page - HP SCR PAGE INDEX ....................................................... 112
4-30 LP SCR temperature controlled (example) ................................................. 115
4-31 LP SCR bypass rate controlled (example) .................................................. 116
4-32 LP SCR control system layout ..................................................................... 118
4-33 LP SCR system - principal control configuration ......................................... 119
4-34 Control box E70 with option SPC ................................................................ 120
4-35 Control box E71 with option SPC ................................................................ 121
4-36 Control boxes E72 and E73 ........................................................................ 122
4-37 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) ......................... 123
4-38 LDU-20 page - LP SCR SYSTEM OVERVIEW ........................................... 124
4-39 LDU-20 page - LP SCR INTERFACES ....................................................... 125
4-40 LDU-20 page - LP SCR SOFTWARE INFO ................................................ 126
4-41 LDU-20 page - LP SCR PAGE INDEX ........................................................ 127
4-42 Example of SPC .......................................................................................... 128
4-43 LDU-20 page - STEAM PRODUCTION CONTROL .................................... 129
5 Design and function of components
5-1 Bedplate (generic) ....................................................................................... 134
5-2 Main bearing (generic) ................................................................................ 136
5-3 Thrust bearing (generic) .............................................................................. 139
5-4 Monoblock column (generic) ....................................................................... 140
5-5 Tie rod (generic) .......................................................................................... 142
5-6 Cylinder liner (generic) ................................................................................ 144
5-7 Cylinder - cooling water outlet (generic) ...................................................... 145
5-8 Lubricating quill (generic) ............................................................................ 146
5-9 Piston rod gland (generic) ........................................................................... 148
5-10 Injection valve (example) ............................................................................. 150
5-11 Starting valve (example) .............................................................................. 152
5-12 Exhaust valve (generic) ............................................................................... 154
5-13 Crankshaft (generic) .................................................................................... 156
5-14 Steel spring damper (generic) ..................................................................... 159
5-15 Viscous damper (generic) ........................................................................... 160
5-16 Axial vibration damper (generic) .................................................................. 162
5-17 Axial vibration damper monitor (generic) ..................................................... 163
5-18 Turning gear (generic) ................................................................................. 164
5-19 Connecting rod and connecting rod bearing (generic) ................................ 166
5-20 Crosshead and guide shoe (example) ........................................................ 168
5-21 Piston (example) ......................................................................................... 170
5-22 Supply unit drive (generic) ........................................................................... 173
5-23 Starting air shut-off valve (example) ............................................................ 174
5-24 Control air supply (generic) ......................................................................... 176
5-25 Local maneuvering stand (generic) ............................................................. 178
5-26 Pick-up for speed measurement (generic) .................................................. 180
5-27 Servo oil pump (example) ........................................................................... 182
5-28 Supply unit (example) .................................................................................. 184
5-29 Fuel pump (generic) .................................................................................... 186
5-30 Pressure control valve - location (example) ................................................ 189
5-31 Flow limiting valve (generic) ........................................................................ 190
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5-32 Exhaust valve control unit (VCU) (example) ............................................... 192
5-33 Scavenge air receiver (example) ................................................................. 194
5-34 Scavenge air receiver - cross section (example) ........................................ 195
5-35 Turbocharger (example) .............................................................................. 196
5-36 Auxiliary blower (generic) ............................................................................ 198
5-37 Switch box (generic) .................................................................................... 200
5-38 Scavenge air cooler (generic) ..................................................................... 202
5-39 Water separator (generic) ............................................................................ 204
5-40 Cylinder lubricating pump (generic) ............................................................. 206
5-41 Usual vertical oil supply ............................................................................... 207
5-42 Exhaust waste gate (generic) ...................................................................... 208
5-43 Crank angle sensor unit on intermediate wheel (example) ......................... 210
5-44 Crank angle sensor unit on flywheel (example) .......................................... 211
5-45 Oil mist detector (example) ......................................................................... 212
5-46 Oil mist detector - schematic diagram (example) ........................................ 213
6 Control system
6-1 ECS modules .............................................................................................. 217
6-2 Signal flow diagram ..................................................................................... 220
6-3 ICC - pressure diagram ............................................................................... 223
6-4 ICC - control schematic ............................................................................... 224
6-5 LDU-20 - overview ....................................................................................... 226
6-6 LDU-20 color display - general items .......................................................... 227
6-7 MAIN ........................................................................................................... 230
6-8 CONTROL LOCATIONS ............................................................................. 234
6-9 CA SENSOR STATUS ................................................................................. 236
