Wingd X72 User manual

Operation Manual

X72

Issue 001 2021-01

Winterthur Gas & Diesel Ltd. Schützenstrasse 3 Tel. +41 (0)52 264 8844

Winterthur Gas & Diesel AG P.O. Box 414, 8401 Fax +41 (0)52 264 8866

Winterthur Gas & Diesel S.A. Winterthur, Switzerland www.wingd.com

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.......................................................34

2 Design and function of the engine

2.1 Short description of the engine..............................................40

2.2 Use of the engine.........................................................42

2.3 The relation between engine and propeller................................... 46

2.4 Safety

2.4.1 Safety precautions and safety guidelines................................ 50

2.4.2 Contamination and fire in the scavenge air spaces........................54

2.4.3 Fire-fighting in the scavenge air space...................................56

2.4.4 Explosions in the crankcase............................................58

2.4.5 Prevent explosions in the crankcase.................................... 60

2.4.6 Access to engine spaces.............................................. 62

3 Design and function of the systems

3.1 General for systems.......................................................66

3.2 Cooling water system......................................................68

3.3 Wash-water system....................................................... 70

3.4 System oil system.........................................................72

3.5 Servo oil system..........................................................74

3.6 Cylinder oil system........................................................76

3.7 Starting air system........................................................ 78

3.8 Scavenge air system......................................................80

3.9 Control air system.........................................................82

3.10 Exhaust gas system.......................................................84

3.11 Fuel system..............................................................86

3.12 HP Selective catalytic reduction system......................................90

3.13 LP Selective catalytic reduction system..................................... 110

3.14 Steam production control system...........................................124

3.15 Synchro phasing system..................................................130

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4 Design and function of the components

4.1 Group 1 - Framework and bearings

4.1.1 Bedplate........................................................... 140

4.1.2 Main bearing........................................................142

4.1.3 Thrust bearing...................................................... 144

4.1.4 Monoblock column...................................................146

4.1.5 Tie rod.............................................................148

4.2 Group 2 - Cylinder

4.2.1 Cylinder liner........................................................150

4.2.2 Lubricating quill..................................................... 152

4.2.3 Piston rod gland.....................................................154

4.2.4 Direct controlled injection valve........................................156

4.2.5 Starting valve.......................................................158

4.2.6 Exhaust valve.......................................................160

4.3 Group 3 - Crankshaft, connecting rod and piston

4.3.1 Crankshaft..........................................................162

4.3.2 Torsional vibration damper............................................164

4.3.3 Axial vibration damper............................................... 168

4.3.4 Turning gear........................................................170

4.3.5 Connecting rod and connecting rod bearing.............................172

4.3.6 Crosshead and guide shoe........................................... 174

4.3.7 Piston..............................................................176

4.4 Group 4 - Drive supply unit and control elements

4.4.1 Supply unit drive.................................................... 178

4.4.2 Starting air shut-off valve.............................................180

4.4.3 Control air supply....................................................182

4.4.4 Local maneuvering stand for UNIC.....................................184

4.4.5 Pick-up for speed measurement.......................................186

4.5 Group 5 - Supply unit, pumps and control valves

4.5.1 Servo oil pump......................................................188

4.5.2 Supply unit......................................................... 190

4.5.3 Fuel pump..........................................................192

4.5.4 Pressure control valve............................................... 194

4.5.5 Flow limiting valve...................................................196

4.5.6 Exhaust valve control unit............................................ 198

4.5.7 Fuel pump actuator..................................................200

4.6 Group 6 - Scavenge air system

4.6.1 Scavenge air receiver................................................202

4.6.2 Turbocharger....................................................... 204

4.6.3 Auxiliary blower..................................................... 206

4.6.4 Auxiliary blower switch box........................................... 208

4.6.5 Scavenge air cooler..................................................210

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4.6.6 Water separator.....................................................212

