OM - WinGD X92 B - 2021 11

Operation Manual
X92-B
Issue 002 2021-11
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
© 2021 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,
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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.
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X92-B
Operation Manual
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 Safety
2.1 Safety precautions and safety guidelines..................................................................40
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..................................................................................................68
4.2 Cooling water system................................................................................................70
4.3 Wash-water system...................................................................................................72
4.4 System oil system......................................................................................................74
4.5 Servo oil system........................................................................................................76
4.6 Cylinder oil system....................................................................................................78
4.7 Starting air system.....................................................................................................80
4.8 Scavenge air system.................................................................................................82
4.9 Control air system......................................................................................................84
4.10 Exhaust gas system..................................................................................................86
4.11 Fuel system...............................................................................................................88
4.12 LP Selective catalytic reduction system....................................................................92
4.13 Steam production control system............................................................................106
5 Design and function of components
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X92-B
Operation Manual
5.1 Group 1 - Engine frame and bearings

5.1.1 Bedplate..........................................................................................................114
5.1.2 Main bearing....................................................................................................116
5.1.3 Thrust bearing.................................................................................................118
5.1.4 Monoblock column...........................................................................................120
5.1.5 Tie rod.............................................................................................................122
5.2 Group 2 - Cylinder
5.2.1 Cylinder liner....................................................................................................124
5.2.2 Lubricating quill................................................................................................126
5.2.3 Piston rod gland...............................................................................................128
5.2.4 Direct controlled injection valve.......................................................................130
5.2.5 Starting valve...................................................................................................132
5.2.6 Exhaust valve..................................................................................................134
5.3 Group 3 - Crankshaft, connecting rod and piston
5.3.1 Crankshaft.......................................................................................................136
5.3.2 Torsional vibration damper..............................................................................138
5.3.3 Axial vibration damper.....................................................................................142
5.3.4 Turning gear....................................................................................................144
5.3.5 Connecting rod and connecting rod bearing....................................................146
5.3.6 Crosshead and guide shoe..............................................................................148
5.3.7 Piston...............................................................................................................150
5.4 Group 4 - Supply unit drive and control components
5.4.1 Supply unit drive..............................................................................................152
5.4.2 Starting air shut-off valve.................................................................................154
5.4.3 Control air supply.............................................................................................156
5.4.4 Local maneuvering stand for UNIC.................................................................158
5.4.5 Pick-up for speed measurement......................................................................160
5.5 Group 5 - Supply unit, pumps and control valves
5.5.1 Servo oil pump.................................................................................................162
5.5.2 Supply unit.......................................................................................................164
5.5.3 Fuel pump........................................................................................................166
5.5.4 Pressure control valve.....................................................................................168
5.5.5 Flow limiting valve...........................................................................................170
5.5.6 Exhaust valve control unit................................................................................172
5.5.7 Fuel pump actuator..........................................................................................174
5.6 Group 6 - Scavenge air components
5.6.1 Scavenge air receiver......................................................................................176
5.6.2 Turbocharger...................................................................................................178
5.6.3 Auxiliary blower...............................................................................................180
5.6.4 Auxiliary blower switch box..............................................................................182
5.6.5 Scavenge air cooler.........................................................................................184
5.6.6 Water separator...............................................................................................186
5.7 Group 7 - Cylinder lubrication and balancer

X92-B
Operation Manual
5.7.1 Cylinder lubrication..........................................................................................188

5.7.2 Integrated electrical balancer (iELBA).............................................................190
5.8 Group 8 - Pipes
5.8.1 Exhaust waste gate.........................................................................................196
5.9 Group 9 - Monitoring instruments
5.9.1 Crank angle sensor unit...................................................................................198
5.9.2 Water in oil monitor..........................................................................................200
5.9.3 Oil mist detector...............................................................................................202
6 Control system
6.1 Engine control system WiCE...................................................................................206
6.2 Intelligent combustion control..................................................................................210
6.3 Integrated gas pressure regulation..........................................................................214
6.4 Local display unit (LDU-20) - general......................................................................218
6.5 LDU-20 page - iELBA Control (optional).................................................................220
6.6 Manual Control Panel (MCP) - Option for WiCE
6.6.1 Operate the manual control panel (MCP)........................................................222
6.6.2 MCP page - MAIN...........................................................................................226
6.6.3 MCP page - Adjust user parameters...............................................................228
6.6.4 MCP page - SYSTEM INFO - Option for WiCE...............................................232
6.6.5 MCP page - TREND - Option for WiCE...........................................................234
6.6.6 MCP page - INSTRUMENTS..........................................................................236
6.6.7 MCP page - FUEL / LUBRICATION SYSTEM................................................238
7 Installation
7.1 Installation...............................................................................................................242
8 Operation
8.1 Prepare the engine before start - general................................................................244
8.2 Prepare the engine before start...............................................................................246
8.3 Start the engine - general........................................................................................254
8.4 Start the engine.......................................................................................................256
8.5 Do checks during operation - general......................................................................258
8.6 Do checks during operation.....................................................................................260
8.7 Do regular safety checks.........................................................................................264
8.8 Maneuver the ship - general....................................................................................268
8.9 Maneuver the ship...................................................................................................270
8.10 Change-over the diesel fuel - general.....................................................................272
8.11 Change-over the diesel fuel automatically...............................................................276
8.12 Change-over from HFO to MDO manually..............................................................278
8.13 Change-over from MDO to HFO manually..............................................................280
8.14 Stop the engine - general........................................................................................282
8.15 Stop the engine.......................................................................................................284

X92-B
Operation Manual
8.16 Emergency stop the engine - general......................................................................286

8.17 Emergency stop the engine.....................................................................................288
8.18 Prepare the engine after stop - general...................................................................290
8.19 Prepare the engine for standstill or for maintenance...............................................292
9 Service during operation

9.1 Do an analysis of the system oil..............................................................................298
9.2 Do an analysis of the cylinder oil.............................................................................300
9.3 Replace the filter element of the duplex filter..........................................................304
9.4 Clean the turbocharger during operation.................................................................306
9.5 Clean the scavenge air cooler during operation......................................................308
9.6 Do a test of the exhaust waste valve.......................................................................312
10 Troubleshooting and Special running condition

10.1 Troubleshooting - general data................................................................................316
10.2 Malfunctions of systems and components...............................................................318
10.3 Failures and defects of UNIC-flex components.......................................................338
10.4 Examine the supply unit for servo oil leakage.........................................................340
10.5 Examine the supply unit for fuel leakage.................................................................344
10.6 Examine the rail unit for leakage.............................................................................348
10.7 Examine the FLV or fuel pipes for fuel leakage.......................................................350
10.8 Temporary cut out a defective injection valve.........................................................354
10.9 Temporary cut out a defective exhaust valve drive.................................................356
10.10 Temporary isolate a cylinder with cooling water leakage........................................358
10.11 Servo oil pump - troubleshooting.............................................................................362
10.12 Servo oil pump - Calibration for Dynex pump..........................................................364
10.13 Servo oil pump - Calibration for Bosch pump..........................................................366
10.14 Servo oil pump - Calibration for Hawe pump...........................................................368
10.15 Fuel pump - cutting out............................................................................................370
10.16 Fuel pump - cutting in..............................................................................................376
10.17 Temporary isolate a defective turbocharger............................................................380
10.18 Temporary isolate the exhaust waste gate..............................................................384
10.19 Isolate a defective engine at twin engine installation...............................................388
10.20 WiCE - Gateway Unit (GTU) replace.......................................................................390
10.21 WiCE - Main Control Unit (MCU) replace................................................................392
10.22 WiCE - Cylinder Control Unit (CCU) module replacement......................................394
10.23 WiCE - Angle Control Unit (ACM20) module replacment........................................396
10.24 WiCE - Manual Control Panel (MCP) replacement.................................................398
10.25 WiCE module - troubleshooting...............................................................................400
10.26 Special running condition: Turbocharger cut out.....................................................402
10.27 Special running condition: Cylinder cut out.............................................................410
11 Technical data

X92-B
Operation Manual
11.1 Engine data.............................................................................................................416

11.2 List of usual values and safeguard settings - general.............................................418
11.3 List of usual values and safeguard settings.............................................................422
11.4 Section views...........................................................................................................434
12 Operating media
12.1 General for operating media....................................................................................436
12.2 Compressed air.......................................................................................................438
12.3 Scavenge air............................................................................................................440
12.4 Diesel engine fuels..................................................................................................442
13 Attachments
13.1 Schematic diagrams - general.................................................................................456

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Operation Manual
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X92-B
Operation Manual
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

4-1 LP SCR SYSTEM STATUS (MAIN PAGE) ................................................. 101
4-2 LP SCR SYSTEM OVERVIEW ................................................................... 102
4-3 LP SCR INTERFACES ................................................................................ 103
4-4 LP SCR SOFTWARE INFO ........................................................................ 104
4-5 LP SCR PAGE INDEX ................................................................................ 105
4-6 STEAM PRODUCTION CONTROL (SPC) ................................................. 107

5-1 iELBA - control cabinet ................................................................................ 194
5-2 iELBA - error indication ............................................................................... 195
6 Control system
6-1 iELBA Control .............................................................................................. 221
6-2 MAIN ........................................................................................................... 227
6-3 SYSTEM INFO ............................................................................................ 232
6-4 TREND ........................................................................................................ 234
6-5 INSTRUMENTS .......................................................................................... 236
6-6 FUEL / LUBRICATION SYSTEM ................................................................ 239

10-1 Supply pressure of the cylinder cooling water is too low ............................. 321
10-2 Supply temperature of the cylinder cooling water is too low ....................... 321
10-3 Cylinder cooling water temperature downstream of a cylinder is too high . . 321
10-4 Supply pressure of the cooling water to the SAC is too low ........................ 321
10-5 Supply temperature of the cooling water to the SAC is too low .................. 322
10-6 Temperature of the cooling water downstream of the SAC is too high ....... 322
10-7 Lubricating oil supply pressure at the engine inlet is too low ...................... 323
10-8 Lubricating oil supply pressure upstream of the injectors is too low ........... 323
10-9 Lubricating oil supply temperature at the engine inlet is too high ................ 323
10-10 Lubricating oil supply pressure upstream of the crossheads is too low ...... 323
10-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted
range .......................................................................................................... 323
10-12 Servo oil leakage flow from the servo oil supply unit is too high ................. 324
10-13 Servo oil flow at a servo oil pump inlet is too low ........................................ 324
10-14 Bearing oil temperature at a bearing outlet is too high ................................ 324
10-15 Oil mist concentration is too high ................................................................ 324

X92-B
Operation Manual
10-16 Piston cooling oil temperature downstream of a piston is too high ............. 325
10-17 Piston cooling oil flow to a piston is not in the permitted range ................... 325
10-18 TC bearing oil temperature at a turbocharger outlet is too high .................. 325
10-19 TC bearing oil supply pressure upstream of a turbocharger is too low ....... 325
10-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil
supply) ........................................................................................................ 325
10-21 Damper oil supply pressure upstream of the torsional vibration damper is
too low ......................................................................................................... 326
10-22 Damper oil supply pressure upstream of the axial vibration damper is too
low ............................................................................................................... 326
10-23 Cylinder oil supply pressure is too low ........................................................ 326
10-24 Cylinder oil flow is too low ........................................................................... 326
10-25 Fuel supply temperature is not in the permitted range ................................ 327
10-26 Fuel supply pressure at the engine inlet is too low ...................................... 327
10-27 Fuel leakage flow from the fuel supply unit is too high ................................ 327
10-28 Temperature difference of the fuel outlet of the two fuel pumps is too high
(for X35/-B or X40/-B engine) ...................................................................... 327
10-29 Leakage flow from the rail unit is too high ................................................... 327
10-30 Fuel leakage flow from fuel rail items is too high (engine with FLV) ........... 327
10-31 Fuel leakage flow from fuel rail items is too high (engine with ICU) ............ 328
10-32 Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine) ....... 328
10-33 Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine) ........ 328
10-34 Gas concentration in piston underside is too high ....................................... 329
10-35 Difference pressure of pilot fuel filter is too high ......................................... 329
10-36 Gas supply pressure is too low ................................................................... 329
10-37 Exhaust gas temperature downstream of a cylinder is too high .................. 330
10-38 Exhaust gas temperature difference downstream of all cylinders is too
high .............................................................................................................. 330
10-39 Exhaust gas temperature upstream of a turbocharger is too high .............. 330
10-40 Exhaust gas temperature downstream of a turbocharger is too high .......... 331
10-41 Exhaust valve does not operate, unwanted noise ....................................... 331
10-42 Smoke is too dark ........................................................................................ 331
10-43 Scavenge air temperature in the receiver is too high .................................. 332
10-44 Scavenge air temperature in the receiver is too low ................................... 332
10-45 Scavenge air pressure is too high ............................................................... 332
10-46 Scavenge air pressure is too low ................................................................ 332
10-47 Condensation flow at a water separator is too high .................................... 333
10-48 Condensation flow upstream of a water separator is too high .................... 333
10-49 Scavenge air temperature in the piston underside is too high .................... 333
10-50 Starting air supply pressure is too low ......................................................... 333
10-51 Pressure of the air spring air supply is too high .......................................... 333
10-52 Pressure of the air spring air supply is too low ............................................ 334
10-53 Oil leakage flow in the collector for leakage oil from the air spring is too
high .............................................................................................................. 334
10-54 Control air supply pressure is too low (usual supply) .................................. 334
10-55 Control air supply pressure is too low (stand-by supply) ............................. 334
10-56 Control air supply pressure is too low (safety supply) ................................. 334
10-57 Temperature of a thrust bearing pad is too high ......................................... 335
Winterthur Gas & Diesel Ltd. - 10 - Issue 002 2021-11

X92-B
Operation Manual
10-58 Cylinder liner wall temperature is too high .................................................. 335

10-59 A fuel pump actuator has a failure ............................................................... 335
10-60 Power supply to the power supply box E85 has a failure ............................ 336
10-61 Unwanted engine speed decrease .............................................................. 336
10-62 Unwanted engine stop ................................................................................. 336
10-63 Examples of failure messages .................................................................... 338
10-64 Special failures ............................................................................................ 339
10-65 GTU - Control module configuration ............................................................ 391
10-66 MCU - Control module configuration ........................................................... 393
10-67 CCU control module configuration .............................................................. 394
10-68 WiCE module warning indication on the LDU-20 panel .............................. 400
11 Technical data
11-1 General data ................................................................................................ 416
11-2 Rated power ................................................................................................ 417
11-3 Function code .............................................................................................. 420
11-4 Function group ............................................................................................ 421
11-5 Applied system ............................................................................................ 421
11-6 Cooling water systems (XX10NN to XX19NN) ............................................ 423
11-7 Oil systems (XX2NNN, part 1) ..................................................................... 424
11-8 Oil systems (XX2NNN, part 2) ..................................................................... 425
11-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil)) .......................... 426
11-10 Oil systems (XX2NNN, part 4) .................................................................... 427
11-11 Fuel system (XX34NN) ............................................................................... 428
11-12 Exhaust gas system (XX37NN) .................................................................. 429
11-13 Air systems (XX40NN to XX44NN) ............................................................ 430
11-14 Miscellaneous items (XX45NN to XX52NN) ............................................... 431
11-15 Failure messages ....................................................................................... 432
12 Operating media
12-1 Specifications for HFO ............................................................................... 444
12-2 Specifications for distillate fuels ................................................................. 449
13 Attachments
13-1 Function code ............................................................................................. 458
13-2 Function group ........................................................................................... 459
13-3 Applied system ........................................................................................... 459

X92-B
Operation Manual

X92-B
Operation Manual
List of illustrations
1 Introduction
1-1 Side view (generic) ...................................................................................... 31
1-2 Engine numbering (generic) ........................................................................ 32

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 Schematic diagram - Relation Speed/Power (FPP) .................................... 65

4-1 Line codes for systems ................................................................................ 68
4-2 Cooling water system (generic and simplified) ............................................ 71
4-3 Wash-water system (generic and simplified) ............................................... 73
4-4 System oil system (generic and simplified) ................................................. 75
4-5 Servo oil system (generic and simplified) .................................................... 77
4-6 Cylinder oil system (generic and simplified, with and without iCAT) ........... 79
4-7 Starting air system (generic and simplified) ................................................ 81
4-8 Scavenge air system ................................................................................... 83
4-9 Control air system (generic and simplified) ................................................. 85
4-10 Exhaust gas system (generic and simplified) .............................................. 87
4-11 Fuel system with FLV (generic and simplified) ............................................ 90
4-12 Fuel system with ICU (generic and simplified) ............................................ 91
4-13 LP SCR temperature controlled (example) ................................................. 93
4-14 LP SCR bypass rate controlled (example) .................................................. 94
4-15 LP SCR control system layout ..................................................................... 96
4-16 LP SCR system - principal control configuration ......................................... 97
4-17 Control box E70 with option SPC ................................................................ 98
4-18 Control box E71 with option SPC ................................................................ 99
4-19 Control boxes E72 and E73 ........................................................................ 100
4-20 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE) ........................ 101
4-21 LDU-20 page - LP SCR SYSTEM OVERVIEW ........................................... 102
4-22 LDU-20 page - LP SCR INTERFACES ....................................................... 103
4-23 LDU-20 page - LP SCR SOFTWARE INFO ................................................ 104
4-24 LDU-20 page - LP SCR PAGE INDEX ........................................................ 105
4-25 Example of SPC .......................................................................................... 106
4-26 LDU-20 page - STEAM PRODUCTION CONTROL .................................... 107
4-27 LDU for the steam boost mode ................................................................... 109

5-1 Bedplate (generic) ....................................................................................... 114
5-2 Main bearing (generic) ................................................................................ 116
5-3 Thrust bearing (generic) .............................................................................. 119

X92-B
Operation Manual
5-4 Monoblock column (generic) ....................................................................... 120