6-10 FUEL SYSTEM ........................................................................................... 238
6-11 CYLINDER BALANCING DIESEL ............................................................... 240
6-12 MAIN FUEL INJECTION ............................................................................. 242
6-13 PAGE INDEX ............................................................................................... 244
6-14 EXHAUST VALVES ..................................................................................... 246
6-15 FAILURE LIST ............................................................................................. 248
6-16 CYLINDER LUBRICATION ......................................................................... 250
6-17 USER PARAMETERS ................................................................................. 252
6-18 PERFORMANCE DATA DIESEL ................................................................. 254
6-19 TEMPERATURES ....................................................................................... 256
6-20 SOFTWARE INFO ....................................................................................... 258
6-21 LOG MESSAGES ........................................................................................ 260
6-22 LOG ENTRY DATA ...................................................................................... 262
6-23 SYSTEM STATUS ....................................................................................... 264
6-24 SOFTWARE TOOLS ................................................................................... 266
6-25 SYSTEM SETTINGS ................................................................................... 268
6-26 ETHERNET ................................................................................................. 270
6-27 DATE ........................................................................................................... 272
6-28 SCAVENGE AIR - EWG (optional) .............................................................. 274
6-29 LDU-20 - navigation menu .......................................................................... 279
8 Operation
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8-1 Cooling water system with bypass cooling .................................................. 290
8-2 Cooling water system without bypass cooling ............................................. 291
8-3 Cooling water system with circulation ......................................................... 292
8-4 Cylinder lubricant quantity ........................................................................... 316
9 Service during operation
9-1 Location of ball valves - dirty oil samples .................................................... 345
9-2 SAC - clean during operation (example) ..................................................... 353
9-3 Feed rate adjustments - running-in ............................................................. 358
10 Troubleshooting
10-1 Example of inspection point ........................................................................ 389
10-2 Supply unit (example) and example of inspection point .............................. 393
10-3 Leakage on FLV and pipes (example) ......................................................... 399
10-4 Exhaust valve with pressure element .......................................................... 407
10-5 Not all turbochargers are defective (example) ............................................ 411
10-6 All turbochargers are defective (example) ................................................... 412
10-7 Exhaust waste gate (example) .................................................................... 415
10-8 SCR system - covers (example for 1 turbocharger) .................................... 421
10-9 SCR system - covers (example for 2 turbocharger) .................................... 422
10-10 SCR system - covers (example for 1 turbocharger) .................................... 425
10-11 SCR system - covers (example for 2 turbocharger) .................................... 426
11 Technical data
11-1 Operating range .......................................................................................... 429
11-2 Signal codes ................................................................................................ 432
11-3 Engine cross section ................................................................................... 446
11-4 Engine longitudinal section .......................................................................... 447
13 Schematic diagrams
13-1 Line codes ................................................................................................... 456
13-2 Process codes ............................................................................................. 457
13-3 Signal codes ................................................................................................ 458
13-4 Color codes and symbols - electric connection diagram ............................. 460
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1 Introduction
1.1 Operation Manual - change record.......................................... 18
1.2 Preface..................................................................20
1.3 Technical documentation set................................................22
1.4 Data module codes (descriptive data)........................................24
1.5 Data module codes (procedural data)........................................26
1.6 About this book...........................................................28
1.7 About the engine..........................................................30
1.8 List of abbreviations.......................................................36
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Operation Manual
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1.1 Operation Manual - change record
Tab 1-1 Change record
Data module code, issue
Chapter number - technical name
Reason for change
Status
New issue 001, 2019-10
All data modules
n/a
Initial issue of the fully new structured Operation Manual. The existing Operation Manual pub-
lished on 2017-07 is no more applicable.
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Operation Manual Operation Manual - change record
Winterthur Gas & Diesel Ltd. - 18 - Issue 001 2019-10

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Winterthur Gas & Diesel Ltd. - 19 - Issue 001 2019-10

1.2 Preface
This manual is for use only for the related type of engine (the engine described in this manual).
Make sure that you know the inspection and overhaul intervals before you operate the engine.
Also obey the items that follow:
•Safety
Make sure that you read carefully this manual before you start work on the engine.
Make sure that you read carefully and obey the data given in chapter safety.
•Data
The specifications and recommendations of the classification societies are included in the
design of the engine.
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 and on the footer). All instructions, graphics and illustrations etc
can change because of continuous new development and modifications.
•Equipment and tools
Keep all equipment and tools for maintenance and operation serviceable and in good
condition.
•Spare parts
Use only original spare parts and components to make sure that the engine will continue
to operate satisfactorily.
•Personnel
Only qualified personnel that have the applicable knowledge and training may do work on
the engine, its systems and related auxiliary equipment.
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