4.7 Group 7 - Cylinder lubrication and balancer

4.7.1 Cylinder lubrication.................................................. 214

4.7.2 Integrated electrical balancer (iELBA)..................................216

4.8 Group 8 - Piping

4.8.1 Exhaust waste gate..................................................222

4.9 Group 9 - Monitoring system

4.9.1 Crank angle sensor unit..............................................224

4.9.2 Water in oil monitor..................................................226

4.9.3 Oil mist detector.....................................................228

4.9.4 Integrated sensor and pressure relief valve............................. 230

5 Control system of the engine

5.1 Engine control system UNIC...............................................232

5.2 Intelligent combustion control..............................................238

5.3 Local display unit (LDU-20) pages for UNIC

5.3.1 LDU-20 pages - general..............................................242

5.3.2 LDU-20 page - MAIN.................................................244

5.3.3 LDU-20 page - CONTROL LOCATIONS................................248

5.3.4 LDU-20 page - CA SENSOR STATUS..................................250

5.3.5 LDU-20 page - CYLINDER BALANCING DIESEL........................252

5.3.6 LDU-20 page - CYLINDER LUBRICATION..............................254

5.3.7 LDU-20 page - iCAT................................................. 256

5.3.8 LDU-20 page - DYNAMIC COMBUSTION CONTROL (DCC)..............260

5.3.9 LDU-20 page - EXHAUST VENTILATION...............................262

5.3.10 LDU-20 page - EXHAUST VALVES....................................264

5.3.11 LDU-20 page - FAILURE LIST........................................ 266

5.3.12 LDU-20 page - FAILURE SIMULATION.................................268

5.3.13 LDU-20 page - FUEL SYSTEM........................................270

5.3.14 LDU-20 page - KNOCK CONTROL....................................272

5.3.15 LDU-20 page - LOG MESSAGES......................................274

5.3.16 LDU-20 page - MAIN FUEL INJECTION................................276

5.3.17 LDU-20 page - PERFORMANCE DATA DIESEL.........................278

5.3.18 LDU-20 page - PILOT FUEL INJECTION...............................280

5.3.19 LDU-20 page - PILOT FUEL PRESSURE...............................282

5.3.20 LDU-20 page - SCAVENGE AIR - EWG (optional)....................... 284

5.3.21 LDU-20 page - SCREENSHOT........................................286

5.3.22 LDU-20 page - SOFTWARE INFO.....................................288

5.3.23 LDU-20 page - IMO CRC INFO........................................290

5.3.24 LDU-20 page - SOFTWARE TOOLS...................................292

5.3.25 LDU-20 page - SYSTEM STATUS..................................... 294

5.3.26 LDU-20 page - SYSTEM SETTINGS...................................296

5.3.27 LDU-20 page - TEMPERATURES..................................... 298

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5.3.28 LDU-20 page - USER PARAMETERS..................................300

5.3.29 LDU-20 page - LOG ENTRY DATA.................................... 302

5.3.30 LDU-20 page - DATE................................................ 304

5.3.31 LDU-20 page - ETHERNET...........................................306

5.4 Control pages for other systems

5.4.1 Local display unit (LDU-20) - general...................................308

5.4.2 Operate the local display unit (LDU-20).................................310

6 Installation of the engine

6.1 Installation..............................................................318

7 Operation of the engine

7.1 Prepare the engine before start - general....................................320

7.2 Prepare the engine before start............................................322

7.3 Start the engine - general.................................................330

7.4 Start the engine..........................................................332

7.5 Do checks during operation - general.......................................334

7.6 Do checks during operation............................................... 336

7.7 Do regular safety checks..................................................340

7.8 Maneuver the ship - general...............................................344

7.9 Maneuver the ship.......................................................346

7.10 Change-over the diesel fuel - general.......................................348

7.11 Change-over the diesel fuel automatically...................................352

7.12 Change-over from HFO to MDO manually...................................354

7.13 Change-over from MDO to HFO manually...................................356

7.14 Stop the engine - general.................................................358

7.15 Stop the engine..........................................................360

7.16 Emergency stop the engine - general.......................................362

7.17 Emergency stop the engine............................................... 364

7.18 Prepare the engine after stop - general..................................... 366

7.19 Prepare the engine for a short service break.................................368

7.20 Prepare the engine for standstill or for maintenance..........................370

7.21 LP-SCR system: Change Tier mode........................................374

7.22 Special running condition: Cylinder cut out.................................. 378

7.23 Special running condition: Turbocharger cut out..............................384

8 Service during operation

8.1 Do an analysis of the system oil............................................394

8.2 Do an analysis of the cylinder oil...........................................396

8.3 Running-in of new components - general....................................400

8.4 Running-in of new components............................................402

8.5 Clean the turbocharger during operation....................................404

8.6 Clean the scavenge air cooler during operation..............................406

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8.7 Replace the filter element of the duplex filter.................................410