5-5 Tie rod (generic) .......................................................................................... 122
5-6 Cylinder - cooling water outlet (generic) ...................................................... 124
5-7 Lubricating quill (generic) ............................................................................ 126
5-8 Piston rod gland (generic) ........................................................................... 128
5-9 Starting valve (example) .............................................................................. 132
5-10 Exhaust valve (generic) ............................................................................... 134
5-11 Crankshaft (generic) .................................................................................... 136
5-12 Steel spring damper (generic) ..................................................................... 139
5-13 Viscous damper (generic) ........................................................................... 140
5-14 Axial vibration damper (generic) .................................................................. 142
5-15 Axial vibration damper monitor (generic) ..................................................... 143
5-16 Turning gear (generic) ................................................................................. 144
5-17 Connecting rod and connecting rod bearing (generic) ................................ 146
5-18 Crosshead and guide shoe (example) ........................................................ 148
5-19 Piston (example) ......................................................................................... 150
5-20 Supply unit drive (generic) ........................................................................... 153
5-21 Starting air shut-off valve (example) ............................................................ 154
5-22 Control air supply (generic) ......................................................................... 156
5-23 Local maneuvering stand (generic) ............................................................. 158
5-24 Pick-up for speed measurement (generic) .................................................. 160
5-25 Servo oil pump (example) ........................................................................... 162
5-26 Supply unit (example) .................................................................................. 164
5-27 Fuel pump (generic) .................................................................................... 166
5-28 Fuel pump - cross section (example) .......................................................... 167
5-29 Pressure control valve - location (example) ................................................ 169
5-30 Flow limiting valve (generic) ........................................................................ 170
5-31 Exhaust valve control unit (VCU) (example) ............................................... 172
5-32 Scavenge air receiver (example) ................................................................. 176
5-33 Scavenge air receiver - cross section (example) ........................................ 177
5-34 Turbocharger (example) .............................................................................. 178
5-35 Auxiliary blower ........................................................................................... 180
5-36 Switch box ................................................................................................... 182
5-37 Scavenge air cooler (generic) ..................................................................... 184
5-38 Water separator (generic) ........................................................................... 186
5-39 Effect of second order moments (M2v) of the engine ................................. 190
5-40 iELBA - function ........................................................................................... 191
5-41 iELBA - control cabinet ................................................................................ 193
5-42 Exhaust waste gate (generic) ...................................................................... 196
5-43 Crank angle sensor unit on intermediate wheel (example) ......................... 198
5-44 Crank angle sensor unit on flywheel (example) .......................................... 199
5-45 Water in oil monitor (generic) ...................................................................... 200
5-46 Oil mist detector (example) ......................................................................... 202
5-47 Oil mist detector - schematic diagram (example) ........................................ 203
6 Control system
6-1 ICC - pressure diagram ............................................................................... 211
6-2 ICC - control schematic ............................................................................... 212

X92-B
Operation Manual
6-3 iGPR - schematic diagram .......................................................................... 214

6-4 LDU-20 - overview ....................................................................................... 218
6-5 LDU-20 color display - general items .......................................................... 219
6-6 iELBA Control .............................................................................................. 220
6-7 MCP page - MAIN locked ............................................................................ 223
6-8 MCP page - MAIN ....................................................................................... 226
6-9 MCP page - Open user parameters ............................................................ 228
6-10 MCP page - Select user parameter ............................................................. 229
6-11 MCP page - Adjust user parameter ............................................................. 230
6-12 MCP page - SYSTEM INFO ........................................................................ 232
6-13 MCP page - TREND .................................................................................... 234
6-14 MCP page - INSTRUMENTS ...................................................................... 236
6-15 MCP page - FUEL / LUBRICATION SYSTEM ............................................ 238
8 Operation
8-1 Cooling water system with bypass cooling ................................................. 248
8-2 Cooling water system without bypass cooling ............................................ 249
8-3 Cooling water system with circulation ........................................................ 250
8-4 Cylinder lubricant quantity .......................................................................... 274

9-1 Location of ball valves - dirty oil samples ................................................... 301
9-2 SAC - clean during operation (example) .................................................... 309

10-1 Example of inspection point ....................................................................... 341
10-2 Supply unit (example) and example of inspection point ............................. 345
10-3 Leakage on FLV and pipes (example) ....................................................... 351
10-4 Exhaust valve with pressure element ......................................................... 359
10-5 Location of flanges ..................................................................................... 372
10-6 Roller lifting tool assembly .......................................................................... 373
10-7 Pre-tensioner install .................................................................................... 374
10-8 Location of flanges ..................................................................................... 378
10-9 Assembly of roller lifter tool ........................................................................ 379
10-10 Not all turbochargers are defective (example) ........................................... 381
10-11 All turbochargers are defective (example) .................................................. 382
10-12 Exhaust waste gate (example) ................................................................... 385
10-13 WiCE - Gateway Unt (GTU) replacement .................................................. 391
10-14 WiCE - Main Control Unit (MCU) module replacement .............................. 393
10-15 WiCE - Cylinder Control Unit (CCU) module replacement ......................... 395
10-16 WiCE - Angle Control Unit (ACM20) module replacement ......................... 397
10-17 WiCE - Manual Control Panel (MCP) replacement - E26 ........................... 399
10-18 WiCE - Manual Control Panel (MCP) replacement - Back Cover .............. 399
10-19 Turbocharger cut out procedure: Illustration 1 ........................................... 405

X92-B
Operation Manual

10-24 Allowed load during cylinder cut out ........................................................... 414
11 Technical data
11-1 Operating range ......................................................................................... 417
11-2 Signal codes ............................................................................................... 420
12 Operating media
12-1 Viscosity / Temperature diagram ................................................................ 446
13 Attachments
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

X92-B
Operation Manual
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

X92-B AA00-0000-00AAA-003A-A
Operation Manual Operation Manual - change record
1.1 Operation Manual - change record

Tab 1-1 Change record
New issue 002, 2021-11
- Rewritten introductory pages with additional explanations.
- Updated safety precautions and safety guidelines.
- Updated description of access to engine spaces.
- Updated descriptions of the design and function of the engine.
- Updated descriptions of the design and function of the systems.
- Updated descriptions of the design and function of the components.
- Updated the control system section.
- Updated the operation section.
- Updated the service during operation section.
- Added new chapters in troubleshooting and special running condition section.
- Updated the technical data section.
- Updated the copyright information.
New issue 001, 2020-06
Initial issue of the Operation Manual.

X92-B AA00-0000-00AAA-003A-A
Operation Manual Operation Manual - change record

X92-B AA00-0000-00AAA-018A-A
Operation Manual Preface
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.

X92-B AA00-0000-00AAA-018A-A
Operation Manual Preface

X92-B AA00-0000-00AAA-018B-A
Operation Manual Technical documentation set
1.3 Technical documentation set

Because of the continuous development of the engine, the technical documentation for the engine
changes and is regularly updated. The change record shows all changes.
Important data and changes are given directly to the customer in the service bulletins.
To order technical documents, the data that follows is necessary:

• Engine type, year of manufacture and engine manufacturer
• Name of ship or site of installation
• Cylinder or engine number
• Special equipment
• Document type (printed manuals, CD or Shipdex dataset).
The technical documentation set for this engine includes the publications that follow.
1.3.1 Operation Manual
The Operation Manual (OM) contains data about engine operation, the necessary operating media
(oil, water, fuel etc) and descriptions of the components and systems. The manual also gives
troubleshooting procedures.
The manual gives data about the standard engine with all cylinder numbers, alternative designs
and special equipment.
In this manual the engine connections (refer to the pipe connection plan) are the interface of the
description. For a description of the plant supply systems refer to the Marine Installation Manual.
1.3.2 Maintenance Manual
The Maintenance Manual (MM) contains data about disassembly / assembly procedures that are
necessary for the engine maintenance. The manual includes the maintenance schedule, a
clearance table, tightening values for important screw connections and a tool list.
1.3.3 Spare Parts Catalogue
In the Spare Parts Catalogue (SPC, or code book) all spare parts of the engine are marked with
a unique code number. You can order spare parts only with the code number from the Spare Parts
Catalogue. Order spare parts from one of the suppliers that follow:
• CSSC Marine Service Co., Ltd.
• Wärtsilä Services Switzerland Ltd.
• Engine supplier.

X92-B AA00-0000-00AAA-018B-A
Operation Manual Technical documentation set
1.3.4 External supplier documentation
The documentation from external suppliers gives data about the parts of the engine that are not
supplied by WinGD, such as turbocharger, automatic filter or damper. Most of this documentation
also contains data about spare parts.
1.3.5 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.
1.3.6 Marine Installation Manual
The Marine Installation Manual (MIM) contains data for design engineers and naval architects,
enabling them to optimize plant items and machinery space, and to do installation design work.

X92-B AA00-0000-00AAA-018D-A
Operation Manual Data module codes (descriptive data)
1.4 Data module codes (descriptive data)

This manual is divided into several data modules. Each data module is identified with a unique
data module code, refer to Table 1-2 - Data module codes (descriptive data). The structure of the
data module codes is as follows:
• ??##-####-##???-###?-? (structure)
• AA00-5551-00AAA-043A-A (example).
Tab 1-2 Data module codes (descriptive data)
Code Description Length/type Property Example

1
?? Alternative versions/designs of items. 2 alphabetic sequential, AA
Used when two or more items could be characters [A-Z] starts with AA
installed in the engine as alternatives for
the same function (for example tur-
bochargers from different suppliers)
2
## Applicability related to cylinder number. 2 numeric char- arbitrary 00
00 = applicable to all engines indepen- acters [0-9]
dent of the number of cylinders; ## = ap-
plicable only to engines with that specific
number of cylinders.
2
#### WinGD design group number 4 numeric char- arbitrary 5551
acters [0-9]
2
## Used for sequential numbering of data 2 numeric char- sequential, 00
modules. acters [0-9] starts with 00
1
??? Used for alternative items differing in de- 3 alphabetic sequential, AAA
sign but not enough to change the vari- characters [A-Z] starts with AAA
ant code.
2
### Shipdex information code, for example 3 numeric char- Shipdex specif- 043
043 = description of function attributed to acters [0-9] ic
the crew (functional breakdown)
1
? Shipdex information code variant. Used 1 alphabetic sequential, A
for sequential numbering character [A-Z] starts with A
1
? Shipdex item location code, for example 1 alphabetic Shipdex specif- A
A = information related to items installed character [A-D] ic, default is A
on the product
1 Placeholder symbol for alphabetic characters.
2 Placeholder symbol for numeric characters.
NOTE: For the full list of available Shipdex information codes and more data about the Shipdex
specification, refer to www.shipdex.org.

X92-B AA00-0000-00AAA-018D-A
Operation Manual Data module codes (descriptive data)

X92-B AA00-0000-00AAA-018E-A
Operation Manual Data module codes (procedural data)
1.5 Data module codes (procedural data)

This manual is divided into several data modules. Each data module is identified with a unique
data module code, refer to Table 1-3 - Data module codes (procedural data). The structure of the
data module codes is as follows:
• ??##-####-##???-###?-? (structure)
• AA00-5556-00AAA-520A-A (example).
Tab 1-3 Data module codes (procedural data)

1
?? Alternative versions/designs of items. 2 alphabetic sequential, AA
Used when two or more items could be characters [A-Z] starts with AA
installed in the engine as alternatives for
the same function (for example tur-
bochargers from different suppliers)
2
## Applicability related to cylinder number. 2 numeric char- arbitrary 00
00 = applicable to all engines indepen- acters [0-9]
dent of the number of cylinders; ## = ap-
plicable only to engines with that specific
number of cylinders.
2
#### WinGD design group number 4 numeric char- arbitrary 5556
acters [0-9]
2
## Used for sequential numbering for the 2 numeric char- sequential, 00
physical breakdown of components; 00 acters [0-9] starts with 00
= complete component, 01 = first break-
down; for illustrated parts (tools) it is
used for sequential numbering of data
modules.
1
??? Used for alternative items differing in de- 3 alphabetic sequential, AAA
sign but not enough to change the vari- characters [A-Z] starts with AAA
ant code (for example AAA = Bearing
shell No.1; AAB = Bearing shell No. 2 to
#)
2
### Shipdex information code, for example 3 numeric char- Shipdex specif- 520
520 = Remove procedure acters [0-9] ic
1
? Shipdex information code variant. Used 1 alphabetic variable A
to differentiate different procedures de- character [A-Z]
fined by the same information code for
the same DMC/Hardware section.

X92-B AA00-0000-00AAA-018E-A
Operation Manual Data module codes (procedural data)

1
? Shipdex item location code. A = informa- 1 alphabetic Shipdex specif- A
tion related to items installed on the character [A-D] ic
product; B = information related to items
installed on a major assembly removed
from the product; C - information related
to items on the bench. In this context, it
does not matter, for example, whether an
item has been removed from the prod-
uct; D - information related to all three
locations A, B, and C. No other combi-
nations are allowed.
1 Placeholder symbol for alphabetic characters.
2 Placeholder symbol for numeric characters.
NOTE: For the full list of available Shipdex information codes and more data about the Shipdex
specification, refer to www.shipdex.org.

X92-B AA00-0000-00AAA-018C-A
Operation Manual About this book
1.6 About this book

In the sections that follow you find the definitions of WinGD for this book.
1.6.1 Definitions for general text
For general text in this book the definitions that follow are applicable:
• ASD Simplified Technical English
The text in this book obeys the rules for ASD Simplified Technical English.
• Illustrations
The items in an illustration are shown, if possible, in clockwise direction, for example 001,
002, 003.
NOTE: Illustrations are usually generic or are shown as example. Thus some items can
be different on the current engine.
• Cross references
A cross reference to a different section of this book has the number and the title of the
section, for example “refer to section 1.2 Preface”. In the electronic version, a mouse click
on the blue text shows the related section.
NOTE: The text “[section not applicable for this engine]” shows, that this cross reference
and the related section are not applicable for this book.
• Instructions
Instructions in the procedures are given as steps, for example 1, 2, 3. These steps can be
divided into sub-steps, for example 1.1, 1.2, 1.3 or also sub-sub-steps, for example 1.1.1,
1.1.2, 1.1.3.
• Notes
Notes give more data to help you do a task, or they give data about the related item. Notes
come immediately before or after the related paragraph.
• Decimal separator
In this book a full stop (.) is used as decimal separator, for example 3.21 bar.

X92-B AA00-0000-00AAA-018C-A
Operation Manual About this book
1.6.2 Warnings
Warnings in procedures give data about a hazard.
Warnings have the basic structure that follows:

• Signal word
The signal words that follow are applicable:
○ WARNING
○ CAUTION
• Hazard
The hazard data gives the dangerous situation.
• Procedure
The procedure gives data of how to prevent the dangerous situation.
The signal words have the different hazard levels that follow:
• WARNING
The signal word WARNING gives a dangerous situation at which death or large injury are
possible. Do the related procedure to prevent this.
• CAUTION
The signal word CAUTION gives a dangerous situation at which moderate or small injury
to personnel or damage to equipment are possible. Do the related procedure to prevent
this.

X92-B AA00-0000-00AAA-018L-A
Operation Manual About the engine
1.7 About the engine

In the sections that follow you find the definitions of WinGD for the engine.
1.7.1 Groups of components
Each component of the engine has a four-digit material number. WinGD has divided these
components related to the first digit of the number into 9 groups:
• Group 1 - Engine frame and bearings
• Group 2 - Cylinder
• Group 3 - Crankshaft, connecting rod and piston
• Group 4 - Supply unit drive and control components
• Group 5 - Supply unit, pumps and control valves
• Group 6 - Scavenge air components
• Group 7 - Cylinder lubrication and balancer
• Group 8 - Pipes
• Group 9 - Monitoring instruments.

X92-B AA00-0000-00AAA-018L-A
1.7.2 Engine sides and ends - names
The sides and ends of the engine have the names and abbreviations that follow (refer to Figure
1-1:
• DE - Driving End (end that has a flange to attach the propeller shaft)
• FS - Fuel Side (side that has the equipment for the supply of fuel and other operating media)
• FE - Free End (end that is closed with a cover)
• ES - Exhaust Side (side that has the equipment for the discard of the exhaust gas and for
the supply of scavenge air).
Fig 1-1 Side view (generic)
DE FE
001
005
002
004
1 2 n-1 n
003
Legend
FE Free end DE Driving end

001 Turbocharger 004 Flywheel
002 Auxiliary blower 005 Supply unit
003 Main bearing number
1.7.3 Standard and LEFT engine
An engine is one of two types:

• A standard engine has the exhaust side (ES) on the right side of the engine (seen from the
driving end).

X92-B AA00-0000-00AAA-018L-A
• A LEFT engine has the exhaust side (ES) on the left side of the engine (seen from the driving
end).
NOTE: In the Spare Parts Catalogue parts that have the mark (LEFT) are only applicable for a
LEFT engine. Parts that are applicable for the two engines types (Standard and LEFT)
have no mark.
1.7.4 Numbering of items
WinGD uses the definitions for the numbering of items as follows (refer to Figure 1-2):
• In axial direction the numbering starts from the flywheel.
• In radial direction the numbering starts from the center of the flywheel.
Fig 1-2 Engine numbering (generic)
DE FE
1 2 n-1 n
004 001
003
1 2 3 4 n-1 n
002
Legend
FE Free end DE Driving end

001 Cylinder number 003 Thrust bearing
002 Main bearing number 004 Flywheel

X92-B AA00-0000-00AAA-018L-A

X92-B AA00-0000-00AAA-005A-A
Operation Manual List of abbreviations
1.8 List of abbreviations

Tab 1-4 List of abbreviations and acronyms
Short form Full form, meaning
ACM Angle Calculation Module
ADA crank Angle Determination Algorithm
AHD ahead
ALM alarm
AMS Alarm and Monitoring System
A/R as required
AST astern
ASTM American Society for Testing and Materials
BDC Bottom Dead Center
BN Base Number
BSEC Brake Specific Energy Consumption
BSFC Brake Specific Fuel Consumption
BSGC Brake Specific Gas Consumption
BSPC Brake Specific Pilot fuel Consumption
CAN Controller Area Network
CCAI Calculated Carbon Aromaticity Index
CCM Cylinder Control Module
CCU Cylinder Control Unit
CCW counterclockwise
CMCR Contract Maximum Continuous Rating
COC Cleveland Open Cup
CPP Controllable Pitch Propeller
CS crankshaft
CW clockwise
Cyl. cylinder
DBT Delta Bypass Tuning
DCC Dynamic Combustion Control
DE Driving End
DENIS Diesel Engine coNtrol and optImizing Specification
DF Dual Fuel

X92-B AA00-0000-00AAA-005A-A
ECA Emission Control Area
ECR Engine Control Room
ECS Engine Control System
eg or e.g. for example (exempli gratia)
EGR Exhaust Gas Recirculation
ELBA ELectrical BAlancer
ES Exhaust Side
ESS Engine Safety System
FAME Fatty Acid Methyl Esters
FAST Fuel Actuated Sacless Technology
FCM Flex Control Module
FCV Forged Crankshaft Version
FE Free End
FGSS Fuel Gas Supply System
FLV Flow Limiting Valve
FPP Fixed Pitch Propeller
FQS Fuel Quality Setting
FS Fuel Side
FZG Forschungsstelle für Zahnräder und Getriebebau (gear research center)
GAV Gas Admission Valve
GSS Gas Safety System
GTD General Technical Data
GTU GaTeway Unit
GVU Gas Valve Unit
HFO Heavy Fuel Oil
HFR High Feed Rate
HP High Pressure
HT High Temperature
IACS International Association of Classification Societies
iCAT integrated Cylinder lubricant Auto Transfer
ICC Intelligent Combustion Control
ICM Intelligent Combustion Monitoring

X92-B AA00-0000-00AAA-005A-A
ICU Injection Control Unit
ie or i.e. that is (id est)
iELBA integrated ELectrical BAlancer
iGPR integrated Gas Pressure Regulation
IMO International Maritime Organization
Ind. Indenture
IOM Input Output Module
ISO International Standard Organization
JIS Japanese Industrial Standard
KOH Potassium hydroxide
LDU Local Display Unit
LED Light Emitting Diode
LEL Lower Explosive Level
LFR Low Feed Rate
LHV Lower Heating Value
LLT Low-Load Tuning
LNG Liquefied Natural Gas
LP Low Pressure
LT Low Temperature
MARPOL International Convention for the Prevention of Pollution from Ships (MARine POLlution)
MCM Main Control Module
MCP Manual Control Panel
MCR Maximum Continuous Rating
MCU Main Control Unit
MDO Marine Diesel Oil
MEG MonoEthylene Glycol
MEP Mean Effective Pressure
MGO Marine Gas Oil
MIM Marine Installation Manual
MM Maintenance Manual
Modbus serial communications protocol published by Modicon
MPG MonoPropylene Glycol

X92-B AA00-0000-00AAA-005A-A
N/A not applicable
nil not illustrated
No. number
OAT Organic Acid Technology
OM Operation Manual
OPI OPerator Interface (user interface in the engine control room)
PCS Propulsion Control System
PCV Pressure Control Valve
PMCC Pensky Martens Closed Cup method
Pos. position
PU Piston Underside
RCS Remote Control System
REF Reference
rpm revolutions per minute
SAC Scavenge Air Cooler
SAE Society of Automotive Engineers
SCR Selective Catalytic Reduction
SCS Speed Control System
SHD shutdown
SLD slowdown
SOI Start Of Injection
SPC Spare Parts Catalogue
SPC Steam Production Control
TC TurboCharger
TDC Top Dead Center
UNIC UNIfied Controls
USB Universal Serial Bus
VCU exhaust Valve Control Unit
VEC Variable Exhaust valve Closing
VEO Variable Exhaust valve Opening
VIT Variable Injection Timing
WECS-9520 WinGD Engine Control System 9520

X92-B AA00-0000-00AAA-005A-A
WHR Waste Heat Recovery
WiCE WinGD Integrated Control Electronics
WinGD Winterthur Gas & Diesel Ltd.
WLL Work Load Limit

X92-B
Operation Manual
2 Safety
2.1 Safety precautions and safety guidelines..................................................................40
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

X92-B AA00-0000-00AAA-012A-A
Operation Manual Safety precautions and safety guidelines
2.1 Safety precautions and safety guidelines
2.1.1 General safety precautions
The aim of this book is to give correct information about operation and maintenance of the engine.
It is important to take the maximum safety in the engine room. All the engine room staff must follow
these general safety precautions and safety guidelines given below as usual procedure.
Use the data given below as a guide to the personnel.

