WinGD X82 Operation Manual

Operation Manual

“Marine”

Vessel:

Type:

Engine No.:

Document ID: DBAC753771

Winterthur Gas & Diesel Ltd. 24hrs Support:

Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur

Switzerland

+41 52 262 80 10 technicalsupport.chts@wartsila.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.

Operation Manual

“Marine”

Vessel:

Type:

Engine No.:

Document ID: DBAC753771

Winterthur Gas & Diesel Ltd. 24hrs Support:

Schützenstrasse 1−3 Wärtsilä Services Switzerland Ltd. CH-8400 Winterthur Zürcherstrasse 12 Switzerland CH 8400 Winterthur

Switzerland

+41 52 262 80 10 technicalsupport.chts@wartsila.com

Winterthur Gas & Diesel Ltd. or Wärtsilä Services Switzerland Ltd. make no representation, warranty (express or implied) in this publication and assumes no responsibility for the correctness, errors or omissions for information contained herein. Information in this publication is subject to change without notice.

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THIS PUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new

exch.

2014 Operation Manual, Issue 2014

Date of publication 2014-08-19

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

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

0080-1/A1 Basic Engine Data Additional illustrat i ons added; x

0590-1/A1

Operation during Unusual

Conditions - Defective

Additional data for three turboc harger c onfiguration and

0710-1/A1 Diesel Engine Fuels Latest data, minor t ext c hanges x

4104-1/A1 Supply Drive Unit

Additional illustrat i on f or 9-cylinder engines added;

7218-1/A1 Cylinder Lubrication

page 2: Illustration schematic diagram f or 9-cylinder

8016-1/A2

Lubricating Oil System - 9-

page 4: New illustration added

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

9314-1/A1

Oil Mist Detector -

Schematic diagram updated; terminology updated x

9314-2/A1

Oil Mist Detector -

New chapter for 9-cylinder engines added x

Date of publication 2014-09-16

OM_2015-05 2015-05

Cover page, Disclaimer

Data about Wintert hur Gas & Diesel (Wi nGD) and Wärtsilä

8019-1/A1 2015-05

Fuel System - 6-cylinders

Fig. 5: Illustrati on updated;

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

Fig. 5: Illustrati on updated;

Date of publication 2015-06-09

0210-1/A1 2015-07

Safety Precautions and

paragraph 2: Warning about oil mist detector added;

0270-1/A1 2015-07

Service

Changing Over from

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

2014-09

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

Turbocharger

Table 1 added

illustrations updated

engines added page 13, 14: pressure transmi tter PT3139C added

cylinders

6-cylinder to 8-cylinder

9-cylinder

and all related pages

to 8-cylinders

page 5: Key to Fig. 1 updated page 8: New illustration added page 9: New illustration added; Key to Fig. 3 updated

Services Switzerland (W SCH) added; New Layout WinGD; Disclaimer updated (WinGD and WS CH added);

para 4.3 and 4.4: reference changed; para 4.4: procedure changed; alternative proc edure added; para 4.5: procedure changed; data about spare part kit added;

para 4.3 and 4.4: reference changed; para 4.4: procedure changed; alternative proc edure added; para 4.5: procedure changed; data about spare part kit added; all paragraphs: minor text changes and updates (e.g. position numbers);

Warnings (General Data)

Bulletin RT-82

Diesel Oil to Heavy Fuel Oil and Vice Versa

paragraph 8: Warning about hot part s added; paragraph 9: Warning about injury hazards added; paragraph 13: Warning about air run added;

related to the Service Bullet i n;

1/4 16/10/2017

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new

exch.

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

0710-1/A1 2015-07

EAAD085468

Service

Diesel Engine Fuels

Latest data from fuel specification added;

Note 2) to Fig. 1: min. val ue f or fuel viscosity changed from

0720-1/A1

2015-07

EAAD085468

Operating Media - Fuel

Fig. 1: Schemati c Diagram - Fuel System updated;

0750-1/A1 2015-07

Service

Operating Media

paragraph 2.1: additional data added

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

Document updated with latest data:

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

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

Document updated with latest data:

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

Bulletin RT-126

Table 1: maximum s ul f ur val ue changed from 4.5 to 3.5 m/m[%]; Fig. 1: Viscosi t y/ T emperature Diagram updated;

13 cSt to 10 cSt; Table 2: Pour point (upper) winter max. value changed from 0 to -6; Carbon residue m ax. value removed; minor changes in the text; Data about Wärtsi l ä Service Switzerland Ltd and Wi nGD added;

EAAD085894

Bulletins RT-138 (Version 4) RT-138_1 (Version 4) RT-161

Treatment and Fuel System

Key to Fig. 1: Item s 31, 32, 33 added; para 3: minor text changes; para 4: text changed; data about additional leakage collection tank added; Structure of the document changed;

Table 1: data FZG gear machine test added Table 2: data FZG gear machine test added paragraph 2.4: Sample point added paragraph 3.1: updated Fig. 1: illustrati on updat ed paragraph 3.2: new data and Fig. 2 added paragraph 3.3: new paragraph added paragraph 3.4: new paragraph added paragraph 7: new paragraph added paragraph 8.1: new paragraph added paragraph 8.2: list of approved lubricat i ng oi l s updated paragraph 8.3: new table added added Chapter updated (latest data from Revision 4 of the Service Bulletin RT-138); Fig. 1 and Fig. 2: new illustrati on with l atest data; Table 4: List of Validat ed Lubri cating Oils updated (latest data from January 2015); Table 5: List of Validat ed System Oils updated (latest data from January 2015);

4.23 and accumulator added;

-Check point 3.17 top of ICU removed.