8.8 Do a test of the exhaust waste valve........................................412

9 Troubleshooting

9.1 Troubleshooting - general data............................................ 416

9.2 Malfunctions of systems and components...................................418

9.3 Failures and defects of UNIC-flex components...............................438

9.4 Examine the supply unit for servo oil leakage................................440

9.5 Examine the supply unit for fuel leakage....................................444

9.6 Examine the ICU or fuel pipes for fuel leakage...............................448

9.7 Examine the FLV or fuel pipes for fuel leakage...............................452

9.8 Examine the rail unit for leakage...........................................456

9.9 Temporary isolate a cylinder with cooling water leakage.......................458

9.10 Temporary isolate a defective turbocharger..................................460

9.11 Temporary isolate the exhaust waste gate...................................464

9.12 Temporary cut out a defective injection valve................................ 468

9.13 Temporary cut out a defective exhaust valve drive............................470

9.14 Temporary isolate the HP SCR system......................................472

9.15 Connect the HP SCR system after isolation................................. 476

9.16 Disconnect the fuel pump.................................................480

9.17 Connect the fuel pump....................................................482

9.18 Isolate a defective engine at twin engine installation..........................484

10 Technical data

10.1 Engine data.............................................................488

10.2 List of usual values and safeguard settings - general......................... 490

10.3 List of usual values and safeguard settings..................................494

11 Operating media

11.1 General for operating media...............................................506

11.2 Compressed air..........................................................508

11.3 Scavenge air............................................................510

12 Schematic diagrams

12.1 Schematic diagrams - general.............................................512

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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 ............................................................. 34

3 Design and function of the systems

3-1 Operation limits of exhaust gas temperature after exhaust gas manifold ... 92

3-2 HP SCR SYSTEM STATUS (MAIN PAGE) ................................................. 103

3-3 HP SCR SYSTEM OVERVIEW ................................................................... 104

3-4 HP SCR INTERFACES ............................................................................... 105

3-5 HP SCR MANUAL VALVE CONTROL ........................................................ 106

3-6 HP SCR SOFTWARE INFO ........................................................................ 107

3-7 HP SCR PAGE INDEX ................................................................................ 108

3-8 LP SCR SYSTEM STATUS (MAIN PAGE) .................................................. 119

3-9 LP SCR SYSTEM OVERVIEW ................................................................... 120

3-10 LP SCR INTERFACES ................................................................................ 121

3-11 LP SCR SOFTWARE INFO ......................................................................... 122

3-12 LP SCR PAGE INDEX ................................................................................. 123

3-13 STEAM PRODUCTION CONTROL (SPC) ................................................. 125

4 Design and function of the components

4-1 iELBA - control cabinet ................................................................................ 220

4-2 iELBA - error indication ............................................................................... 221

5 Control system of the engine

5-1 MAIN ........................................................................................................... 245

5-2 CONTROL LOCATIONS ............................................................................. 249

5-3 CA SENSOR STATUS ................................................................................. 251

5-4 CYLINDER BALANCING DIESEL ............................................................... 253

5-5 CYLINDER LUBRICATION ......................................................................... 255

5-6 iCAT (integrated Cylinder lubricant Auto Transfer) ...................................... 257

5-7 DYNAMIC COMBUSTION CONTROL (DCC) ............................................. 261

5-8 EXHAUST VENTILATION ........................................................................... 263

5-9 EXHAUST VALVES ..................................................................................... 265

5-10 FAILURE LIST ............................................................................................. 267

5-11 FAILURE SIMULATION ............................................................................... 269

5-12 FUEL SYSTEM ........................................................................................... 271

5-13 KNOCK CONTROL ..................................................................................... 273

5-14 LOG MESSAGES ........................................................................................ 275

5-15 MAIN FUEL INJECTION ............................................................................. 277

5-16 PERFORMANCE DATA DIESEL ................................................................. 279

5-17 PILOT FUEL INJECTION ............................................................................ 281

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5-18 PILOT FUEL PRESSURE ........................................................................... 283

5-19 SCAVENGE AIR - EWG (optional) .............................................................. 285