• Lighting
Make sure that there is good permanent lighting available at applicable places in the engine
room.
Make sure that the sufficient number of portable lamps available at different locations in the
engine room.
Make sure that special lamp is available to insert through the scavenge ports.
• Cleanliness
Keep the engine and engine room as clean as possible. Also keep the area above and below
floor plates clean. Keep the electronic control boxes on the rail unit clean and dry.
Make sure that no dust, grit, sand or chemical vapor can go into the engine room. This will
help to prevent a fire in the engine room.
If there is a risk of grit and sand blow into the engine room when the ship is at port, ventilation
must be stop, skylights and engine room door must be close.
Do not do weld or other work near the engine except if done in closed and protected
environment, this will prevent spread of grit or swarf particles. Make sure that the
turbocharger intake filters are covered.
Keep the external part of the engine clean and maintain the paintwork to find the leakages
easily.
• Fire
Make sure that fire-fighting equipment is available in the engine room. Keep covers and
casings of the engine closed until the engine is sufficiently cool.
Clean the area around the relief valves free of oil, grease etc. This will prevent risk of fire
cause by hot air or gas when the relief valves are open.
Do not weld or use naked lights in the engine room. Make sure that no explosive gases,
vapour or liquids are available which can cause fire or explosion.
Be careful when using paint and solvents which has a low flash point. There is a risk of fire
and explosion.
Be careful when the crankcase doors are open before the engine is at suitable temperature,
weld or use of naked flames can cause risk of explosion and fire. Same is applicable to oil
tanks and spaces below the floor at the time of inspection.
Make sure that the emergency exits are clearly marked and easy to access.
Do not use the porous insulating materials soaked in oil due to leakages. These materials
are highly inflammable and must be replace with new materials.

X92-B AA00-0000-00AAA-012A-A
• Tools
Make sure that hand tools are available on tool panels and easy to access when required.
Keep the special tools near the work area in the engine room.
Make sure that all tools have protection from corrosion.
Keep all the tools and devices ready to use and make sure that no large objects are available
on the floors and passages near engine area. Always keep the engine area clean.
• Spare parts
Keep the large spare parts near the work area and must be easy to access for the engine
room crane.
Make sure that the spare parts have protection from corrosion and mechanical damage.
Replace used spare parts as soon as possible.
Check and maintain the stock of spare parts at regular intervals and refill the stock if
required.
• Low temperature - Freezing
To avoid freezing, drain all the cooling water from the engine, pumps, coolers and pipe
systems.
NOTE: Make sure that engine is cool down before repair and maintenance work.
• Check and Maintain
Do a check of measuring equipment, filter element and lubricating oil condition.
• Frost hazard
If the ambient air temperature decreases below 0°C and the engine is not in operation, the
water in the pipe systems can freeze. To prevent this, drain the pipe systems or increase
the temperature in the engine room.
• Alarms
Make sure that all the alarms are fully functional and helps to troubleshooting and solve the
error.
All the alarms are important and most serious alarm are with slow-down and shut-down
functions.
Make sure that all the engine crew members are trained and knows about the use and
importance of the alarm system
• Sealing Materials
Use hand gloves to remove the o-rings and other rubber or plastic based sealing materials.
The sealing material from the area of abnormally high temperature can have caustic effect
to personnel skin. To avoid this the hand gloves must be made up of neoprene or PVC.
Discard the gloves after use.
• Entering the Crankcase or Cylinder
Make sure that the turning gear is engage, even at the quay, the wake from the other ship
may turn the propeller and then engine.
Make sure that starting air supply to the engine and the starting air distributor is shutoff.
If there is alert from the oil mist alarm, before you open the crankcase follow all the
precautions.

X92-B AA00-0000-00AAA-012A-A
• Turning Gear and Slow turning

Before you engage the turning gear, make sure that the starting air supply is shutoff and
the indicator cocks are open.
When turning gear is engage, make sure that the indicator lamp “Turning gear in” is change
to local. Make sure that turning gear is locked during the maintenance procedure.
When the engine is stop for more than 30 min, do the slow turning of the turning gear just
before the engine start in order to prevent free rotation of the engine.
• IMO and NOX components number
Make sure that identification numbers are available to easily find the required drawings and
certificate.
The schematic diagrams shows where to find the markings on the individual component
types as below.
○ Fx fuel valve nozzle or TC diffuser etc.
○ Pictures that show the number.
○ Technical files descriptions.
2.1.2 Safety notes
• Danger
This warning is used when an operation, procedure, or use may cause personal injury or
loss of life.
• Warning
This warning is used when an operation, procedure, or use may cause a latently dangerous
state of personal injury or loss of life.
• Caution
This warning is used when an operation, procedure, or use may cause damage to or
destruction of equipment and a injury.
• Note
This warning is used when an operation, procedure, or use may cause damage to or
destruction of equipment.
2.1.3 General safety warnings and cautions
WARNING
Injury hazard: Engine parts can fall down and injury to personnel can occur. Make sure that
no personnel is standing below the crane and the area is clear.
WARNING
Injury hazard: Do not open the cocks suddenly because it can discharge hot fluids and
gases. Make sure to give a clear way for liquids, gases and flames to flow through it.
WARNING
Injury hazard: The disassembly of the engine parts can cause sudden release of springs
and injury to personnel can occur. Always use the correct personal protective equipment.

X92-B AA00-0000-00AAA-012A-A
WARNING
Injury hazard: The removal of fuel valves or other valves in the cylinder cover can cause
the oil to fall on the piston crown. If the piston is hot this can cause explosion. Make sure
that the engine is cool down before maintenance.
WARNING
Injury hazard: Do not touch the spray holes during the function test of the fuel valves. The
sudden release of oil can cause injury to personal. Always use the correct personal
protective equipment.
WARNING
Injury hazard: Make sure that the engine is stop and the current is switch-off from the main
switch before maintenance work starts. The drain valve must be open and decrease the
pressure to 0 bar during the maintenance procedure.
WARNING
Injury hazard: Before disassembly of the part from the system Check and release the
pressure of the related system. injury to personnel can occur.
WARNING
Injury hazard: Do not repair the hydraulic servo oil or rail system, when pumps are in
operation. Injury to personnel can occur.
WARNING
Injury hazard: Do not stand near the crankcase doors, engine room casing doors or relief
valves when the alarm is active for oil mist, high lube oil temperature, no piston colling oil
flow or scavenge box fire. Injury to personnel can occur.
CAUTION
Damage hazard: Always replace the damaged sealing materials with new sealing materials.
Do not try to repair them.
CAUTION
Damage hazard: Do not weld or solder on any part of the fuel system and servo oil system.
Damage to the system can occur.
2.1.4 Personal safety and protection equipment
Always use the below given personal protection equipment during repair and maintenance work
on the engine.
• Safety helmet.
• Ear protection.

X92-B AA00-0000-00AAA-012A-A
• Work card
• Cotton boiler suite.
• Safety shoes.
• Hand gloves.
• Safety goggles.
• Safety harness
2.1.5 General safety guidelines for Hot work
If you do hot work at or near the engine, obey the guidelines that follow to prevent risks of harm
or damage to personal, to equipment, or to environment.
• Guidelines for hot work: General
Hot work means any work requiring the use of electric arc or gas welding equipment, cutting
burner equipment or other forms of naked flame, as well as heating or spark generating
tools, regardless of where it is carried out on board.
The Safety Management System (SMS) on board must include guidance on control of hot
work and which must ensure compliance.
Always use safe workspaces to perform any hot work.
Hot work performed outside of safe workspaces must respect the guidelines below:
• Guidelines for hot work: Outside of safe workspaces
The safety officer ensures that the hot work is carried out safely.
The safety officer provides a permit to everybody related to hot work.
Hot work procedures must follow national laws, regulations and any other national safety
and health regulations.
Another safety officer must ensure that safety procedures are followed.
All officers follow a written instruction plan.
The work area must be completely isolated before the hot work starts.
Review the fire safety precautions. This includes: firefighting equipment preparations,
designation of a fire watch in all nearby areas and fire-extinguishing measures.
Continue the isolation of the workspaces and the fire safety precautions until the risk of fire
no longer exists.
Protect components like the turbocharger silencer, ECS electronic control boxes and
cables, with a cover.

X92-B AA00-0000-00AAA-012A-A
• Guidelines for hot work: inside the engine room

Stop the engine before proceed any hot work in the engine room.
Set the engine room fire extinguisher to Manual mode.
Isolate the work area.
Make sure that emergency exists are open and cleared.
Make sure that telecommunication or radio communication operates correctly.
Set to OFF the electronic module system and wait for one minute.
Disconnect the electronic modules and sensors near the work area.
Make sure that there are no explosive fluids or gases in the work area.
Use the earthing connection as near as possible to the work area.
Make sure that welding cables have no loops.
Make sure that welding cables lie parallel to the cables of electronic units.
Only use DC power supply and OCV below 70 volts.
Make sure that the connection clamp is near to the work area.
Make sure that electronic parts have protection to prevent damage from sparks and heat.
• Guidelines for work with hydraulic tools
Always use personal protection safety goggles and safety gloves while operating hydraulic
tools.
Check high pressure double walled hydraulic hoses for any damages before operation.
Check all connection points from the pump to the hydraulic tool for leaks during pressure
build-up.
Make sure the pressure gauges are properly calibrated before operation. Applied oil
pressure must be within a range of +/-5 bar of the specified pressure for each stud type and
size.

X92-B AA00-0000-00AAA-012B-A
Operation Manual Contamination and fire in the scavenge air spaces
2.2 Contamination and fire in the scavenge air spaces
2.2.1 Causes of contamination
The primary cause of contamination is when combustion materials are blown between the piston
and cylinder into the scavenge air spaces (blow-by). The contamination will be more if the fuel is
not fully burned, which causes exhaust smoke.
2.2.1.1 Unsatisfactory combustion
The causes of unsatisfactory combustion are as follows:

• The injection valves do not operate correctly (the nozzle tip has trumpets or is worn).
• The fuel is too cold, specially at low load.
• Operation with a temporarily low air supply during large differences in engine load and the
scavenge air pressure fuel-limiter set too high.
• Too much load.
• Low air supply because the ventilation in the engine room is not sufficient.
• The silencer and diffuser on the air side of the turbocharger has contamination.
• The wire mesh and nozzle ring upstream of the turbocharger has contamination.
• The exhaust gas boiler, the air cooler and water separator, the air flaps in the scavenge air
receiver and the scavenge ports have contamination.
2.2.1.2 Blow-by
The causes of blow-by are as follows:

• Worn piston rings, broken piston rings or piston rings that cannot move.
• Worn cylinder liner.
• Incorrect operation of a lubricating quill.
• The running surface of the cylinder liners have damage.
If there are one or more of these conditions, the remaining particles will collect at the areas that
follow:
• Between the piston ring and piston ring groove.
• On the piston skirt.
• In the scavenge ports.
• On the bottom of the cylinder block (piston underside).
• In the scavenge air receiver.

X92-B AA00-0000-00AAA-012B-A
Operation Manual Contamination and fire in the scavenge air spaces
2.2.2 Causes of fire
The causes of fires are as follows:

• If sealing rings of the piston rod gland are defective, system oil and cylinder oil will collect
in the piston underside. If the drain pipes from the piston underside are blocked, this oil can
not drain. A high temperature in the piston underside then can cause a fire.
• If piston rings are defective, combustion gases and sparks can go into the piston underside.
Contamination in the piston underside then can cause a fire.
You must do regular checks of the bottom of the cylinder block and scavenge air receiver to keep
clean the cylinder block and scavenge air receiver, refer to section 8.5 Do checks during operation
- general.
2.2.3 Indication of a fire
The indications of a fire are as follows:

• You can hear the related temperature alarms.
• A large increase in the exhaust gas temperature of the related cylinder and an increase in
piston underside temperature.
For the fire-fighting procedures, refer to section 2.3 Fire-fighting in the scavenge air space.

X92-B AA00-0000-00AAA-140B-A
Operation Manual Fire-fighting in the scavenge air space
2.3 Fire-fighting in the scavenge air space

Periodicity
Description
Unscheduled
Duration for performing preliminary requirements 0.0 man-hours
Duration for performing the procedure 1.0 man-hours
Duration for performing the requirements after job completion 0.0 man-hours
Personnel
Description Specialization QTY
Engine crew Intermediate 1
Support equipment
Description Part No. CSN QTY
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
PRELIMINARY OPERATIONS
• Refer to section 2.2 Contamination and fire in the scavenge air spaces

X92-B AA00-0000-00AAA-140B-A
Operation Manual Fire-fighting in the scavenge air space
PROCEDURE
1 If you think there is no fire, do the steps as follows:

1.1 Decrease the engine power.
1.2 Cut out the injection of the related cylinder.
1.3 Increase the feed rate of the lubricating oil in the related cylinder to the maximum,
although there is high temperature in the related cylinder.
WARNING
Injury Hazard. Where CO2 is used to extinguish a fire in the engine, there is a risk of
suffocation. Make sure that all related spaces have good airflow to remove all CO2 gas
before you go into the engine.
CAUTION
Damage Hazard. Steam can cause corrosion. If steam is used to extinguish a fire you must
do procedures to prevent corrosion.
2 If you think there is a fire, do the steps as follows:

2.1 Shut down the engine.
2.2 Fight the fire with the installed fire extinguishing system.
3 After approximately 5 minutes to 15 minutes, do the checks as follows:

3.1 Do a check of the exhaust gas temperature.
3.2 Do a careful check of the temperatures of the doors to the piston underside space.
4 Find the causes of the problems as follows:

4.1 Do a check of the cylinder liner running surface, piston and piston rings.
4.2 Do a check of the flaps in the scavenge air receiver (replace if necessary).
4.3 Do a check for possible leaks.
4.4 Do a check of the piston rod gland as much as possible.
4.5 Do a check of the injection nozzles.
4.6 If necessary, clean or repair the defective items.
5 Start the engine as follows:

5.1 If applicable, cut in the injection.
5.2 Start the engine.
5.3 Start the injection and slowly increase the load.
5.4 Set the cylinder oil feed rate to the applicable value.
NOTE: Do not operate the engine for long periods with a high cylinder oil setting.
CLOSE UP
• None

X92-B AA00-0000-00AAA-012C-A
Operation Manual Explosions in the crankcase
2.4 Explosions in the crankcase

Examples of explosions in the crankcase of diesel engines have shown that they can only occur
in special conditions, and thus do not occur frequently.
The cause of crankcase explosions is oil mist. Oil mist comes from components that have become
unusually hot.
The engine has oil mist detectors, refer to section 5.9.3 Oil mist detector.
Correct engine maintenance will help prevent explosions in the crankcase.