4.23 and accumulator added and connection L2 with T2042A, PI2042L, 8.11-2 removed;

-At cylinder lubrication c onnection L2 remov

onnected the two servo oil pipes to one pipe.

2/4 16/10/2017

ed and

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new

exch.

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

4003-3/A1 2015-01 EAAD085118

Control and Auxiliary

Systems

Document updated with latest data:

Date of publication 2015-07-28

0050-1/A1 2017-08

Update WinGD

Short Description of the Engine

Minor text changes x

0120-1/A1 2017-08

Update

Prepare the Fuel System

Correction of References to Fi g 1; Chapter 3.2 Leak Test

0120-1/A2 2017-08

Update

Prepare the Fuel System

Correction of References to Fi g 1; Chapter 3.2 Leak Test

0250-1/A1 2017-04

Update

Operating Data Sheet

Torisional vibration damper (damper inlet):

0250-2/A1 2017-04

Update

Operating Data Sheet

PT2711A: ALM value changed from 1. 5 bar to 2.2 bar;

0270-1/A1 2017-08

Update WinGD

Change-over from HFO to MDO and back

Changed description and changed procedure x

0410-1/A1 2017-08

Update

Running in of New

Changed procedure for running-in x

0710-1/A1 2017-08

Update

Diesel Engine Fuels Text changed for Fuel additives x

0750-1/A1 2017-08

Update

Lubricating Oil

Update according to Service Bull etin (Text changes, Particle Count; new Tables 4 and 5, updated F i gures 1 and

1203-1/A1 2017-08

Update WinGD

Thrust Bearing Minor text changes, Section 1.1 deleted x

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

3326-1/A1 2017-08 EAAD086618

Crosshead and Guide Shoe

Text changed; Fig. 1 updated with shorter Guide rail s x

4003-1/A1 2017-08

Update

Engine Control

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

4325-1/A1 2017-08

Update

Starting Air Shut-off

Steps 2 to 6 deleted x

5556-2/A1 2017-08

Update

Fuel Pump - Cutting Out

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

5583-1/A1 2017-08

Update WinGD

Fuel Pump Actuator Update drawing x

-Page 11: PT2041A, PI2041L, 8. 11-1 have been removed.

Address 313 has been changed to 314;

-Page 12: PT2041A, PI2041L, 8. 11-1, PT2042A, PI2042L,

8.11-2 and connection 319 have been removed. Addres s

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

-Page 13: All signals relat ed to the turbocharger updated;

-Page 14: All signals relat ed to the turbocharger updated;

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

4.23 added;

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

4.23 added. Connection 319 has been removed;

-Page 19,20: Check point 3.17 t op of ICU has

emoved;

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

MK7.

been

WinGD

for Operation

Pressure and Temperature Ranges

Alarms and Safeguards

Cylinder Liners and Piston Rings

deleted

Min. pressure value changed from 1.0 bar to

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

Note added;

Medium name changed to 'Tors i onal vibration damper oil (steel spring damper)'; Note 5 changed

2, updated Tables 6 and 7)

WinGD

Valve

and Cutting In

step 2 deleted; Para 4.11: s t ep 2 changed, step 3 added; Para 4.12.1: step 4 changed

step 6 to 10)

3/4 16/10/2017

Summary for Operation Manual (OM)

Page No. Title Subject

Date No.

new

exch.

Manual

Page or

Modification Service

Engine Documentation

Modification

W-X82

6510-1/A1 2017-08

Update

WinGD

Cleaning the

Minor text changes (only cleaning of com pressor) x

6606-1/A1 2017-08

Update WinGD

Operating Instructions and Cleaning

Fig. 1 FW line changed x

6735-1/A1 2017-08

Update

Scavenge Air Was te

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

7218-3/A1 2017-08

Update WinGD

Feed Rate - Adjustment Updates according to Service B ul l etin x

Date of publication 2017-10-16

Turbocharger during Operation

WinGD

Gate

value; Table 1 Corrections; In paragraph 2. 1 l ast two sentences deleted.