5-20 SOFTWARE INFO ....................................................................................... 289

5-21 IMO CRC INFO ........................................................................................... 291

5-22 SOFTWARE TOOLS ................................................................................... 293

5-23 SYSTEM STATUS ....................................................................................... 295

5-24 SYSTEM SETTINGS ................................................................................... 297

5-25 TEMPERATURES ....................................................................................... 299

5-26 USER PARAMETERS ................................................................................. 301

5-27 LOG ENTRY DATA ...................................................................................... 303

5-28 DATE ........................................................................................................... 305

5-29 ETHERNET ................................................................................................. 307

9 Troubleshooting

9-1 Supply pressure of the cylinder cooling water is too low ............................. 421

9-2 Supply temperature of the cylinder cooling water is too low ....................... 421

9-3 Cylinder cooling water temperature downstream of a cylinder is too high .. 421

9-4 Supply pressure of the cooling water to the SAC is too low ........................ 421

9-5 Supply temperature of the cooling water to the SAC is too low .................. 422

9-6 Temperature of the cooling water downstream of the SAC is too high ........ 422

9-7 Lubricating oil supply pressure at the engine inlet is too low ...................... 423

9-8 Lubricating oil supply pressure upstream of the injectors is too low ........... 423

9-9 Lubricating oil supply temperature at the engine inlet is too high ................ 423

9-10 Lubricating oil supply pressure upstream of the crossheads is too low ...... 423

9-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted

range ........................................................................................................... 423

9-12 Servo oil leakage flow from the servo oil supply unit is too high ................. 424

9-13 Servo oil flow at a servo oil pump inlet is too low ........................................ 424

9-14 Bearing oil temperature at a bearing outlet is too high ................................ 424

9-15 Oil mist concentration is too high ................................................................ 424

9-16 Piston cooling oil temperature downstream of a piston is too high ............. 425

9-17 Piston cooling oil flow to a piston is not in the permitted range ................... 425

9-18 TC bearing oil temperature at a turbocharger outlet is too high .................. 425

9-19 TC bearing oil supply pressure upstream of a turbocharger is too low ....... 425

9-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil

supply) ......................................................................................................... 425

9-21 Damper oil supply pressure upstream of the torsional vibration damper is

too low ......................................................................................................... 426

9-22 Damper oil supply pressure upstream of the axial vibration damper is too

low ............................................................................................................... 426

9-23 Cylinder oil supply pressure is too low ........................................................ 426

9-24 Cylinder oil flow is too low ........................................................................... 426

9-25 Fuel supply temperature is not in the permitted range ................................ 427

9-26 Fuel supply pressure at the engine inlet is too low ...................................... 427

9-27 Fuel leakage flow from the fuel supply unit is too high ................................ 427

9-28 Temperature difference of the fuel outlet of the two fuel pumps is too high

(for X35/-B or X40/-B engine) ...................................................................... 427

9-29 Leakage flow from the rail unit is too high ................................................... 427

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9-30 Fuel leakage flow from fuel rail items is too high (engine with FLV) ............ 427

9-31 Fuel leakage flow from fuel rail items is too high (engine with ICU) ............ 428

9-32 Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine) ....... 428

9-33 Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine) ........ 428

9-34 Gas concentration in piston underside is too high ....................................... 429

9-35 Difference pressure of pilot fuel filter is too high ......................................... 429

9-36 Gas supply pressure is too low ................................................................... 429

9-37 Exhaust gas temperature downstream of a cylinder is too high .................. 430

9-38 Exhaust gas temperature difference downstream of all cylinders is too

high .............................................................................................................. 430

9-39 Exhaust gas temperature upstream of a turbocharger is too high .............. 430

9-40 Exhaust gas temperature downstream of a turbocharger is too high .......... 431

9-41 Exhaust valve does not operate, unwanted noise ....................................... 431

9-42 Smoke is too dark ........................................................................................ 431

9-43 Scavenge air temperature in the receiver is too high .................................. 432

9-44 Scavenge air temperature in the receiver is too low ................................... 432

9-45 Scavenge air pressure is too high ............................................................... 432

9-46 Scavenge air pressure is too low ................................................................ 432

9-47 Condensation flow at a water separator is too high .................................... 433

9-48 Condensation flow upstream of a water separator is too high .................... 433

9-49 Scavenge air temperature in the piston underside is too high .................... 433

9-50 Starting air supply pressure is too low ......................................................... 433