X92-B AA00-0000-00AAA-012C-A
Operation Manual Explosions in the crankcase

X92-B AA00-0000-00AAA-012D-A
Operation Manual Prevent explosions in the crankcase
2.5 Prevent explosions in the crankcase

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
WARNING
Danger: If an oil mist alarm is activated, keep away from the engine. There is a risk of
explosion.
WARNING
Danger: Do not open the crankcase doors or the covers for a minimum of 20 minutes after
engine stop. If air goes into the crankcase, an explosion can occur.
WARNING
Injury hazard: The crankcase doors have relief valves. To prevent accidents no person must
be in the areas of gases that can come out of these relief valves. Injury to personnel can
occur.
• None

X92-B AA00-0000-00AAA-012D-A
Operation Manual Prevent explosions in the crankcase
PROCEDURE
1 If an oil mist detector activates an alarm, do as follows:

1.1 Decrease immediately the engine speed (power).
1.2 Stop the engine if possible.
1.3 Let the engine temperature decrease for a minimum of 20 minutes.
1.4 Find the cause and repair the fault.
NOTE: If no fire-extinguishing system is installed or not in use, a portable fire
extinguisher must be kept ready when the crankcase doors are opened.
CLOSE UP
• None

X92-B AA00-0000-00AAA-012E-A
Operation Manual Access to engine spaces
2.6 Access to engine spaces

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
WARNING
Injury Hazard: Be careful of the slippery and sharp edges inside the engine spaces.
• The engine must be stopped and prepared for maintenance, refer to section 8.18 Prepare
the engine after stop - general

X92-B AA00-0000-00AAA-012E-A
PROCEDURE
1 Make sure that there is always a safety person on the outer side of the engine.
2 Use the correct personal protection equipments.
3 For a DF engine, obey the safety rules for natural gas, refer to section [section not
applicable for this engine].
4 De-pressurize the air spring to open the exhaust valve housing.
5 Make sure that the starting air supply pipe has no pressure (ie starting air shut-off valve
30-4325_E0_1 is closed, ball valves 30-8605_E0_6 and 30-8605_E0_7 are open).
6 Engage the turning gear and lock the lever in this position.
NOTE: Other ships in the water cause currents, which cause the movement of the
propeller and the engine. The engine and propeller cannot move when the
turning gear is engaged.
7 Make sure the indicator valves are open.
8 Make sure that there is sufficient air in the engine spaces, e.g use a ventilator.
9 When you go out of the engine spaces, move all the equipment out of the engine.
CLOSE UP
• None

X92-B AA00-0000-00AAA-012E-A

X92-B
Operation Manual

3.1 Short description of the engine..................................................................................58
3.2 Use of the engine......................................................................................................60
3.3 The relation between engine and propeller...............................................................64

X92-B AA00-0000-00AAA-020A-A
Operation Manual Short description of the engine
3.1 Short description of the engine

The engine is a single acting two-stroke diesel engine of crosshead design. The engine has a
turbocharger and exhaust valves.
General data about the engine are given as follows:

• The engine uses the common-rail system with full electronic control of the fuel injection
system, exhaust valve operation, starting valve operation, and cylinder operation.
• Related to the design, the engine turns clockwise or counterclockwise for the ahead
direction. For the astern direction the engine can turn in the other direction.
• The engine control system (ECS) electronically controls all important engine functions (eg
speed control, overspeed protection and fuel injection). The engine control can have
different remote controls, which are related to the WinGD specifications from recommended
manufacturers.

X92-B AA00-0000-00AAA-020A-A
Operation Manual Short description of the engine
3.1.1 Cycle of a two-stroke diesel engine
The sequences of a two-stroke diesel engine are as follows (refer to Figure 3-1):
• Sequence 1 - 2
The piston moves up and thus compresses the scavenge air. This increases the
temperature of the air above the self-ignition temperature of the fuel.
• Sequence 2 - 3
At almost TDC fuel at very high pressure is injected into the hot air in the combustion
chamber. The fuel ignites and combustion starts.
• Sequence 3 - 4
The gases expand and push the piston down. The pressure in the combustion chamber
decreases.
• Sequence 4 - 1
The scavenge air replaces the exhaust gas as follows:
○ At (4) the exhaust valve opens.
○ At (a) the scavenge ports get uncovered. Scavenge air enters the cylinder and pushes
the exhaust gas into the exhaust gas manifold.
○ At (b) the scavenge ports get covered.
○ At (1) the exhaust valve closes.
The cycle is completed and starts again.
Fig 3-1 Pressure - volume diagram and schematic of the two-stroke diesel cycle
p 2 3
2 3
4
1 4
1 b a
V 00120

X92-B AA00-0000-00AAA-020C-A
Operation Manual Use of the engine
3.2 Use of the engine
3.2.1 Intended use
The engine is intended to drive a propeller of a vessel. The engine changes the chemical energy
of the fuel to mechanical energy.
The engine must only be used in the operating range as given in the data sheets, refer to
chapter 11.
Related to the contract the Contract Maximum Continuous Rating (CMCR) is specified in the range
of Figure 3-2. The points R1+ and R2+ are only applicable, if the engine has an extended range.
Fig 3-2 Operating range
P
R1 R1+
R3
R4
R2 R2+
R4
S
Legend
R1 Highest power at highest speed R3 Highest power at lowest speed

R1+ Highest power at highest speed (extended) R4 Lowest power at lowest speed
R2 Lowest power at highest speed P Power
R2+ Lowest power at highest speed (extended) S Speed
The intended use of the engine includes the items that follow:
• Obey this Operation Manual.
• Obey the related safety regulations.
• Obey the instructions of the operating company.
• Operate the engine in the specified limits.
• Use the correct operating media.

X92-B AA00-0000-00AAA-020C-A
3.2.2 Incorrect use
Incorrect use of the engine can result in personal injury and in damage to physical properties.
Personal injury or damage to physical properties caused by incorrect use will be the responsibility
of the operating company.
The actions that follow must be looked as examples to be an incorrect use:

• Operation of the engine with disabled, changed or defective safety devices
• Operation of the engine with personnel who are not approved.

X92-B AA00-0000-00AAA-020C-A
3.2.3 Tuning
Related to the contract the engine has one of the tuning options that follow (refer to Figure 3-3):
• Standard tuning
The standard tuning gives a good fuel consumption over the full engine power range.
• Delta tuning
The delta tuning decreases the fuel consumption below 90% engine power compared to
standard tuning. But it increases the fuel consumption between 90% and 100% of engine
power.
• Delta bypass tuning
The delta bypass tuning decreases the fuel consumption below 50% engine power
compared to delta tuning. For more than 50% of engine power the fuel consumption is the
same as delta tuning, but the steam production is increased.
• Low-load tuning
The low-load tuning decreases the fuel consumption below 75% engine power compared
to delta tuning or delta bypass tuning. But it increases the fuel consumption between 90%
and 100% of engine power compared to delta tuning.
Fig 3-3 Tuning options

X92-B AA00-0000-00AAA-020C-A

X92-B AA00-0000-00AAA-042B-A
Operation Manual The relation between engine and propeller
3.3 The relation between engine and propeller
3.3.1 General
There is a specified relation between the propeller speed and the absorbed power in ships that
have fixed pitch propellers. The relation is between the propeller and the speed at which it turns.
The formula that follows (where P = power and n = speed) gives an approximate result, which is
sufficient for conventional vessels:
The graph from this formula is known as the propeller property.
If the engine is in good condition, correctly supplied with air (ie turbochargers in good condition
and the resistance of the air and exhaust pipes is in the specifications) and the fuel injection
quantity is correctly adjusted (see the shop test protocol), then the mean effective pressure (MEP)
developed during service conditions (in accordance with the specified load indication), is related
to the approximate MEP for this position on the test bed.
In the diagram (see Figure 3-4), the propeller property line through the CMCR point (100% power
at 100% engine speed) is known as the nominal propeller property. Engines that are used for the
propulsion of vessels with fixed propellers have a load applied on the test bed in accordance with
this propeller property. But, during sea trial of a new ship with a smooth and clean hull, the
applicable power is lower and the operation point is below the nominal propeller property.
During operation, a higher torque is necessary for the propeller to keep its speed than at the time
of the sea trial (sea margin) because:
• There are changes in wake flow conditions because of marine growth on the hull
• The cargo load has an effect on the depth of the vessel in the water
• The propeller has a rough surface or has mechanical damage
• The vessel operates in bad sea and weather conditions
• The vessel operates in shallow water. The MEP of the engine (and thus the fuel injection
quantity) will increase. In such a condition, the operation point will then be at the left of the
initial propeller curve which was calculated during sea trials.
A hull that was cleaned and painted will help to decrease the resistance as the vessel moves
through the water. It is not possible to get the hull back to its initial condition.
Because the thermal load of the engine is related to the MEP, the position of the operation point
is also important. The air supply to the engine and the operation conditions will become
unsatisfactory if the operation point is far above the propeller curve.
To get the best conditions, the operation point of the engine for service range must be on or below
the nominal propeller property.

X92-B AA00-0000-00AAA-042B-A
3.3.2 Fixed pitch propeller (FPP)
3.3.2.1 Continuous service rating
Point A (Figure 3-4) shows the power and speed of a ship that operates at contractual speed in
calm seas with a new clean hull and propeller. A power / speed combination at point D is necessary
for the same ship at the same speed during service conditions with aged hull and average weather.
Point D is then the CSR point.
3.3.2.2 Engine margin / operational margin
Most owners specify the contractual loaded service speed of the ship at 85% to 90% of the contract
maximum continuous rating (CMCR). The remaining 10% to 15% of power can be used to catch
up with changes in schedules or for the timing of dry-dock intervals. This margin is usually
subtracted from the CMCR. Thus, to get the 100% power line, you divide the power at point D by
between 0.85 to 0.90.
3.3.2.3 Load range limits
Fig 3-4 Schematic diagram - Relation Speed/Power (FPP)
Engine power
[% Rx] CMCR (Rx)
110
Engine load range 2
100
1
95 EM/OM
90
D B
Constant torque
SM
80
A
4
70 LR
c i
rist
3
cte
60
ara
6
r ch
elle
rop
al p
50 5
min
No
Propeller curve
without SM
Engine speed
40 [% Rx]
65 70 80 90 95 100 104 108 00117
When the engine has the best values at CMCR (RX), the limits that follow give the load range of
the engine:
• Line 1 is a constant MEP or torque line through CMCR from 100% speed and power down
to 95% speed and power.

X92-B AA00-0000-00AAA-042B-A
• Line 2 is the overload limit. This is a constant MEP line from 100% power and 93.8% speed
to 110% power and 103.2% speed. 103.2% speed is the intersection point between the
nominal propeller property and 110% power.
• Line 3 is the 104% speed limit where an engine can operate continuously. For RX with
decreased speed (NCMCR ≤0.98 NMCR) this limit can be extended to 106%, but, the torsional
vibration must not be more than the specified limits.
• Line 4 is the overspeed limit. The overspeed range between 104% (106%) and 108% speed
is only permitted during sea trials if necessary. This is to demonstrate the speed of the ship
at CMCR power with a light running propeller in the presence of authorized representatives
of the engine builder. The torsional vibration must not be more than the specified limits.
• Line 5 is the permitted torque limit from 95% power and speed to 45% power and 70%
speed. This shows a curve defined by the equation: P2 ÷ P1 = (N2 ÷ N1)2.45. When the engine
speed and power is near the data in Line 5 there will be a decrease in scavenge air, which
has an effect on the engine. The area between Lines 1, 3 and 5 show the range in which
the engine must be operated. The area in the nominal propeller property, 100% power and
Line 3 is recommended for continuous operation. The area between the nominal propeller
property and Line 5 must be reserved for acceleration, shallow water and usual flexibility of
operation.
• Line 6 gives the equation: P2 ÷ P1 = (N2 ÷ N1)2.45 through 100% power and 93.8% speed and
the maximum torque limit in transient conditions. The area above Line 1 is the overload
range. You must only operate the engine in this range for a maximum of one hour during
sea trails in the presence of authorized representatives of the engine builder. The area
between Lines 5 and 6 and the constant torque line (shown as a dark area) must only be
used for transient conditions, ie during fast acceleration. This range is known as the service
range with operational time limit.

X92-B
Operation Manual

4.1 General for systems..................................................................................................68
4.2 Cooling water system................................................................................................70
4.3 Wash-water system...................................................................................................72
4.4 System oil system......................................................................................................74
4.5 Servo oil system........................................................................................................76
4.6 Cylinder oil system....................................................................................................78
4.7 Starting air system.....................................................................................................80
4.8 Scavenge air system.................................................................................................82
4.9 Control air system......................................................................................................84
4.10 Exhaust gas system..................................................................................................86
4.11 Fuel system...............................................................................................................88
4.12 LP Selective catalytic reduction system....................................................................92
4.13 Steam production control system............................................................................106

X92-B AA00-0000-00AAA-043U-A
Operation Manual General for systems
4.1 General for systems

In the chapters that follow you can find a short description of the systems of the engine. The
descriptions and figures are generic and simplified.
You can find an overview of the used line codes in Figure 4-1.
Fig 4-1 Line codes for systems
001 006
002 007
003 008
004 009
005
Legend
001 Main supply pipe 006 Double wall pipe

002 Drain / leakage pipe 007 Heating pipe
003 Vent pipe 008 Insulated pipe
004 Waste pipe (dirty drain pipe) 009 Trace heated and insulated pipe
005 Optional pipe

X92-B AA00-0000-00AAA-043U-A
Operation Manual General for systems

X92-B AA00-0000-00AAA-043A-A
Operation Manual Cooling water system
4.2 Cooling water system

The cooling water system supplies the items that follow with cooling water:
• Cylinder liner
• Cylinder cover
• Exhaust valve cages
• Scavenge air cooler (SAC).
For the schematic diagrams, refer to section 13.1 Schematic diagrams - general.
The cooling water system has the engine connections as interface to the plant as follows (in Figure
4-2 marked with a circle):
• Connection 01 (cylinder cooling water inlet)
• Connection 02 (cylinder liner cooling water inlet (bypass cooling water system)) (optional)
• Connection 03 (cylinder cooling water outlet)
• Connection 05 (cylinder cooling water drain outlet)
• Connection 07 (SAC LT-cooling water inlet) (not shown)
• Connection 08 (SAC LT-cooling water outlet) (not shown).
If the supply at the engine connection 02 is installed, the cylinder liner is supplied with cooling
water at a higher temperature than the cylinder cover.
The cooling water system has the parts that follow:

• Automatic venting unit
The automatic venting unit (001) constantly releases unwanted air from the cooling water.
• Optional vent valve
The optional vent valves (008) can be used manually to release unwanted air from the
cooling water, if the automatic venting unit (001) does not operate correctly.
• Vent valve
The vent valves (009) constantly release cooling water to the automatic venting unit (001)
to release unwanted air from the cooling water.
• Vent valve
The vent valve (010) can be used manually to release unwanted air from the cooling water,
if the automatic venting unit (001) does not operate correctly.

X92-B AA00-0000-00AAA-043A-A
Operation Manual Cooling water system
Fig 4-2 Cooling water system (generic and simplified)
001
010
ENGINE
PLANT
03
002
009
008
007
003
Cyl. 1 Cyl. n
004
006
005
05
01
02
Legend
001 Automatic venting unit 006 Drain valve

002 Shut-off valve cooling water outlet 007 Orifice
003 Shut-off valve, if supply 02 is installed 008 Optional vent valve (usually closed)
004 Shut-off valve, if supply 02 is not installed 009 Vent valve (usually open)
005 Shut-off valve 010 Vent valve (usually closed)

X92-B AA00-0000-00AAA-043P-A
Operation Manual Wash-water system
4.3 Wash-water system

The wash-water system supplies the scavenge air cooler (SAC) with wash-water. This lets you
wash the SAC, refer to 9.5 Clean the scavenge air cooler during operation. To regularly wash the
SAC increases the service life of the cooler and keeps the performance in the specified range.
The wash-water system has the engine connections as interface to the plant as follows (in Figure
• Connection 06 (SAC drain outlet) (for X35 and X40)
• Connection 11 (water for cleaning plant for TC and SAC inlet)
• Connection 12 (air for cleaning plant for TC and SAC inlet)
• Connection 13 (oily water from receiver outlet)
• Connection 16 (SAC condensate water outlet)
• Connection 17 (SAC wash-water outlet) (optional)
• Connection 18 (SAC venting).
Condensation and wash-water flow through the cyclone separator and back to the plant at the
connection 16.
The wash-water system has the parts that follow:

• Wash-water tank
The wash-water tank (001) keeps the wash-water for the wash procedure of the SAC.
Compressed air is used to pressurize the wash-water tank before the wash procedure.
• Cyclone separator
The cyclone separator (004) separates the air and the wash-water.

X92-B AA00-0000-00AAA-043P-A
Operation Manual Wash-water system
Fig 4-3 Wash-water system (generic and simplified)
11 12
005 001
002
002
003 003
13
18
06 06
16
17
ENGINE
ENGINE
PLANT
PLANT
004
Legend
001 Wash-water tank 004 Cyclone separator

002 Scavenge air cooler (SAC) 005 Turbocharger
003 Auxiliary blower

X92-B AA00-0000-00AAA-043B-A
Operation Manual System oil system
4.4 System oil system

The system oil system supplies the items that follow with system oil:
• Bearings
• Gear wheels
• Vibration dampers
• Pistons
• Crosshead assemblies
• iELBA (optional)
• Other running parts
• Servo oil system.
The system oil system has the engine connections as interface to the plant as follows (in Figure
• Connection 22 (oil drain bedplate horizontal) (if applicable)
• Connection 23 (oil drain bedplate vertical)
• Connection 25 (main oil inlet)
• Connection 26 (lubricating oil turbocharger inlet) (optional)
• Connection 27 (lubricating oil turbocharger outlet)
• Connection 30 (lubricating oil crosshead inlet) (optional)
• Connection 37 (leakage oil gland box outlet).
System oil from the bearings and gear wheels drops into the crankcase.
The system oil system has the parts that follow:

• Oil pipes
The oil pipes connect the items that use oil.
• Lever
The levers (010) in the crankcase supply the oil to the crosshead.
• Oil sample valve
Use the oil sample valve (009) to get a sample of the supplied oil.

X92-B AA00-0000-00AAA-043B-A
Operation Manual System oil system
Fig 4-4 System oil system (generic and simplified)
27
001 001
PLANT ENGINE ENGINE PLANT
26
012
002
011
002
30
37
25
010
009
007
008
22 23 23 22
006 005 004 003
Legend
001 Turbocharger 007 Crosshead

002 iELBA (optional) 008 Thrust bearing
003 Torsional vibration damper (optional) 009 Oil sample valve
004 Axial vibration damper 010 Lever
005 Main bearing 011 Supply pipe to servo oil system
006 Crank bearing 012 Piston

X92-B AA00-0000-00AAA-043Q-A
Operation Manual Servo oil system
4.5 Servo oil system

The servo oil system supplies the items that follow with servo oil:
• Exhaust valve control units (VCU)
• Cylinder lubricating pumps
• Injection control units, if applicable.
The system oil system supplies the servo oil through the supply pipe.
The servo oil system has the engine connections as interface to the plant as follows (in Figure
• Connection 25 (main oil inlet)
• Connection 34 (leakage oil of driving end outlet)
• Connection 35 (leakage oil of free end outlet)
• Connection 38 (oil pipe drain of supply unit outlet).
Servo oil from the pumps and valves collects in the square collector pipe (003). The oil then flows
to the connections 34 and 35.
The servo oil system has the parts that follow:

• Oil pipes
The oil pipes connect the items that use oil. All the high pressure oil pipes have double wall.
Inspection points in the pipes let find oil leaks.
• Servo oil service pump
The servo oil service pump (005) can supply the servo oil system with oil before the engine
start or during maintenance.
• Servo oil pump (number related to the configuration)
The servo oil pumps (004) supply the servo oil system with oil during usual operation.
• Servo oil rail
The servo oil rail (007) supplies the exhaust valve control units with servo oil at
approximately 200 to 300 bar.
• Exhaust valve control unit
The exhaust valve control units (VCU) (002) control the servo oil flow to the exhaust valve.
From the first exhaust valve control unit some of the oil flows to the pressure reducing valve.
• Pressure reducing valve
The pressure reducing valve (009) decreases the servo oil pressure to the value that is
necessary in the distributor pipe (mini-rail).
• Distributor pipe (mini-rail)
The distributor pipe (mini-rail) (010) supplies the cylinder lubricating pumps with servo oil at
approximately 60 to 65 bar.