4/4 16/10/2017

Operating Descriptions

Bedplate and Tie Rod

Cylinder Liner and Cylinder Cover

Crankshaft, Connecting Rod and Piston

Engine Control and Control Elements

Supply Unit, Servo Oil Pump and Fuel Pump

Scavenge Air System

Cylinder Lubrication

Piping Systems

OM / X82 / Register

Engine Monitoring

Intentionally blank

Operation

Group0

Operating Descriptions Group 0

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

General

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

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

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

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

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

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

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

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

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

Prepare the Engine for Operation

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

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

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

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

Operation during Usual Conditions

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

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

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

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

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

Operating Data Sheet

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

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

Operation

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

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

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

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

Engine Shutdown

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

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

Special Procedures

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

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

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

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

Winterthur Gas & Diesel Ltd. X82 / OM / 2014

Winterthur Gas & Diesel Ltd.

1/ 1

OperationGroup0

Operation during Unusual Conditions

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

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

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

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

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

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

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

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

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

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

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

Special Procedures Before and After Operation

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

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

Operation Media

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

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

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

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

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

Problems during Operation

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

Problems During Engine Start and Stop

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

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

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

0810−1/A1................................................

X82 / OM / 2014 Winterthur Gas & Diesel Ltd.

2/ 1

Winterthur Gas & Diesel Ltd.

For Your Attention

1. General

This manual is for the operator and is for use only for the related type of diesel engine (the engine described in this manual). The data in this manual is confidential.

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

Make sure that you know the Inspection and Overhaul intervals in the Maintenance Manual before you operate the engine.

Make sure that you read the data in Group 0 in the Maintenance Manual before you do maintenance work on the engine.

2. Spare Parts

Use only original spare parts and components to make sure that the engine will continue to operate satisfactorily. All equipment and tools for maintenance and operation must be serviceable and in good condition.

Operation

0000−1/A1

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

3. Data

The specifications and recommendations of the classification societies, which are essential for the design, are included in this manual.

The data, instructions, graphics and illustrations etc. in this manual are related to drawings from Winterthur Gas & Diesel Ltd. (WinGD). These data relate to the date of issue of the manual (the year of the issue is shown on the title page). All instructions, graphics and illustrations etc can change because of continuous new development and modifications.

4. Personnel

Only qualified personnel that have the applicable knowledge and training must do work on the engine, its systems and related auxiliary equipment.

Data related to protection against danger and damage to equipment are specified in this manual as Warnings and Cautions.

Winterthur Gas & Diesel Ltd.

1/ 1

2014

Intentionally blank

General

Operation

Preface

5. Technical Documentation Set

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

5.1 Operation Manual

The operation manual contains data about engine operation, the necessary operating media (oil, water and fuel) and descriptions of the components and systems. The manual also gives troubleshooting procedures.

5.2 Maintenance Manual

The maintenance manual contains data about disassembly / assembly procedures that are necessary for the engine maintenance and the maintenance schedule. This manual gives more data about the masses (weight) of components, a clearance table, tightening values for important screw connections and a tool list.

0010−1/A1

5.3 Code Book (spare parts catalogue)

In the code book all parts of the engine are marked with a unique code number. The code number is necessary to order spare parts from Winterthur Gas & Diesel Ltd. (WinGD) or the engine supplier. The spare parts can only be ordered with the code number from the code book.

5.4 External Supplier Documentation

The documentation from external suppliers gives data about the parts of the engine that are not supplied by Winterthur Gas & Diesel Ltd (WinGD), such as turbocharger, automatic filter, torsional or vibration damper. Most of this documentation also contains data about spare parts.

5.5 Records and Drawings

The setting tables, shop trial documents, schematic diagrams and survey certificates of the related engine are given with the first supply of the documentation.

6. Manual Structure

The manual is divided into different groups. Each group contains data about components or systems referred to in the design groups.

The manuals give data about the standard engine with all cylinder numbers, alternative designs and special equipment.

Winterthur Gas & Diesel Ltd.

The documentation for alternative engine designs are separated into different chapters with the related design name.

1/ 3

2014

Preface

Operation0010−1/A1

6.1 Structure of the Manual

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

Title

Subtitle

Engine type (Version)

W-X62

Manual type

0peration

Group No.

1132−1/A1

− − − − −

Design variant

Variant description

2014

Winterthur Gas & Diesel Ltd 1 / 4

Page number

Total pages of group

2/ 3

2015

2015-05

Year of issue

(or)

Modification date

Winterthur Gas & Diesel Ltd.

Preface

Operation

6.2 Symbols

This symbol shows that the text is safety related. The signal word WARNING is used to show a hazardous condition. If ignored, these conditions could cause serious injury or death to personnel.

This symbol shows that the text is safety related. The signal word CAUTION is used to show a potentially hazardous condition. If ignored, these conditions could cause minor injury to personnel, or damage to engine components.

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

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

7. Technical Documentation

0010−1/A1

WARNING

CAUTION

Because of the continuous development of the engine, the technical documentation also changes and is regularly updated. The modification service leaflet on the first page of the manual shows all changes.

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

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

D Engine type, year of manufacture and engine manufacturer

D Name of vessel or site of installation

D Cylinder or engine number

D Special equipment

D Document type (printed manuals or CD).

Winterthur Gas & Diesel Ltd.

3/ 3

2014

Intentionally blank

Operation

0020−1/A1

Table of Contents