9-51 Pressure of the air spring air supply is too high .......................................... 433

9-52 Pressure of the air spring air supply is too low ............................................ 434

9-53 Oil leakage flow in the collector for leakage oil from the air spring is too

high .............................................................................................................. 434

9-54 Control air supply pressure is too low (usual supply) .................................. 434

9-55 Control air supply pressure is too low (stand-by supply) ............................. 434

9-56 Control air supply pressure is too low (safety supply) ................................. 434

9-57 Temperature of a thrust bearing pad is too high .......................................... 435

9-58 Cylinder liner wall temperature is too high .................................................. 435

9-59 A fuel pump actuator has a failure ............................................................... 435

9-60 Power supply to the power supply box E85 has a failure ............................ 436

9-61 Unwanted engine speed decrease .............................................................. 436

9-62 Unwanted engine stop ................................................................................. 436

9-63 Examples of failure messages .................................................................... 438

9-64 Special failures ............................................................................................ 439

10 Technical data

10-1 General data ................................................................................................ 488

10-2 Rated power ................................................................................................ 489

10-3 Function code .............................................................................................. 492

10-4 Function group ............................................................................................ 493

10-5 Applied system ............................................................................................ 493

10-6 Cooling water systems (XX10NN to XX19NN) ............................................ 495

10-7 Oil systems (XX2NNN, part 1) ..................................................................... 496

10-8 Oil systems (XX2NNN, part 2) ..................................................................... 497

10-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil)) ........................... 498

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10-10 Oil systems (XX2NNN, part 4) ..................................................................... 499

10-11 Fuel system (XX34NN) ................................................................................ 500

10-12 Exhaust gas system (XX37NN) ................................................................... 501

10-13 Air systems (XX40NN to XX44NN) ............................................................. 502

10-14 Miscellaneous items (XX45NN to XX52NN) ................................................ 503

10-15 Failure messages ........................................................................................ 504

12 Schematic diagrams

12-1 Function code .............................................................................................. 514

12-2 Function group ............................................................................................ 515

12-3 Applied system ............................................................................................ 515

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List of illustrations

1 Introduction

1-1 Side view (generic) ...................................................................................... 31

1-2 Engine numbering (generic) ........................................................................ 32

2 Design and function of the engine

2-1 Pressure - volume diagram and schematic of the two-stroke diesel cycle .. 41

2-2 Operating range .......................................................................................... 42

2-3 Tuning options ............................................................................................. 44

2-4 Schematic diagram - Relation Speed/Power (FPP) .................................... 47

3 Design and function of the systems

3-1 Line codes for systems ................................................................................ 66

3-2 Cooling water system (generic and simplified) ............................................ 69

3-3 Wash-water system (generic and simplified) ............................................... 71

3-4 System oil system (generic and simplified) ................................................. 73

3-5 Starting air system (generic and simplified) ................................................ 79

3-6 Scavenge air system ................................................................................... 81

3-7 Fuel system with FLV (generic and simplified) ............................................ 88

3-8 Fuel system with ICU (generic and simplified) ............................................ 89

3-9 HP SCR system - layout .............................................................................. 91

3-10 HP SCR system - emergency bypass ......................................................... 93

3-11 HP SCR system - change from Tier III to bypass ........................................ 94

3-12 HP SCR system - purging and venting ........................................................ 95

3-13 HP SCR system - emergency bypass ......................................................... 96

3-14 HP SCR system - preparation ..................................................................... 97

3-15 HP SCR system - Tier III ............................................................................. 98

3-16 HP SCR system - principal control configuration ........................................ 99

3-17 Control box E48 ........................................................................................... 100

3-18 Control box E49 ........................................................................................... 101

3-19 Control box E50 ........................................................................................... 102

3-20 LDU-20 page - HP SCR SYSTEM STATUS (MAIN PAGE) ......................... 103

3-21 LDU-20 page - HP SCR SYSTEM OVERVIEW .......................................... 104

3-22 LDU-20 page - HP SCR INTERFACES ....................................................... 105

3-23 LDU-20 page - HP SCR MANUAL VALVE CONTROL ................................ 106

3-24 LDU-20 page - HP SCR SOFTWARE INFO ............................................... 107

3-25 LDU-20 page - HP SCR PAGE INDEX ....................................................... 108

3-26 LP SCR temperature controlled (example) ................................................. 111