X92-B AA00-0000-00AAA-043Q-A
Operation Manual Servo oil system
Fig 4-5 Servo oil system (generic and simplified)
008 009 010
001
007
002
ENGINE
PLANT
ENGINE
PLANT
34 35
003
006
Cyl. 1 Cyl. 2 Cyl. n
005
25
38
004
Legend
001 Injection control unit (ICU) for X82 and X92 006 Oil pipe to exhaust valve
002 Exhaust valve control unit (VCU) 007 Servo oil rail
003 Square collector pipe 008 Rail unit
004 Servo oil pump 009 Pressure reducing valve
005 Servo oil service pump 010 Distributor pipe (mini-rail)

X92-B AA00-0000-00AAA-043R-A
Operation Manual Cylinder oil system
4.6 Cylinder oil system

The cylinder oil system supplies cylinder oil onto the cylinder liners. The engine control system
(ECS) controls the adjustable load-related supply rate of cylinder oil to each lubrication point.
The engine has an automatic pre-lubrication sequence. At each engine start the ECS automatically
starts this sequence. This makes sure that the cylinders are sufficiently lubricated. The sequence
includes a specified number of lubrication pulses. For the specified number refer to chapter 11
Technical data.
NOTE: You can also start the pre-lubrication sequence manually.
The cylinder oil system has the engine connections as interface to the plant as follows (in Figure
• Connection 32 (cylinder oil inlet (high BN)), only applicable on an engine with iCAT
• Connection 33 (cylinder oil inlet (low BN, on an engine with iCAT))
• Connection 36 (dirty oil of piston underside outlet).
The cylinder oil is used only one time.
The cylinder oil system has the parts that follow:

• Oil pipes
The oil pipes connect the items that use oil.
• Duplex oil filter
The duplex oil filter (004) filters the oil before it flows to the cylinder lubricating pumps. The
change-over valve makes it possible to shut off one filter chamber.
• Cylinder lubricating pump
Each cylinder has a cylinder lubricating pump (003). Servo oil operates the cylinder
lubricating pumps. The ECS controls the cylinder lubricating pumps.
• Lubricating quill
The lubricating quills (002) spray cylinder oil onto the running surface of the cylinder liners.
The lubricating quills are installed on the circumference of the cylinder liner.
• Oil sample valve
To drain a sample of dirty oil, use the oil sample valve (001) at the cylinder liner underside.
• iCAT (if installed)
The iCAT system (integrated Cylinder lubricant Auto Transfer system) automatically selects
the cylinder oil with the correct base number (BN) related to the fuel in use. If necessary,
the iCAT system automatically changes over the cylinder oil. The change-over valve (007)
is near the cylinder lubricating pump (003). Thus the correct cylinder oil is immediately
supplied to the cylinder liner. The engine control system (ECS) controls the iCAT system.
NOTE: You have to enter the correct basic values (eg the sulfur content of the fuels) for
the iCAT system in the RCS, refer to the related documentation.

X92-B AA00-0000-00AAA-043R-A
Operation Manual Cylinder oil system
Fig 4-6 Cylinder oil system (generic and simplified, with and without iCAT)
001
iCAT
36
Cyl. 1 Cyl. n
002
003
008
007 32
33
004
006 005
ENGINE
PLANT
Legend
001 Oil sample valve 005 Square collector pipe

002 Lubricating quill 006 Rail unit
003 Cylinder lubricating pump 007 Change-over valve
004 Duplex oil filter 008 Servo oil supply

X92-B AA00-0000-00AAA-043C-A
Operation Manual Starting air system
4.7 Starting air system

The starting air system turns the crankshaft before the usual combustion cycle of the engine is
started.
The starting air system has the engine connections as interface to the plant as follows (in Figure
• Connection point 40 (starting air pipe inlet)
• Connection point 41 (venting crankcase outlet)
• Connection point 45 (control air supply inlet).
The starting air system has the parts that follow:

• Starting air shut-off valve
The starting air shut-off valve (009) supplies the starting air supply pipe with starting air.
The starting air shut-off valve has three positions:
○ CLOSED
○ AUTO
○ OPEN.
• Starting air supply pipe

The starting air supply pipe (007) supplies the starting valves of each cylinder with starting
air. The starting air supply pipe has a safety valve (003) and two drain valves (004).
• Starting valve
Each cylinder has a starting valve with a solenoid valve (001). Each starting valve supplies
the related cylinder with the specified quantity of starting air at the correct time.
• Valve unit for start E
The valve unit for start E (008) supplies the starting air shut-off valve with control air.
• Disengaging device turning gear
When the turning gear is engaged, the disengaging device turning gear (006) closes the
shut-off valve in the supply pipe. This prevents the supply of control air to the valve unit for
start E, and thus prevents engine start.
• Flame arrestor
The flame arrestor (002) prevents combustion gas to flow back into the air pipe.

X92-B AA00-0000-00AAA-043C-A
Operation Manual Starting air system
Fig 4-7 Starting air system (generic and simplified)
010
001
009
008
Cyl. 1 Cyl. n 002
40 E
003
ENGINE
PLANT
004
007
41
A2 A1
45
A3
A6
A
ENGINE
PLANT
006 005
Legend
001 Solenoid valve 006 Disengaging device turning gear

002 Flame arrestor 007 Starting air supply pipe
003 Safety valve 008 Valve unit for start E
004 Drain valve 009 Starting air shut-off valve
005 Control air supply 010 Collector for leakage oil from the air spring

X92-B AA00-0000-00AAA-043S-A
Operation Manual Scavenge air system
4.8 Scavenge air system

The scavenge air system replaces the exhaust gas in the cylinder with fresh air.
The scavenge air comes in from the outside through a duct or from the engine room. The scavenge
air enters at the silencer of the turbocharger.
The scavenge air system has the parts that follow:

• Scavenge air receiver
The scavenge air receiver (013, Figure 4-8) supplies the cylinders with the applicable
quantity of air.
• Turbocharger
The compressor (005) of the turbocharger compresses the air to the applicable pressure.
The compressor is attached to the shaft of the turbine (004). The remaining energy of the
exhaust gas operates the turbine and thus the compressor.
• Auxiliary blower
The two auxiliary blowers (010) supply the scavenge air at the engine start and during low
load operation.
• Auxiliary blower switch box
The auxiliary blower switch box controls the auxiliary blowers.
• Scavenge air cooler
The scavenge air cooler (SAC) (006) decreases the temperature of the hot compressed air
from the turbocharger. This increases the mass of air and thus increases the quantity of air
that is supplied to the cylinders.
• Water separator
The water separator (007) removes water from the scavenge air. This prevents damage
and gives better combustion in the cylinders. Water occurs when the scavenge air cooler
decreases the temperature of wet air. Water also occurs during the wash procedure of the
SAC.
• Drains
The scavenge air system has the drains (009) that follow:
○ Condensation drain from the scavenge air cooler
○ Water drain from the water separator
○ Oily water drain.

X92-B AA00-0000-00AAA-043S-A
Operation Manual Scavenge air system
Fig 4-8 Scavenge air system
001
015 002
003
004
005
014
013
012 006
011
007
010 008
009
00148
Legend
001 Exhaust gas manifold 009 Drains

002 Exhaust gas outlet 010 Auxiliary blower
003 Scavenge air inlet 011 Piston underside
004 Turbine 012 Piston
005 Compressor 013 Scavenge air receiver
006 Scavenge air cooler 014 Cylinder liner
007 Water separator 015 Exhaust valve
008 Charging unit

X92-B AA00-0000-00AAA-043T-A
Operation Manual Control air system
4.9 Control air system

The control air system supplies the air spring of the exhaust valves and the starting air system
with control air.
The plant supply systems supply compressed air with the specified properties at the two engine
connections (in Figure 4-9 marked with a circle) that follow:
• Connection 45 (control air supply inlet) for usual supply
• Connection 40 (starting air pipe inlet) for stand-by supply.
The control air system has the parts that follow:

• Control air supply
The control air supply (002) decreases the supply air pressure to the specified pressures.
• Air tank
The air tank (003) is a container for control air. If the two plant air supply systems become
defective, the air tank supplies control air to the engine for a short period.
• Air bottle
The air bottle (001) collects condensation from the starting air.
• Collector for leakage oil from the air spring
The collector for leakage oil from the air spring (007) controls the oil leakage from the air
spring of the exhaust valves with a float control. When the collector pipe is full, the shut-off
valve opens and the oil flows into the crankcase.

X92-B AA00-0000-00AAA-043T-A
Operation Manual Control air system
Fig 4-9 Control air system (generic and simplified)
007
005
006
Cyl. 1 Cyl. n
40 E
ENGINE
PLANT
A2 A1
45
A3
A6
A
ENGINE
PLANT
004 003 002 001
Legend
001 Air bottle 005 Starting air shut-off valve

002 Control air supply 006 Valve unit for start
003 Air tank 007 Collector for leakage oil from the air spring
004 Disengaging device

X92-B AA00-0000-00AAA-043D-A
Operation Manual Exhaust gas system
4.10 Exhaust gas system

The exhaust gas system collects the exhaust gas of the cylinders in a manifold. The remaining
energy of the exhaust gas is used to operate the turbine of the turbocharger (002, Figure 4-10)
(refer to section 4.8 Scavenge air system).
The exhaust gas system has as interface to the plant the engine connection 71 (exhaust gas
turbocharger outlet, in Figure 4-10 marked with a circle).
The exhaust gas system has the parts that follow:

• Exhaust valve
The exhaust valve (004) of each cylinder releases the exhaust gas of the combustion into
the exhaust gas manifold.
• Exhaust gas manifold
The exhaust gas manifold (003) collects the exhaust gas from the cylinders.
• Turbocharger bypass pipe
Usually the engine has a turbocharger bypass pipe (001) for different operating conditions.

X92-B AA00-0000-00AAA-043D-A
Operation Manual Exhaust gas system
Fig 4-10 Exhaust gas system (generic and simplified)
T
001 002
AN
E
PL
IN
G
EN
71
003 004
Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. n
Legend
001 Turbocharger bypass pipe 003 Exhaust gas manifold

002 Turbocharger 004 Exhaust valve

X92-B AA00-0000-00AAA-043E-A
Operation Manual Fuel system
4.11 Fuel system

The fuel system supplies the injection valves of the cylinders with the applicable quantity of fuel.
The fuel system has the engine connections as interface to the plant as follows (in Figure 4-11
and Figure 4-12 marked with a circle):
• Connection 49 (fuel inlet)
• Connection 50 (fuel return outlet)
• Connection 51 (fuel leakage rail unit outlet)
• Connection 52 (fuel leakage outlet)
• Connection 57 (leakage outlet)
• Connection 59 (trace heating fuel inlet)
• Connection 60 (trace heating fuel outlet)
• Connection 67 (fire extinguishing plant cylinder block inlet).
The constant flow of fuel through the fuel system keeps the fuel warm.
At low load the ECS automatically cuts out injection valves in each cylinder as follows:
• For an engine with two injection valves - one of the two injection valves
• For an engine with three injection valves - one or two of the three injection valves.
This makes sure that the engine has the best fuel and combustion properties, which decreases
smoke and fuel consumption. The ECS cuts out a different injection valve at regular intervals to
get an equal thermal load in the combustion chamber. There is no time limit to operate the engine
at low load.
The fuel system has the parts that follow:

• Fuel pipes
The fuel pipes connect the items of the fuel system. All the fuel pipes have a trace heating
to keep the fuel warm during operation and for short engine stops. The high pressure fuel
pipes that are not in the rail unit have a double wall design and leakage inspection points.
• Pressure retaining valve
The adjustable pressure retaining valve (009) in the return pipe keeps the fuel pressure in
the supply pipe to the fuel pumps at the correct value.
• Supply unit
The supply unit (007) holds the fuel pumps and the related items.
• Fuel pump (number related to the configuration)
The fuel pumps (008) supply the fuel rail with fuel at up to 1000 bar.
• Fuel rail
The fuel rail (004) supplies the flow limiting valves or the injection control units with fuel.
• Non-return valve
The non-return valves prevent fuel flow back from the fuel rail to the fuel pumps (eg if a fuel
pump has no delivery, or a fuel pipe is defective).

X92-B AA00-0000-00AAA-043E-A
• Pressure control valve

The pressure control valve (001) has different functions to control the flow and the pressure
in the fuel rail.
• Relief valve
The relief valve (002) is a safety device. If the fuel pressure increases to more than the set
value, the relief valve opens.
• Flow limiting valve
The flow limiting valves (003) (FLV, not for X82, X92, RT-flex, and related DF engines)
installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity
of fuel.
• Injection control unit
The injection control units (003) (ICU, for X82, X92, RT-flex, and related DF engines)
installed on the fuel rail supply fuel to the related injection valves with the adjusted quantity
of fuel.
• Injection valve
The injection valves (006) supply the fuel into the combustion chamber as a spray.

X92-B AA00-0000-00AAA-043E-A
Fig 4-11 Fuel system with FLV (generic and simplified)
001 002 003 004 005
ENGINE
009 008 006
PLANT
50 51
Cyl. 1 Cyl. n 59
67
49
52
60
57
ENGINE
PLANT
007
Legend
001 Pressure control valve 006 Injection valve

002 Relief valve 007 Supply unit
003 Flow limiting valve (FLV) 008 Fuel pump
004 Fuel rail 009 Pressure retaining valve
005 Rail unit

X92-B AA00-0000-00AAA-043E-A
Fig 4-12 Fuel system with ICU (generic and simplified)
001 002 003 004 005
ENGINE
ENGINE
PLANT
PLANT
51 Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4 Cyl. n 59
67
006
57
52
60 50 49 009 008 007
Legend
001 Pressure control valve 006 Injection valve

002 Relief valve 007 Supply unit
003 Injection control unit (ICU) 008 Fuel pump
004 Fuel rail 009 Pressure retaining valve
005 Rail unit

X92-B AA00-9270-00AAA-043B-A
Operation Manual LP Selective catalytic reduction system
4.12 LP Selective catalytic reduction system

The Low Pressure Selective Catalytic Reduction (LP SCR) system is an optional system to
decrease the level of nitrogen oxides in the exhaust gas. This makes sure that the emissions of
nitrogen oxides obey the Tier III regulations of the International Maritime Organization (IMO).
Nitrogen oxides are dangerous and are made in secondary reactions in the engine during fuel
combustion.
The LP SCR system is installed after the turbocharger. The system design and the supply of
components is divided between the LP SCR system supplier, the shipyard and WinGD/engine
builder.
The LP SCR system adds a urea water solution to the exhaust gas flow. Chemical reactions
change nitrogen oxides to molecular nitrogen and water, which are not dangerous.
Because of the low exhaust gas temperature after the turbocharger ammonia bisulfates are formed
in the LP SCR reactor. You must regularly change to bypass operation and do a regeneration
procedure to remove these deposits, refer to the related documentation of the manufacturer.
During this procedure the LP SCR system cannot operate.
NOTE: For a DF engine: The LP SCR system can only be used in diesel mode.
NOTE: For further details about the operation, maintenance and troubleshooting aspects of the
LP SCR system, please refer to the manuals of the manufacturer.
4.12.1 Description of the LP SCR system
4.12.1.1 LP SCR system parts
The LP SCR system has the parts shown in the paragraphs that follow (see Figure 4-13 and Figure
4-14):
• Urea pump unit
This unit supplies the urea solution from the tank to the urea solution dosing unit. This keeps
the applicable pressure in the related pipes.
• Urea dosing unit
The urea dosing unit controls the supply of urea solution to the decomposition unit.
• Burner
The burner heats up the exhaust gas flow that is used to inject the urea.
• Decomposition unit
In the decomposition unit the exhaust gas and the urea is mixed to form ammonia.
• LP SCR reactor
The LP SCR reactor has a steel wall and has an inlet and an outlet cone. A steel structure
holds the catalyst layers. At the catalytic surface of the catalyst layers the nitrogen oxides
(NO and NO2) react with the ammonia into molecular nitrogen (N2) and water (H2O). These
gases are part of the ambient air and are not dangerous.
Manholes in the reactor walls are used to examine and, if necessary, to clean or replace
the catalyst elements.

X92-B AA00-9270-00AAA-043B-A
• Valves
The valves in the LP SCR system are used for the different operation modes. The LP SCR
system has the valves that follow:
○ V1 - reactor inlet valve
○ V2 - reactor outlet valve
○ V3 - reactor bypass valve
○ V4 - turbine bypass valve
The turbine bypass valve (V4) is also used for other functions of the ECS, for example for
low-load tuning (LLT) or for steam production control (SPC).
4.12.1.2 Layout
The LP SCR system can be designed in different layouts related to the project. Two examples are
shown in Figure 4-13 and Figure 4-14.
Fig 4-13 LP SCR temperature controlled (example)
001 002 003 004 005
V4
006
V1 V2
V3
Legend
001 Engine 004 Burner

002 Urea dosing unit 005 LP SCR reactor
003 Decomposition unit 006 Turbocharger

X92-B AA00-9270-00AAA-043B-A
Fig 4-14 LP SCR bypass rate controlled (example)
001 004 002 003 005
V4
006
V1 V2
V3
Legend
001 Engine 004 Burner

002 Urea dosing unit 005 LP SCR reactor
003 Decomposition unit 006 Turbocharger
4.12.2 Operation modes
The LP SCR system can be operated if the exhaust gas temperature is in the permitted limits.
These limits are adjusted during commissioning. A temperature that is less than the permitted limit
can cause the catalyst elements to clog. A temperature that is more than the permitted limit can
cause the catalyst elements to become worn quickly.
4.12.2.1 LP SCR system - (emergency) bypass
In this operation mode, the LP SCR system is bypassed. The engine operates in Tier II mode.
Urea solution is not injected.
The valves have the conditions that follow:

• V1 - closed
• V2 - closed
• V3 - open
• V4 - the control systems control this valve.

X92-B AA00-9270-00AAA-043B-A
4.12.2.2 LP SCR system - preparation
In this operation mode, exhaust gas causes the temperature of the LP SCR reactor to slowly
increase. Urea solution is not injected.

• V1 - slowly changes from closed to open
• V2 - slowly changes from closed to open
• V3 - slowly changes from open to closed
• V4 - the control systems control this valve.
When the temperature of the LP SCR reactor has the value for operation in Tier III mode, a timer
starts. As long as the timer runs, the operator must change to Tier III mode. If the operator does
not change to Tier III and the timer stops, the ECS changes back to bypass mode (Tier II).
4.12.2.3 LP SCR system - Tier III
In this operation mode, the LP SCR system is set to ON. The engine operates in Tier III mode.
Urea solution is injected.

• V1 - open
• V2 - open
• V3 - closed
• V4 - the control systems control this valve to keep the temperature of the exhaust gas in
the correct range.
4.12.2.4 LP SCR system - at engine stop
If you stop the engine in Tier III mode, the LP SCR system changes to bypass mode immediately
and urea solution injection stops.