3-27 LP SCR bypass rate controlled (example) .................................................. 112

3-28 LP SCR control system layout ..................................................................... 114

3-29 LP SCR system - principal control configuration ......................................... 115

3-30 Control box E70 with option SPC ................................................................ 116

3-31 Control box E71 with option SPC ................................................................ 117

3-32 Control boxes E72 and E73 ........................................................................ 118

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3-33 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) ......................... 119

3-34 LDU-20 page - LP SCR SYSTEM OVERVIEW ........................................... 120

3-35 LDU-20 page - LP SCR INTERFACES ....................................................... 121

3-36 LDU-20 page - LP SCR SOFTWARE INFO ................................................ 122

3-37 LDU-20 page - LP SCR PAGE INDEX ........................................................ 123

3-38 Example of SPC .......................................................................................... 124

3-39 LDU-20 page - STEAM PRODUCTION CONTROL .................................... 125

3-40 LDU for the steam boost mode ................................................................... 127

3-41 LDU-20 page for operation mode "Control On" ........................................... 131

3-42 LDU-20 page for adjusting the set point ...................................................... 132

3-43 LDU-20 page for operation mode "Off" ........................................................ 133

3-44 LDU-20 page for operation mode "Estimate Only" ...................................... 134

3-45 LDU-20 page for crank angle and speed states .......................................... 135

4 Design and function of the components

4-1 Bedplate (generic) ....................................................................................... 140

4-2 Main bearing (generic) ................................................................................ 142

4-3 Thrust bearing (generic) .............................................................................. 145

4-4 Monoblock column (generic) ....................................................................... 146

4-5 Tie rod (generic) .......................................................................................... 148

4-6 Cylinder - cooling water outlet (generic) ...................................................... 150

4-7 Lubricating quill (generic) ............................................................................ 152

4-8 Piston rod gland (generic) ........................................................................... 154

4-9 Starting valve (example) .............................................................................. 158

4-10 Exhaust valve (generic) ............................................................................... 160

4-11 Crankshaft (generic) .................................................................................... 162

4-12 Steel spring damper (generic) ..................................................................... 165

4-13 Viscous damper (generic) ........................................................................... 166

4-14 Axial vibration damper (generic) .................................................................. 168

4-15 Axial vibration damper monitor (generic) ..................................................... 169

4-16 Turning gear (generic) ................................................................................. 170

4-17 Connecting rod and connecting rod bearing (generic) ................................ 172

4-18 Crosshead and guide shoe (example) ........................................................ 174

4-19 Piston (example) ......................................................................................... 176

4-20 Supply unit drive (generic) ........................................................................... 179

4-21 Starting air shut-off valve (example) ............................................................ 180

4-22 Control air supply (generic) ......................................................................... 182

4-23 Local maneuvering stand (generic) ............................................................. 184

4-24 Pick-up for speed measurement (generic) .................................................. 186

4-25 Supply unit (example) .................................................................................. 190

4-26 Fuel pump (generic) .................................................................................... 192

4-27 Flow limiting valve (generic) ........................................................................ 196

4-28 Scavenge air receiver (example) ................................................................. 202

4-29 Scavenge air receiver - cross section (example) ........................................ 203

4-30 Turbocharger (example) .............................................................................. 204

4-31 Auxiliary blower (generic) ............................................................................ 206

4-32 Switch box (generic) .................................................................................... 208

4-33 Scavenge air cooler (generic) ..................................................................... 210

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4-34 Water separator (generic) ............................................................................ 212

4-35 Cylinder lubricating pump ............................................................................ 214

4-36 Effect of second order moments (M2v) of the engine ................................. 216

4-37 iELBA - function ........................................................................................... 217

4-38 iELBA - control cabinet ................................................................................ 219

4-39 Exhaust waste gate (generic) ...................................................................... 222

4-40 Crank angle sensor unit on flywheel (example) .......................................... 225

4-41 Water in oil monitor (generic) ...................................................................... 226

4-42 Oil mist detector (example) ......................................................................... 228

4-43 Oil mist detector - schematic diagram (example) ........................................ 229

5 Control system of the engine

5-1 ECS modules .............................................................................................. 233

5-2 Signal flow diagram ..................................................................................... 236