X92-B AA00-9270-00AAA-043B-A
4.12.3 LP SCR control system
The main tasks of the WinGD control system for the LP SCR system are as follows:
• Calculate the setpoint position for the turbine bypass valve (V4) to control the exhaust gas
temperature.
• Control the operation of the auxiliary blowers.
• Calculate the setpoint for the urea dosing unit.
Related to the input signals the LP SCR control system gives the related signals to the LP SCR
system, refer to Figure 4-15.
Fig 4-15 LP SCR control system layout
001 002 003
Legend
001 Input signals 003 Output signals

002 LP SCR control system
The main input signals are as follows:

• Engine parameters
• Prepare Tier III command from RCS
• Tier III command from RCS
• Position of turbine bypass valve (V4)
• Different temperatures and pressures
The main output signals are as follows:

• Different temperatures and pressures
• Signals to enable or disable the LP SCR system
The principal control configuration of the LP SCR system is shown in Figure 4-16.

X92-B AA00-9270-00AAA-043B-A
Fig 4-16 LP SCR system - principal control configuration
ECR Engine room
PCS
ECS Signals
AMS
E72 External main

E71 E70 control panel
(E73)
4.12.3.1 Messages of the LP SCR control system
The LP SCR control system gives three messages to the alarm and monitoring system (AMS).
The messages are as follows:
• LP SCR ON - This message shows that the LP SCR system is set to ON and thus urea is
injected.
• LP SCR minor failure - This message shows a failure that does not have an effect on LP
SCR system operation.
• LP SCR major failure - This message shows a failure that has an effect on LP SCR system
operation. The LP SCR control system stops the LP SCR system operation and changes
to Tier II mode.

X92-B AA00-9270-00AAA-043B-A
4.12.3.2 Control box E70
The control box E70 is installed on the engine and has switches and visual indicators.
Fig 4-17 Control box E70 with option SPC
010
009
001
002
008
007 003
004
005
006
Legend
001 SCR bypass switch 006 Indication (orange) - SPC bypass

002 Indication (red) - SCR failure 007 Indication (green) - SPC running
003 Indication (orange) - SCR bypass 008 Indication (green) - SCR running
004 Indication (red) - SPC failure 009 Indication (green) - Power on
005 SPC bypass switch 010 Power switch

X92-B AA00-9270-00AAA-043B-A
4.12.3.3 Control box E71
The control box E71 is installed on the engine or in the engine room and has switches below the
LDU-20.
Fig 4-18 Control box E71 with option SPC
001
003 002
Legend
001 LDU-20 003 SCR bypass switch

002 SPC bypass switch

X92-B AA00-9270-00AAA-043B-A
4.12.3.4 Control box E72 or E73
The control box E72 (without SPC) or E73 (with SPC) is installed in the engine control room and
has switches below the LDU-20.
Fig 4-19 Control boxes E72 and E73
001
002
003
004
Legend
001 LDU-20 003 SPC bypass switch

002 SCR bypass switch 004 Conductor terminal block

X92-B AA00-9270-00AAA-043B-A
4.12.4 LDU-20 pages
The LDU-20 panel has the pages that follow (examples).
Fig 4-20 LDU-20 page - LP SCR SYSTEM STATUS (MAIN PAGE)
007
008
010
009
006
001 002 003 004 005
Tab 4-1 LP SCR SYSTEM STATUS (MAIN PAGE)
Item Function Effect
001 OVERVIEW button Opens the SCR system overview page
002 INTERFACES button Opens the interfaces page
003 INDEX button Opens the index page
004 SCREENSHOT button Makes a screenshot of the current screen
005 RCS CTRL OFF button Gets control from the remote control system (if button is active)
006 Status indication Shows the SCR status
007 Status indication Shows the control location
008 Status indication Shows the related status
009 Button and indication Starts and indicates the related SCR operation mode
010 Status indication Shows the status of the SCR system

X92-B AA00-9270-00AAA-043B-A
Fig 4-21 LDU-20 page - LP SCR SYSTEM OVERVIEW
006
009
007
008
005
001 002 003 004
Tab 4-2 LP SCR SYSTEM OVERVIEW
001 INTERFACES button Opens the interfaces page
007 Status indication Shows the values
008 Status indication Shows the engine status
009 Status indication Shows the current value and the valve setpoint value in percent
(0% to 100%)

X92-B AA00-9270-00AAA-043B-A
Fig 4-22 LDU-20 page - LP SCR INTERFACES
006
008
007
005
001 002 003 004
Tab 4-3 LP SCR INTERFACES
001 OVERVIEW button Opens the SCR system overview page
007 Status indication Shows the auxiliary blower status
008 Status indication Shows the status of the SCR system

X92-B AA00-9270-00AAA-043B-A
Fig 4-23 LDU-20 page - LP SCR SOFTWARE INFO
004
005
006
007
008
009
001 002 003
Tab 4-4 LP SCR SOFTWARE INFO
003 RCS CTRL ON button Gets control from the remote control system (if button is active)
004 Application type Shows the name of the application
005 Software version Shows the software version number, (major) (middle) (minor),
for example 1.2.0
006 Application CRC (Cyclic Redun- Shows the check-sum of the application (binary)
dancy Check)
007 Engine type Shows the applicable engine
008 Manufacturer number Shows the software manufacturer number
009 DB number Shows identification number of the installation

X92-B AA00-9270-00AAA-043B-A
Fig 4-24 LDU-20 page - LP SCR PAGE INDEX
004
001 002 003
Tab 4-5 LP SCR PAGE INDEX
004 Page button Opens the selected page

X92-B AA00-9270-00AAA-043C-A
Operation Manual Steam production control system
4.13 Steam production control system

The steam production control system (SPC) supplies the steam production of the ship with exhaust
gas, which has a higher temperature.
SPC is an optional system.

NOTE: The engine obeys the IMO NOx limits, with and without steam production.
Fig 4-25 Example of SPC
001 002 003 004 005 006
007
Legend
001 Engine 005 Steam production

002 Exhaust waste gate valve 006 Steam consumer
003 Steam production control system 007 Turbocharger
004 Stack
4.13.1 Function
The SPC controls the exhaust waste gate valve (002, Figure 4-25). If the exhaust waste gate valve
(EWG) opens, a part of the exhaust gas bypasses the turbocharger (007). As a result the
temperature of the exhaust gas increases, which is supplied to the steam production (005).
The supply of the turbocharger comes first, before the supply of the steam production.
The supply of the steam production is only permitted in the range between the minimum engine
load and the maximum bypass rate. These limits are related on the ambient conditions and are
project specific.
4.13.2 User interface on the LDU-20
If an SCR system is installed, the control for SPC is part of the SCR system.
If no SCR system is installed, the control for SPC has separate control boxes.

X92-B AA00-9270-00AAA-043C-A
Fig 4-26 LDU-20 page - STEAM PRODUCTION CONTROL
007 006
008
009
010
011
012
013
005
014
015
001 002 003 004
Tab 4-6 STEAM PRODUCTION CONTROL (SPC)
001 ON/OFF button Starts or stops the SPC system
003 SCREENSHOT button Makes a screen shot of the current screen
005 Value indication Shows the values
006 SPC/EXT. CONTROL button Changes to the external control of the SPC
007 MinEWGPos mode button Sets the minimum permitted EWG position
Other SPC modes than the initial mode MinEWGPos are only
possible, if the signal Engine ready for SPC from ECS is active
(green).
008 MaxEWGPos mode button Sets the maximum permitted EWG position
009 ManEWGSetp mode button Sets the EWG setpoint, if the specific LDU-20 is in control
You can set a value of 0 to 100%, but the SPC uses only a value
in the permitted range.

X92-B AA00-9270-00AAA-043C-A
010 PressCtrl mode 1 button Starts the PressCtrl mode 1

This mode is applicable only, if the steam pressure signal from
the steam plant is correct.
SPC compares the setpoint and the actual steam pressure. If
there is a difference, it opens or closes the EWG to change the
steam pressure.
If the status of the steam pressure signal changes to FAIL, SPC
will change to MinEWGPos mode.
011 PressCtrl mode 2 button Starts the PressCtrl mode 2

Same effect as PressCtrl mode 1: But, if the burner is ON, the
SPC uses the minimum permitted EWG position only.
012 Steam Pressure Setpoint Shows the actual setpoint of the steam pressure
You can manually set the setpoint, if the PressCtrl mode 1 or 2
is active.
It is only possible to set the setpoint if the specific LDU-20 is in
control.
013 Manual EWG Setpoint Shows the actual EWG setpoint

If the ManEWGSetp mode is active, you can enter the EWG
setpoint.
014 EWG Limitation Shows the current EWG setpoint together with the actual mini-
mum and maximum limitations
Too wide EWG opening decreases the scavenge air pressure.
This will start the auxiliary blowers.
The limit of the EWG opening prevents the scavenge air pres-
sure to decrease below the switching-On point of the auxiliary
blowers.
015 dIT Shows the delta injection timing (dIT)

SPC calculates the dIT. The dIT controls the timing of the fuel
injection. This timing is related to the difference between EWG
setpoint and the minimum permitted EWG position.
The ECS controls, if the dIT from SPC will be used or not.
Rule: If ICC is on, then dIT is not used.
4.13.3 Steam boost mode (SBM)
Steam boost mode is an optional application that can be activated or deactivated manually. It is
only available in gas mode operation. Activating the steam boost mode allows for a higher steam
production on board. The steam boost mode is available for two different power ranges:
• 51% to 91% of the contracted maximum continuous rating
• 76% to 91% of the engine power
The steam boost mode offset can be chosen freely on the LDU from 0% to 100%. Use the LDU-
Screen to control the steam boost mode functions.

X92-B AA00-9270-00AAA-043C-A
4.13.4 LDU screen for steam boost mode
Fig 4-27 LDU for the steam boost mode

X92-B AA00-9270-00AAA-043C-A
4.13.5 Activate the steam boost mode
Before activating the steam boost mode, make sure the LDU-Screen (Figure 4-27) shows the
following:
• Firing Pressure Gas Mode indicates (5) “OK”.
• Servo Oil (6) indicates “OK”.
• DCC (7) indicates “Not Active”.
• Load Range (8) indicates “OK”.
1 Press the button “Enable SBM” (1) to activate the steam boost mode.
NOTE: The indication “SBM Enabled” (4) becomes green.
4.13.6 Deactivate the steam boost mode
Before deactivating the steam boost mode, make sure the LDU-Screen (Figure 4-27) shows the
following:
1 Press the button “Disable SBM” (2) to deactivate the steam boost mode.
4.13.7 Adjust the steam boost mode offset
Before adjusting the steam boost mode offset, make sure the following conditions are met:
• The engine is running with correct power ranges for the steam boost mode.
• The load range (8) indicates “OK”.
• The steam boost mode is activated.
1 a.) On the right side of LDU-Screen, turn the control key to the left to decrease the SBM-
Offset-%.
or
1 b.) On the right side of LDU-Screen, turn the control key to the right to increase the SBM-
Offset-%.
2 Press the control key to acknowledge the selected value of the Exhaust-Valve-Operation-
Offset.
NOTE: Adjusting the SBM-Offset advances the exhaust valve opening timing. This leads
to an increase of the exhaust gas temperatures of the cylinder. Depending on the
engine load, the exhaust gas waste gate will also be opening and closing for steam
boost production. This is a desired effect to further increase the exhaust gas
temperature before entering the economizer.

X92-B
Operation Manual

5.1.1 Bedplate..........................................................................................................114
5.1.2 Main bearing....................................................................................................116
5.1.3 Thrust bearing.................................................................................................118
5.1.4 Monoblock column...........................................................................................120
5.1.5 Tie rod.............................................................................................................122
5.2.1 Cylinder liner....................................................................................................124
5.2.2 Lubricating quill................................................................................................126
5.2.3 Piston rod gland...............................................................................................128
5.2.4 Direct controlled injection valve.......................................................................130
5.2.5 Starting valve...................................................................................................132
5.2.6 Exhaust valve..................................................................................................134
5.3.1 Crankshaft.......................................................................................................136
5.3.2 Torsional vibration damper..............................................................................138
5.3.3 Axial vibration damper.....................................................................................142
5.3.4 Turning gear....................................................................................................144
5.3.5 Connecting rod and connecting rod bearing....................................................146
5.3.6 Crosshead and guide shoe..............................................................................148
5.3.7 Piston...............................................................................................................150
5.4.1 Supply unit drive..............................................................................................152
5.4.2 Starting air shut-off valve.................................................................................154
5.4.3 Control air supply.............................................................................................156
5.4.4 Local maneuvering stand for UNIC.................................................................158
5.4.5 Pick-up for speed measurement......................................................................160
5.5.1 Servo oil pump.................................................................................................162
5.5.2 Supply unit.......................................................................................................164
5.5.3 Fuel pump........................................................................................................166
5.5.4 Pressure control valve.....................................................................................168
5.5.5 Flow limiting valve...........................................................................................170
5.5.6 Exhaust valve control unit................................................................................172
5.5.7 Fuel pump actuator..........................................................................................174
5.6.1 Scavenge air receiver......................................................................................176
5.6.2 Turbocharger...................................................................................................178
5.6.3 Auxiliary blower...............................................................................................180
5.6.4 Auxiliary blower switch box..............................................................................182

X92-B
Operation Manual
5.6.5 Scavenge air cooler.........................................................................................184

5.6.6 Water separator...............................................................................................186
5.7.1 Cylinder lubrication..........................................................................................188
5.7.2 Integrated electrical balancer (iELBA).............................................................190
5.8 Group 8 - Pipes
5.8.1 Exhaust waste gate.........................................................................................196
5.9.1 Crank angle sensor unit...................................................................................198
5.9.2 Water in oil monitor..........................................................................................200
5.9.3 Oil mist detector...............................................................................................202

X92-B
Operation Manual

X92-B AA00-1115-00AAA-043A-A
Operation Manual Bedplate

5.1.1 Bedplate
The bedplate is the basic structure of the engine. The bearing girders (001, Figure 5-1) are
attached in the bedplate and hold the crankshaft.
The bottom part of the bedplate is the crankcase and collects lubricating oil. This oil flows back to
the oil supply system through oil drains (002).
The length of the bedplate is related to the number of cylinders.
Fig 5-1 Bedplate (generic)
001
002
Legend
001 Bearing girder 002 Oil drain

X92-B AA00-1115-00AAA-043A-A
Operation Manual Bedplate

X92-B AA00-1132-00AAA-043A-A
Operation Manual Main bearing
5.1.2 Main bearing

The main bearings hold the crankshaft (007, Figure 5-2) and transmit the forces through the
bearing girders (008) into the bedplate.
The bottom bearing shell (006) is installed in the bearing girder (008) of the bedplate and the top
bearing shell (004) in the bearing cover (003). The screws (005) engage and hold the top bearing
shell and bottom bearing shell in position. The spring dowel pin (009) helps to get the bearing
cover (003) in position.
The elastic studs (001) have a non-hardening locking compound applied to the threads. Hydraulic
tension is applied to the elastic studs during the install procedure. The round nuts (002) keep the
bearing cover (003) against the bearing girder.
For the main bearings adjacent to the thrust bearing the oil flows through the oil bore (013) to the
running surface of the bearing. For the other main bearings the oil flows from the oil supply pipe
through the oil inlet (011) to the running surface of the bearings.
Fig 5-2 Main bearing (generic)
001
013 010
002
012
003
004
009
005 009 005
014
005
005 008 007 006 011
Legend
001 Elastic stud 008 Bearing girder

002 Round nut 009 Spring dowel pin
003 Bearing cover 010 Flange
004 Top bearing shell 011 Oil inlet
005 Screw 012 Oil groove
006 Bottom bearing shell 013 Oil bore
007 Crankshaft 014 Coating

X92-B AA00-1132-00AAA-043A-A
Operation Manual Main bearing

X92-B AA00-1203-00AAA-043A-A
Operation Manual Thrust bearing
5.1.3 Thrust bearing

The thrust bearing is installed on the crankshaft at the driving end of the engine. The thrust bearing
flange (014, Figure 5-3) transmits the axial thrust from the propeller through the thrust pads into
the bedplate:
• The thrust pads on the engine side adapt the propeller thrust of the ahead direction.
• The thrust pads on the driving end adapt the propeller thrust of the astern direction.
The thrust pads adapt to the clockwise or counterclockwise rotation of the engine.
The arbor supports (004) prevent circular movement of the thrust pads.
Bearing oil flows through the oil pipe (002) to the two nozzles (003). The oil flows out of the two
nozzles as a spray, which becomes an oil layer between the thrust bearing flange (014) and the
thrust pads (006, 013).

X92-B AA00-1203-00AAA-043A-A
Operation Manual Thrust bearing
Fig 5-3 Thrust bearing (generic)
001
002
003
007
004
006
005
008
015
007
014
009
013
006
012
010
011
Legend
001 Column 009 Crankshaft

002 Oil pipe 010 2-part oil baffle
003 Nozzle 011 Flywheel
004 Arbor support 012 Bedplate
005 Bedplate 013 Thrust pad (engine side)
006 Thrust pad (driving end) 014 Thrust bearing flange
007 Bearing cover 015 Column
008 Crankshaft gear wheel

X92-B AA00-1406-00AAA-043A-A
Operation Manual Monoblock column
5.1.4 Monoblock column

The monoblock column is the middle part of the engine. The monoblock column is installed on the
bedplate and holds the cylinders.
On the exhaust side (ES) the monoblock column has one relief valve (001, Figure 5-4) per cylinder.
The relief valves open, if the pressure in the monoblock increases too much.
On the fuel side (FS) the monoblock column has one door (002) per cylinder. During normal
operation the doors are closed and locked. For maintenance or inspection work the doors can be
opened. Obey the safety rules before you open the doors.
The length of the monoblock column is related to the number of cylinders.
Fig 5-4 Monoblock column (generic)
FS ES
001
002
Legend
001 Relief valve FS Fuel side

002 Door ES Exhaust side

X92-B AA00-1406-00AAA-043A-A
Operation Manual Monoblock column

X92-B AA00-1903-00AAA-043A-A
Operation Manual Tie rod
5.1.5 Tie rod

The tie rods (004, Figure 5-5) keep the cylinder block (002), column (003) and bedplate (005)
together at four locations around each cylinder.
Fig 5-5 Tie rod (generic)
001
002
003
004
005
001
Legend
001 Protection cover 004 Tie rod

002 Cylinder block 005 Bedplate
003 Column
If a tie rod breaks in the bottom area, a special device makes sure that the nut of the tie rod does
not fall into the crankcase.

X92-B AA00-1903-00AAA-043A-A
Operation Manual Tie rod

X92-B AA00-2124-00AAA-043A-A
Operation Manual Cylinder liner

5.2.1 Cylinder liner
The cylinder liner is one of the primary parts of the engine. The cylinder liner is on the cylinder
jacket and holds the cylinder cover and the water guide jackets. The nuts and the elastic bolts hold
these parts together.
The surfaces of the cylinder liner and the cylinder jacket make a metallic seal. A non-hardening
compound is applied around the surface of the metallic seal to prevent leakage.
The antipolishing ring (001) is installed in the top part of the cylinder liner. The antipolishing ring
removes coke contamination at the piston crown during operation.
Fig 5-6 Cylinder - cooling water outlet (generic)
Legend
001 Exhaust valve cage 003 Cooling water outlet

002 Cylinder cover
Cooling water flows from the bottom water guide jacket to the top water guide jacket. Then the
cooling water flows into the cylinder cover (002, Figure 5-6) and the exhaust valve cage (001).
The cooling water flows back through the cooling water outlet (003) to the cooling water system
of the plant.
To prevent unwanted tension in the top part of the cylinder liner the temperature of the cooling
water must stay in the permitted range:
• ±2°C at constant load
• ±4°C during load changes.

X92-B AA00-2124-00AAA-043A-A
Operation Manual Cylinder liner

X92-B AA00-2138-00AAA-043A-A
Operation Manual Lubricating quill
5.2.2 Lubricating quill

The lubricating quills spray oil onto the cylinder liner wall. The lubricating quills are installed on the
circumference of the cylinder liner.
The cylinder lubricating pump supplies a specified quantity of cylinder oil at high pressure through
the cylinder oil inlet (006, Figure 5-7) into the lubricating quills. The non-return valve (009) opens
and the cylinder oil flows out of the nozzle tip (003) and the lubricating point (004) as a spray.
Some of the cylinder oil flows into the grooves of the cylinder liner wall. The non-return valve (009)
prevents the exhaust gas to flow back into the oil pipe.
Fig 5-7 Lubricating quill (generic)
009
008
001
007
002
006 003
004
005
Legend
001 Piston 006 Cylinder oil inlet

002 Piston ring 007 Holder
003 Nozzle tip 008 Cylinder liner
004 Lubricating point in cylinder liner 009 Non-return valve
005 Compression spring

X92-B AA00-2138-00AAA-043A-A
Operation Manual Lubricating quill

X92-B AA00-2303-00AAA-043A-A
Operation Manual Piston rod gland
5.2.3 Piston rod gland

The piston rod gland keeps the dirty cylinder oil in the scavenge space and thus prevents
contamination of the bearing oil in the crankcase. Also, the piston rod gland seals the scavenge
air from the crankcase.
Use the sample valve to get system oil samples regularly. The analysis of this oil gives data about
the quality of the cylinder lubrication.
Do regular checks of the leakage oil drain to make sure that oil flows freely. This prevents the risk
of fire.
Fig 5-8 Piston rod gland (generic)
001
011
010 002
003
009
004
008
005
006
007
Legend
001 Scraper ring (4-part) 007 Oil drain

002 Housing (2-part) 008 Ring support (3-part)
003 Relief opening 009 Scraper ring (3-part)
004 Neutral space 010 Gasket (4-part)
005 Cylinder jacket 011 Tension spring
006 Support
During operation, the two scraper rings (001, Figure 5-8) remove dirty oil from the piston rod. The
dirty oil flows through oil bores and collects in the bottom of the scavenge space. The dirty oil flows
out through the leakage oil drain on the fuel side.
The two gaskets (010) prevent the release of scavenge air into the crankcase.
The oil that flows through the relief openings (003) into the neutral space (004) flows into the oil
drain.
The ring supports (008) hold the scraper rings (009) in position. The scraper rings (009) remove
bearing oil from the piston rod. This bearing oil flows through the oil drain (007) to the crankcase.
The tension springs (011) push the scraper rings (009) and (012) against the piston rod.

X92-B AA00-2303-00AAA-043A-A
Operation Manual Piston rod gland

X92-B AA00-2722-00AAA-043A-A
Operation Manual Direct controlled injection valve
5.2.4 Direct controlled injection valve

The injection valves are installed in the cylinder cover of each cylinder. The injection valves spray
the fuel into the combustion chamber. The ECS controls the pilot valve of the injection valves
indirectly through the solenoid valve. ECS also controls the timing and the quantity of the injected
fuel.

X92-B AA00-2722-00AAA-043A-A
Operation Manual Direct controlled injection valve

X92-B AA00-2728-00AAA-043A-A
Operation Manual Starting valve
5.2.5 Starting valve

The starting valve in each cylinder cover supplies pressurized air into the combustion chamber in
the two situations that follow:
• To start the engine before combustion starts
• To decrease the engine speed when combustion has stopped.
The ECS and the cylinder control modules (CCM-20) control and monitor the starting valves. Each
starting valve opens and closes at the correct crank angle of the related cylinder. This makes the
piston move down (for engine start) or makes the piston speed decrease (for engine speed
decrease).
As soon as combustion starts the starting air supply stops.
Fig 5-9 Starting valve (example)
001
002
003
004
005
006
009
007
008
Legend
001 Solenoid valve 006 Valve spindle

002 Cover 007 Cylinder cover
003 Piston 008 Starting air outlet
004 Housing 009 Starting air inlet
005 Compression spring

X92-B AA00-2728-00AAA-043A-A
Operation Manual Starting valve

X92-B AA00-2751-00AAA-043A-A
Operation Manual Exhaust valve
5.2.6 Exhaust valve

The exhaust valve in each cylinder cover releases the exhaust gas of the combustion into the
exhaust gas manifold. The hydraulic oil pressure from the exhaust valve control unit (VCU) opens
the exhaust valve. The pneumatic pressure of the air spring closes the exhaust valve.
Fig 5-10 Exhaust valve (generic)
014
001
013 002
012 003
004
011
010 005
009 006
007
008
Legend
001 Upper housing 008 Cylinder cover

002 Inside piston and outside piston 009 Rotation wing
003 Lower housing 010 Cup spring
004 Air spring piston 011 Air spring
005 Valve spindle 012 Leakage oil collection space
006 Valve cage 013 Hydraulic oil inlet
007 Valve seat 014 Damper
The exhaust valve has the parts that follow:

• Inside piston and outside piston
The inside piston and the outside piston (002, Figure 5-10) move down when the VCU
applies pressurized oil through the hydraulic oil inlet (013). The valve spindle (005) moves
down and the valve seat (007) is open.
• Rotation wing
The exhaust gas applies a force on the rotation wing (009). This turns the valve spindle
(005) to balance the heat and mechanical forces and to prevent particles on the exhaust
valve.

X92-B AA00-2751-00AAA-043A-A
Operation Manual Exhaust valve
• Air spring
When the exhaust valve is closed, compressed air flows through an air inlet connection into
the air spring (011). When the exhaust valve opens, this air is compressed to a higher value.
When the hydraulic oil pressure releases, the compressed air expands and thus closes the
exhaust valve.
• Thrust piece
The thrust piece on the valve spindle (005) prevents damage to the inside piston (002) and
to the top of the valve spindle (005) when the exhaust valve operates.
• Valve stroke sensor
The valve stroke sensor monitors and transmits the open and closed positions of the valve
spindle (005) to the ECS.
• Cup spring
The cup spring (010) absorbs vibration and shock to prevent damage to the exhaust valve.
Different parts of the exhaust valve are lubricated as follows:

• Leakage oil from the outer piston and inner piston (002) lubricates the air spring piston (004).
Oil in the leakage oil collection space (012) drains to the leakage oil drain.
• While the exhaust valve closes, oil flows through the air spring piston (004) and into the air
spring (011). The air in the air spring (011) changes oil that collects at the bottom of the air
spring into a mist. The mist lubricates the upper part of the valve spindle (005).
• Oil that collects at the bottom of the air spring (011) flows through a groove on the lower
side of the distance ring and through holes in the guide bush. Thus the oil lubricates the
bottom part of the valve spindle (005).
• When the exhaust valve opens, oil flows out of the air spring (011) through the throttle valve
in the air spring pipe to the collector for leakage oil. The oil in the collector automatically
drains through the leakage oil pipe into the crankcase.

X92-B AA00-3103-00AAA-043A-A
Operation Manual Crankshaft

5.3.1 Crankshaft
The crankshaft turns as it gets the power from the pistons. The crankshaft transmits the power to
the attached propeller shaft of the ship.
Main bearings on the two sides of each crank (002, Figure 5-11) hold the crankshaft in position.
The crankshaft gear wheel (005) is part of the thrust bearing.
On the driving end of the crankshaft there is a flywheel (004). This flywheel decreases the pulsation
from the cylinders.
The length of the crankshaft is related to the number of cylinders.
Fig 5-11 Crankshaft (generic)
005 001
004 002
003
Legend
001 Torsional vibration damper (optional) 004 Flywheel

002 Crank 005 Crankshaft gear wheel
003 Crankshaft

X92-B AA00-3103-00AAA-043A-A
Operation Manual Crankshaft

X92-B AA00-3130-00AAA-043A-A
Operation Manual Torsional vibration damper
5.3.2 Torsional vibration damper

The torsional vibration damper decreases the torsional vibrations in the shafting system and in
other components of the engine.
If a torsional vibration damper is necessary for the engine, one of the two damper types that follow
can be used.

X92-B AA00-3130-00AAA-043A-A
5.3.2.1 Steel spring damper
A steel spring damper (Figure 5-12) is a tuned torsional vibration damper. It consists of two main
parts:
• The inner part (inner star (005) and spring pack (004)) is attached to the crankshaft flange
at the free end.
• The outer part (side plates (001), clamping ring (002) and intermediate pieces (003)) is
connected with spring packs (004) to the inner part.
The damper is supplied with pressurized system oil that fills the chambers between the inner and
outer part. The usual setting value for the oil supply pressure is 2.8 bar. But the setting value can
be different, refer to the specification of the damper manufacturer.
If torsional vibrations move the steel springs, oil is pressurized on one side of the oil chambers
and pushed through small clearances to the other side of the chambers. This small oil flow creates
the damping effect of the damper. The combined effect of spring stiffness and damping decreases
the torsional vibrations in the shafting system. The damping work causes heat which is dissipated
by the oil flow. The oil drains into the crankcase.
The optional damper monitoring system monitors the dynamic twist in the damper and the oil
supply pressure.
Fig 5-12 Steel spring damper (generic)
001 001
005
006
005
002 001 004 003 002 001
Legend
001 Side plate 004 Spring pack

002 Clamping ring 005 Inner star
003 Intermediate piece 006 Sealing

X92-B AA00-3130-00AAA-043A-A
5.3.2.2 Viscous damper
A viscous damper (Figure 5-13) is a tuned torsional vibration damper. It consists of two main parts:
• The housing (002) is fully sealed and is attached to the crankshaft flange at the free end.
• The inertia ring (004) is in the housing. The bearing (005) holds the inertia ring in the housing.
Between the housing and the inertia ring there is a layer of silicone oil (006) of a specified viscosity.
If no torsional vibrations occur during engine operation, the housing and the inertia ring turn with
the same speed, as the silicone oil transfers the torque. If torsional vibrations occur during engine
operation, the housing and the inertia ring dynamically turn at different speeds. This difference
shears the silicone oil and thus decreases the vibration.
The damping work causes heat. This heat increases the temperature of the outer side of the
damper. The heat dissipates to the ambient air in the crankcase. If installed, system oil is sprayed
on the damper to dissipate more heat. The oil drains into the crankcase.
If the viscous damper gets too much dynamic torque and thus causes too much heat, the viscosity
of the silicone oil can change. Then the damping effect can change. Thus do regularly a check of
the viscosity of the silicone oil, refer to the Maintenance Manual.
Fig 5-13 Viscous damper (generic)
002 003 004 002 003 001
004
001
005
006
Legend
001 Cover 004 Inertia ring

002 Housing 005 Bearing
003 Sealing 006 Silicone oil

X92-B AA00-3130-00AAA-043A-A

X92-B AA00-3140-00AAA-043A-A
Operation Manual Axial vibration damper
5.3.3 Axial vibration damper

The axial vibration damper decreases the axial vibrations of the crankshaft. The axial vibration
damper is attached with bolts to the last bearing girder at the free end of the engine.
The axial vibration damper includes a top cylinder half (002, Figure 5-14) and a bottom cylinder
half (006).
Fig 5-14 Axial vibration damper (generic)
Legend
001 Control plate 007 Bearing girder (part of bedplate)

002 Top cylinder half 008 Small sealing ring
003 Annular space 009 Bearing cover
004 Crankshaft 010 Inlet pipe
005 Large sealing ring 011 Non-return valve
006 Bottom cylinder half 012 Oil inlet

X92-B AA00-3140-00AAA-043A-A
Operation Manual Axial vibration damper
5.3.3.1 Function
Oil flows from the oil inlet (012) through the top cylinder half (002) into the two annular spaces
(003). When the crankshaft (004) moves in an axial direction, the pressure of the oil in the
compressed annular space (003) increases. This makes the oil slowly flow through the small holes
in the control plate (001) into the other annular space (003). This slow oil flow decreases the axial
vibrations. When the pressure is equal again in the two annular spaces (003), the oil flow stops.
The constant oil flow through the vent bore in the top cylinder half (002) keeps air away from the
annular spaces (003).
The small oil leakage through the gap of the large sealing rings (005) drains into the crankcase.
5.3.3.2 Axial vibration damper monitor
The axial vibration damper monitor monitors the oil pressure in the two annular spaces (003, Figure
5-14) of the axial vibration damper. The needle valve (004, Figure 5-15) and the throttle (003)
prevent fast movement of the pointer in the pressure gauges (001).
Fig 5-15 Axial vibration damper monitor (generic)
001
002
003
004
Legend
001 Pressure gauge 003 Throttle

002 Pressure transmitter 004 Needle valve

X92-B AA00-3206-00AAA-043A-A
Operation Manual Turning gear
5.3.4 Turning gear

The turning gear slowly turns the crankshaft and thus moves the pistons, if the pinion (002, Figure
5-16) is engaged on the flywheel (003). The electric motor (001) turns the pinion (002) and is
attached on the driving end of the engine. Related to the ratio of the gear wheels there is
approximately one full turn of the crankshaft in ten minutes.
Fig 5-16 Turning gear (generic)
003
002
001
Legend
001 Electric motor 003 Flywheel

002 Pinion

X92-B AA00-3206-00AAA-043A-A
Operation Manual Turning gear

X92-B AA00-3303-00AAA-043A-A
Operation Manual Connecting rod and connecting rod bearing
5.3.5 Connecting rod and connecting rod bearing

The connecting rod connects the crosshead with the crankshaft and converts the linear movement
of the piston into a circular movement of the crankshaft.
The bearing shells are installed on the connecting rod for the bottom end bearing and the top end
bearing. The top bearing cover is lined with white metal.
Crosshead lubricating oil flows through the guide shoe into the crosshead pin. A hole in the
crosshead pin lets lubricating oil flow into the bearing shells.
Fig 5-17 Connecting rod and connecting rod bearing (generic)
Legend
001 Top bearing cover 006 Round nut

002 Bearing shell (top end bearing) 007 Elastic bolt
003 Top bearing shell (bottom end bearing) 008 Dowel pin
004 Bottom bearing cover 009 Allen screw
005 Bottom bearing shell (bottom end bearing) 010 Oil bore

X92-B AA00-3303-00AAA-043A-A
Operation Manual Connecting rod and connecting rod bearing

X92-B AA00-3326-00AAA-043A-A
Operation Manual Crosshead and guide shoe
5.3.6 Crosshead and guide shoe

The crosshead guides the piston rod (009, Figure 5-18) and absorbs the lateral forces that come
from the connecting rod (005).
The piston rod (009) is attached to the compression shim (007) and the crosshead pin (006) with
screws. The bearing oil necessary to keep the piston cool, flows through the space (002) to the
piston. The oil from the piston flows back through the oil pipe (001) to the crosshead pin (006).
Then the oil flows into the crankcase.
The guide shoes (004) are attached to the crosshead pin (006) and move up and down on the
guide ways of the column. The guide rails (008) hold the guide shoes (004) and thus the crosshead
in the horizontal position.
Fig 5-18 Crosshead and guide shoe (example)
010
001
009
002
008 003
007 004
006
005
Legend
001 Oil pipe (from piston) 006 Crosshead pin

002 Space 007 Compression shim
003 Top bearing half (top end bearing) 008 Guide rail
004 Guide shoe 009 Piston rod
005 Connecting rod 010 Oil flow (to piston and from piston)

X92-B AA00-3326-00AAA-043A-A
Operation Manual Crosshead and guide shoe

X92-B AA00-3403-00AAA-043A-A
Operation Manual Piston
5.3.7 Piston
The piston moves in each cylinder. The piston rings seal the combustion chamber. The piston
transmits the force from the gas that expands in the cylinder to the crankshaft through the
connecting rod.
Elastic bolts (008, Figure 5-19) and round nuts (009) attach the piston crown (001) to the piston
rod (004). The piston skirt (003) is attached to the piston rod with screws. The piston rod (004) is
attached to the crosshead pin in a specified position. The compression shims are installed between
the piston rod and the crosshead pin. The thickness of the compression shims is related to the
specified compression ratio.
System oil is used to keep cool the piston crown (001). This oil flows from the crosshead pin into
the space (005) between the oil pipe (007) and the piston rod (004). The oil then flows to the spray
plate (010). The oil comes out as a spray from the nozzles (011) into the cooling bores of the piston
crown (001). The oil then flows through the oil pipe (007) into the crosshead pin and out through
the oil bores to the crankcase.
Fig 5-19 Piston (example)
001
011
002
010
003
009
008
007 004
005
006
Legend
001 Piston crown 007 Oil pipe (from piston crown)

002 Piston ring groove 008 Elastic bolt
003 Piston skirt 009 Round nut
004 Piston rod 010 Spray plate
005 Space 011 Nozzle
006 Oil flow

X92-B AA00-3403-00AAA-043A-A
Operation Manual Piston

X92-B AA00-4104-00AAA-043A-A
Operation Manual Supply unit drive

5.4.1 Supply unit drive
The supply unit drive is installed at the driving end of the engine on the fuel side.
The crankshaft gear wheel (003, Figure 5-20) moves the intermediate wheel (001). The
intermediate wheel (001) moves the intermediate wheel (006).
The gear wheel (005) operates the gear wheels (004) for the servo oil pumps. The camshaft of
the gear wheel (005) also operates the fuel pumps.
Oil flows through an oil inlet to lubricate the bearings of the gear wheels (004). Oil also flows
through the nozzles in the bearing housing to lubricate the teeth of the gear wheels (004) and the
gear wheel (005).
If you hear unusual noises from the area of the supply unit drive, you must find the cause and
repair the fault immediately.