5-3 ICC - pressure diagram ............................................................................... 239

5-4 ICC - control schematic ............................................................................... 240

5-5 MAIN ........................................................................................................... 244

5-6 CONTROL LOCATIONS ............................................................................. 248

5-7 CA SENSOR STATUS ................................................................................. 250

5-8 CYLINDER BALANCING DIESEL ............................................................... 252

5-9 CYLINDER LUBRICATION ......................................................................... 254

5-10 iCAT (integrated Cylinder lubricant Auto Transfer) ...................................... 256

5-11 DYNAMIC COMBUSTION CONTROL (DCC) ............................................. 260

5-12 EXHAUST VENTILATION ........................................................................... 262

5-13 EXHAUST VALVES ..................................................................................... 264

5-14 FAILURE LIST ............................................................................................. 266

5-15 FAILURE SIMULATION ............................................................................... 268

5-16 FUEL SYSTEM ........................................................................................... 270

5-17 KNOCK CONTROL ..................................................................................... 272

5-18 LOG MESSAGES ........................................................................................ 274

5-19 MAIN FUEL INJECTION ............................................................................. 276

5-20 PERFORMANCE DATA DIESEL ................................................................. 278

5-21 PILOT FUEL INJECTION ............................................................................ 280

5-22 PILOT FUEL PRESSURE ........................................................................... 282

5-23 SCAVENGE AIR - EWG (optional) .............................................................. 284

5-24 SOFTWARE INFO ....................................................................................... 288

5-25 IMO CRC INFO ........................................................................................... 290

5-26 SOFTWARE TOOLS ................................................................................... 292

5-27 SYSTEM STATUS ....................................................................................... 294

5-28 SYSTEM SETTINGS ................................................................................... 296

5-29 TEMPERATURES ....................................................................................... 298

5-30 USER PARAMETERS ................................................................................. 300

5-31 LOG ENTRY DATA ...................................................................................... 302

5-32 DATE ........................................................................................................... 304

5-33 ETHERNET ................................................................................................. 306

5-34 LDU-20 - overview ....................................................................................... 308

5-35 LDU-20 color display - general items .......................................................... 309

5-36 LDU-20 - navigation menu .......................................................................... 311

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7 Operation of the engine

7-1 Cooling water system with bypass cooling .................................................. 324

7-2 Cooling water system without bypass cooling ............................................. 325

7-3 Cooling water system with circulation ......................................................... 326

7-4 Cylinder lubricant quantity ........................................................................... 350

7-5 Select: Prepare Tier III ................................................................................. 375

7-6 Select: Tier III .............................................................................................. 376

7-7 Select: Tier II ............................................................................................... 377

7-8 Allowed load during cylinder cut out ............................................................ 382

7-9 Turbocharger cut out procedure: Illustration 1 ............................................. 387

7-10 Turbocharger cut out procedure: Illustration 2 ............................................. 388

7-11 Turbocharger cut out procedure: Illustration 3 ............................................. 389

7-12 Turbocharger cut out procedure: Illustration 4 ............................................. 390

7-13 Turbocharger cut out procedure: Illustration 5 ............................................. 391

8 Service during operation

8-1 Location of ball valves - dirty oil samples .................................................... 397

8-2 Feed rate adjustments - running-in ............................................................. 400

8-3 SAC - clean during operation (example) ..................................................... 407

9 Troubleshooting

9-1 Example of inspection point ........................................................................ 441

9-2 Supply unit (example) and example of inspection point .............................. 445

9-3 Leakage on FLV and pipes (example) ......................................................... 453

9-4 Not all turbochargers are defective (example) ............................................ 461

9-5 All turbochargers are defective (example) ................................................... 462

9-6 SCR system - covers (example for 1 turbocharger) .................................... 473

9-7 SCR system - covers (example for 2 turbocharger) .................................... 474

9-8 SCR system - covers (example for 1 turbocharger) .................................... 477

9-9 SCR system - covers (example for 2 turbocharger) .................................... 478

10 Technical data

10-1 Operating range .......................................................................................... 489

10-2 Signal codes ................................................................................................ 492

12 Schematic diagrams

12-1 Line codes ................................................................................................... 512

12-2 Process codes ............................................................................................. 513

12-3 Signal codes ................................................................................................ 514

12-4 Color codes and symbols - electric connection diagram ............................. 516

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