X92-B AA00-4104-00AAA-043A-A
Operation Manual Supply unit drive
Fig 5-20 Supply unit drive (generic)
I
001
006
001
003
007
003 002
006
005 001
003
004
002
Legend
001 Intermediate wheel 005 Gear wheel (servo oil pumps)

002 Flywheel 006 Intermediate wheel
003 Crankshaft gear wheel 007 Crankshaft
004 Gear wheel (servo oil pump)

X92-B AA00-4325-00AAA-043A-A
Operation Manual Starting air shut-off valve
5.4.2 Starting air shut-off valve

The starting air shut-off valve supplies the starting air pipe with starting air. The starting air shut-
off valve has a hand-wheel with three positions:
• CLOSED
• AUTO
• OPEN.
Fig 5-21 Starting air shut-off valve (example)
012
001
I
002
003
004
005
011 010 009 008 007 006

I
017
018
016
015
014
013
Legend
001 Control valve 010 Non-return valve

002 Valve space 011 Starting air outlet
003 Spindle 012 Inlet chamber
004 Hand-wheel 013 Pressure switch PS5017C
005 To test valve 014 Solenoid valve CV7014C
006 Spring 015 Double check valve
007 Valve 016 Solenoid valve CV7013C
008 Starting air inlet 017 Control air inlet
009 Balance bore 018 Lever
With the lever (018, Figure 5-21) you can lock the valve in the selected position. During usual
operation the starting air shut-off valve is in position AUTO.
Starting air flows through the starting air inlet (008) into the inlet chamber (012), then through the
balance bore (009) into the valve space (002). The spring (006) and the pressure in the valve
space (002) keep the valve (007) closed.

X92-B AA00-4325-00AAA-043A-A
Operation Manual Starting air shut-off valve
During the start sequence the MCM-20 / IOM-20 module operates the solenoid valves (014) and
(016). The control air from the control air inlet (017) opens the control valve (001) through the
solenoid valve CV7014C (014) and releases the pressure in the valve space (002). The valve (007)
opens and starting air from the inlet chamber (012) flows through the non-return valve (010) to the
starting air outlet (011).
When the control valve (001) closes, starting air flows through the balance bores (009) and fills
the inlet chamber (012) again. The valve (007) closes.
The starting air shut-off valve has a test valve. You can use this test valve for a function check of
the starting air shut-off valve.

X92-B AA00-4605-00AAA-043A-A
Operation Manual Control air supply
5.4.3 Control air supply

The control air supply supplies control air to the engine. The plant supply systems supply
compressed air with the specified properties at the two engine connections that follow:
• Connection 45 (control air supply inlet) for usual supply
• Connection 40 (Starting air pipe inlet) for stand-by supply.
The pressure reducing valves (008, Figure 5-22) and (009) decrease the pressure of the
compressed air to the set values. If the plant supply system for control air becomes defective, the
supply changes over to stand-by supply. The non-return valves (007) and (010) control the
automatic change over of the compressed air supply.
Fig 5-22 Control air supply (generic)
001
012 002
003
004
005
011 010 009
008 007 006

Legend
001 Pressure transmitter PT4411A 007 Non-return valve 35-342HA

002 Pressure transmitter PT4401A 008 Pressure reducing valve 35-23HA
003 Pressure gauge PI4401L 009 Pressure reducing valve 35-19HA
004 3/2-way valve 35-36HB (connection point A1) 010 Non-return valve 35-342HB
005 3/2-way valve 35-36HC (connection point A2) 011 Air filter 35-351HA
006 3/2-way valve 35-36HA (connection point A6) 012 Pressure gauge PI4411L

X92-B AA00-4605-00AAA-043A-A
Operation Manual Control air supply

X92-B AA00-4618-00AAA-043A-A
Operation Manual Local maneuvering stand for UNIC
5.4.4 Local maneuvering stand for UNIC

The local maneuvering stand has the local control panel (001, Figure 5-23) and is attached to the
engine at the free end. The local control panel has the components necessary for engine operation.
Some components can look different because the remote control manufacturer supplies the local
control panel (001).
For data about maneuvering instructions, refer to section 8.8 Maneuver the ship - general.
Fig 5-23 Local maneuvering stand (generic)
Legend
001 Local control panel 003 Main engine tachometer

002 LDU-20 004 Telegraph receiver

X92-B AA00-4618-00AAA-043A-A
Operation Manual Local maneuvering stand for UNIC
5.4.4.1 Local control panel

NOTE: If a fault occurs in the remote control, which prevents engine control from the control
room, you can operate the engine from the local control panel.
The local control panel (001) has the electronic components that follow:
• Local display unit (LDU-20)
There are two LDU-20 (002, Figure 5-23). One LDU-20 is installed in the local control
panel (001). The other LDU-20 is installed in the engine control room. The two LDU-20
operate independently from the remote control system. For more data about the LDU-20,
refer to section 6.4 Local display unit (LDU-20) - general.
• ME tachometer
The ME tachometer (003) shows the engine speed in the ahead or astern directions.
• Emergency stop button
NOTE: Not all local control panels have an emergency stop button installed.
When you operate the emergency stop button (not shown), the engine stops immediately.
The fuel pressure control valve (PCV) releases the pressure in the fuel rail. At the same
time, the fuel pump supply decreases to 0 (zero).
○ For data about the PCV, refer to section 5.5.4 Pressure control valve.
○ For data about engine stop, refer to section 8.15 Stop the engine.
• Telegraph receiver
The telegraph system is part of the propulsion control system, refer to section [section not

X92-B AA00-4628-00AAA-043A-A
Operation Manual Pick-up for speed measurement
5.4.5 Pick-up for speed measurement

To measure the engine speed (rpm), proximity sensors are installed in a speed pick-up unit,
attached to the support near the flywheel.
For safety, there are three electrically isolated proximity sensor groups as follows:
• Speed identification in the remote control system (RCS)
• Overspeed safety system
• Speed control system.
The proximity sensors measure the speed of the flywheel (003, Figure 5-24). When the flywheel
turns, the proximity sensors (002) sense the movement of the teeth. The engine control system
sends signals to the RCS to monitor the load and speed related functions. Data are also sent to
the speed indication instruments.
Fig 5-24 Pick-up for speed measurement (generic)
001
002
003
004
Legend
001 Cover 003 Flywheel

002 Proximity sensor 004 Crank angle mark

X92-B AA00-4628-00AAA-043A-A
Operation Manual Pick-up for speed measurement

X92-B AA00-5551-00AAA-043A-A
Operation Manual Servo oil pump

5.5.1 Servo oil pump
The servo oil pumps (004, Figure 5-25) supply the servo oil system with oil during usual operation.
The number of servo oil pumps is related to the engine.
The pressure value is related to the engine load. The electrically controlled system adjusts the
system pressure for the full load range, ie high pressure (approximately 300 bar) at high engine
load, and decreased pressure at low engine load.
Flow sensors monitor the oil supply in each inlet pipe of the servo oil pumps. A malfunction of a
servo oil pump will show in the alarm and monitoring system.
If a servo oil pump cannot turn, for safety the waisted shaft (003) will break. This will prevent too
much damage to the supply unit drive.
Also if one servo oil pump becomes defective, the engine can continue to operate at full load.
NOTE: Do not operate the engine with a defective servo oil pump for too long. You must replace
a defective servo oil pump as soon as possible.
Fig 5-25 Servo oil pump (example)
004
001
002
003
Legend
001 Supply unit 003 Shaft

002 Intermediate wheel (supply unit) 004 Servo oil pump

X92-B AA00-5551-00AAA-043A-A
Operation Manual Servo oil pump

X92-B AA00-5552-00AAA-043A-A
Operation Manual Supply unit
5.5.2 Supply unit

The supply unit includes the servo oil pumps and the fuel pumps. The supply unit is installed on
the column at the driving end of the engine. The gear wheels and intermediate wheels in the supply
unit operate the fuel pumps and servo oil pumps, refer to section 5.4.1 Supply unit drive.
Fig 5-26 Supply unit (example)
Legend
001 Fuel pump 004 Bedplate

002 Supply unit with covers 005 Column
003 Flywheel

X92-B AA00-5552-00AAA-043A-A
Operation Manual Supply unit

X92-B AA00-5556-00AAA-043A-A
Operation Manual Fuel pump
5.5.3 Fuel pump

The fuel pumps (001, Figure 5-27) supply the fuel rail with fuel at high pressure. The number of
fuel pumps is related to the engine.
Fig 5-27 Fuel pump (generic)
001
002
Legend
001 Fuel pump 002 Supply unit
5.5.3.1 Function
When the cam (007, Figure 5-28) moves the roller (006) up, the guide piston (008) moves up.
Then the bottom spring carrier (005) compresses the compression spring (004). The pump
plunger (003) then moves up. The control grooves in the pump plunger (003) control the fuel
quantity.
When the toothed rack (011) moves, the teeth engage with the teeth on the regulating sleeve (010)
and the regulating sleeve turns. The regulating sleeve (010) turns the driver (009) and thus the
pump plunger (003). The quantity of fuel that goes into the plunger chamber is related to the control
position (between 0 for zero supply and 10 for maximum supply).

X92-B AA00-5556-00AAA-043A-A
Operation Manual Fuel pump
Fig 5-28 Fuel pump - cross section (example)
001
014
013
012 002
011 003
010
009 004
005
008
006
007
Legend
001 HP fuel to fuel rail 008 Guide piston

002 Fuel inlet 009 Driver (of pump plunger)
003 Pump plunger 010 Regulating sleeve
004 Compression spring 011 Toothed rack
005 Bottom spring carrier 012 Fuel outlet
006 Roller 013 Non-return valve
007 Cam 014 Pump cover
5.5.3.2 Lubrication
Engine lubricating oil, which flows through the lubricating oil inlet into the bottom housing,
lubricates the fuel pump.
Leakage fuel lubricates the pump plunger (003). The leakage fuel and the engine lubricating oil
from the regulating sleeve (010) flows through the drain bore. This mixture then flows into an
internal bore in the housing of the fuel pump unit.
5.5.3.3 Operation with an unserviceable fuel pump
If a fuel pump is unserviceable (eg the pump plunger cannot move) or the HP fuel pipe is broken
(between the fuel pump and the fuel rail) the fault must be repaired immediately. If the fault cannot
be repaired, it is possible to cut out the unserviceable fuel pump. Related to the number of installed
fuel pumps, there are limits of operation.

X92-B AA00-5562-00AAA-043A-A
Operation Manual Pressure control valve
5.5.4 Pressure control valve

The pressure control valve (PCV) (002, Figure 5-29) is attached to the fuel rail (007) and has the
functions that follow:
• Usual operation
During usual operation the engine software controls the fuel flow and thus the fuel pressure.
The PCV is closed because the pressure in the fuel rail is lower than necessary to open the
PCV.
• Operation with a defective item
If an item becomes defective or unserviceable (for example missing or incorrect control
signals, a flow control valve of a fuel pump is unserviceable), the operator must do the
related procedures. Then the engine control sets the fuel pumps to the maximum flow and
the PCV controls the pressure in the fuel rail. The PCV opens to gradually drain sufficient
fuel to keep the adjusted pressure. Prevent a longer engine operation time in this operation
mode to prevent a possible damage to the PCV.
After this operation mode, do a check of the PCV for a tight seal. The seal can be damaged.
You can hear a loud sound like a whistle. Replace the PCV seal if necessary.
• Engine stand-by
During engine stand-by, the engine software opens the PCV. This gives a constant flow of
fuel through the fuel system.
• Emergency stop
If an emergency stop is activated, the safety system operates the solenoid valve (001) and
the fuel pressure in the fuel rail decreases immediately to less than 200 bar (usually to 0 bar).
Thus, fuel injection is not possible.
Attached to the PCV are the solenoid valve (001), the relief valve (003) and the fuel return
pipes (004, 005). As a safety device the relief valve opens, if the fuel pressure is more than the
specified pressure.

X92-B AA00-5562-00AAA-043A-A
Operation Manual Pressure control valve
Fig 5-29 Pressure control valve - location (example)
001
002
003
004
005
006
007
008
Legend
001 Solenoid valve (ZV7061S) 005 Fuel return pipe

002 Pressure control valve (10-5562_E0_5) 006 Rail unit
003 Relief valve 007 Fuel rail
004 Fuel return pipe 008 Drain pipe

X92-B AA00-5565-00AAA-043A-A
Operation Manual Flow limiting valve
5.5.5 Flow limiting valve

For each cylinder there is one flow limiting valve installed on the fuel rail.
The position of the piston (003, Figure 5-30) gives the quantity of fuel for the injection. When the
injection valves open, the piston (003) moves to the right until the injection stops. When the
injection valves are closed, the piston (003) moves back to the start position.
If the injection time is too long (for example if an injection valve is stuck open), the piston (003)
closes the supply.
If an injection valve is damaged, the flow limiting valve sets the maximum limit of fuel that can be
injected into the cylinder.
Fig 5-30 Flow limiting valve (generic)
Legend
001 Fuel outlet (number related to the engine) 003 Piston

002 Fuel inlet

X92-B AA00-5565-00AAA-043A-A
Operation Manual Flow limiting valve

X92-B AA00-5612-00AAA-043A-A
Operation Manual Exhaust valve control unit
5.5.6 Exhaust valve control unit

The exhaust valve control units (VCU) control the servo oil to the exhaust valve of the related
cylinders. The exhaust valve control units are attached to the servo oil rail.
When the solenoid valve operates, servo oil is released to the slide rod (001, Figure 5-31). This
releases servo oil to the piston (003). Thus servo oil from the servo oil outlet (004) opens the
exhaust valve.
Fig 5-31 Exhaust valve control unit (VCU) (example)
004
001
003
002
Legend
001 Slide rod 003 Piston

002 Servo oil inlet 004 Servo oil outlet

X92-B AA00-5612-00AAA-043A-A
Operation Manual Exhaust valve control unit

X92-B AA00-5583-00AAA-043A-A
Operation Manual Fuel pump actuator
5.5.7 Fuel pump actuator

The fuel pump actuator moves the regulating sleeve of the fuel pump and thus controls the fuel
quantity, refer to section 5.5.3 Fuel pump. Each fuel pump is connected to its related actuator (for
an X92 engine two fuels pumps are connected to there related actuator).
The ECS controls the fuel pump actuators. During operation the fuel pump actuators move at the
same time. Each fuel pump actuator has an overload protection. Thus you do not have to
disconnect a fuel pump actuator, if the regulating sleeve of a fuel pump cannot move.

X92-B AA00-5583-00AAA-043A-A
Operation Manual Fuel pump actuator

X92-B AA00-6420-00AAA-043A-A
Operation Manual Scavenge air receiver

5.6.1 Scavenge air receiver
The scavenge air receiver (005, Figure 5-32) supplies the cylinders with the applicable quantity of
air.
The scavenge air receiver is a welded assembly attached to the cylinder block on the exhaust
side.
The relief valve, installed on the scavenge air receiver, opens when the air pressure increases to
more than the permitted value in the air space (001, Figure 5-33).
For more data about the scavenge air system, refer to section 4.8 Scavenge air system.
Fig 5-32 Scavenge air receiver (example)
001
005
002
003
004
Legend
001 Scavenge air from turbocharger 004 Auxiliary blower

002 Diffuser 005 Scavenge air receiver
003 Scavenge air cooler
The longitudinal wall (002, Figure 5-33) divides the scavenge air receiver into the receiver
space (003) and the air space (001). The flaps (005) are attached to the longitudinal wall (002).
The flaps (005) prevent the scavenge air to flow back into the air space (001).

X92-B AA00-6420-00AAA-043A-A
Operation Manual Scavenge air receiver
Fig 5-33 Scavenge air receiver - cross section (example)
005
001
004 002
003
Legend
001 Air space 004 Outlet to piston underside

002 Longitudinal wall 005 Flap
003 Receiver space

X92-B AA00-6500-00AAA-043A-A
Operation Manual Turbocharger
5.6.2 Turbocharger
The compressor (001, Figure 5-34) of the turbocharger compresses the scavenge air to the
applicable pressure. The compressor is directly attached to the shaft of the turbine (005). The
remaining energy of the exhaust gas drives the turbine and thus the compressor.
The number and the size of the turbochargers is accurately tuned to the engine and the number
of cylinders.
Fig 5-34 Turbocharger (example)
Legend
001 Compressor 005 Turbine

002 Air inlet 006 Exhaust gas outlet
003 Silencer 007 Exhaust gas inlet
004 Air outlet
If a turbocharger becomes defective, you must stop the engine as quickly as possible to prevent
damage.
If repair or replacement of a turbocharger is not immediately possible, you can cut out the defective
turbocharger, refer to section 10.17 Temporary isolate a defective turbocharger. Then the engine
can operate at decreased load, refer to the limits in section 8.3 Start the engine - general.
WinGD recommends to regularly clean the turbochargers and the silencers, refer to section 9.4
Clean the turbocharger during operation. This prevents or decreases contamination of the
turbochargers and thus increases the time between overhauls.

X92-B AA00-6500-00AAA-043A-A
Operation Manual Turbocharger

X92-B AA00-6545-00AAA-043A-A
Operation Manual Auxiliary blower
5.6.3 Auxiliary blower

The auxiliary blowers supply air from the engine room through the duct into the scavenge air
receiver during the engine start and operation at low load. The flaps prevent the back flow of air
to the scavenge air receiver during usual operation of the turbochargers and during engine stop.
The electric motor (004, Figure 5-35) operates the auxiliary blower (003).
The pressure relief valve is installed to protect the scavenge air receiver, when pressure is more
than set limit.
The auxiliary blowers are installed on the scavenge air receiver, refer to section 5.6.1 Scavenge
air receiver.
Fig 5-35 Auxiliary blower
001
004 002
003
Legend
001 Air outlet 003 Auxiliary Blower

002 Air inlet 004 Electric motor
During the engine start operation, the auxiliary blowers start one by one at two or three seconds
interval, to avoid electric overload.
Minimum one auxiliary blower is necessary to start the engine.

NOTE: During emergency operation, the auxiliary blowers can be manually controlled when all
the scavenge air pressure transmitters are faulty.
During the engine operation, when the turbochargers supply sufficient air pressure in the scavenge
air receiver, the auxiliary blowers stop automatically by tunings depended setup and starts again
if required, (Delta bar).
The auxiliary blower switch box (refer to section 5.6.4 Auxiliary blower switch box) is the interface
between the operator and auxiliary blower and gives data about the condition of the auxiliary
blowers.

X92-B AA00-6545-00AAA-043A-A
Operation Manual Auxiliary blower

X92-B AA00-6547-00AAA-043A-A
Operation Manual Auxiliary blower switch box
5.6.4 Auxiliary blower switch box

The auxiliary blower switch box is used to operate the auxiliary blowers in Auto mode or Manual
mode.
When the auxiliary switch box is in Auto mode, the first auxiliary blower will start and second will
start after few seconds.
Auxiliary blower will automatically stop when the turbochargers give sufficient air pressure. The
auxiliary blowers will automatically start when the scavenge air pressure drops.
When the engine stops, the auxiliary blowers will continue to operate for some time period for
cooling and ventilation of the engine.
In Manual mode, the operator can start or stop the auxiliary blowers manually.
In Off mode, the auxiliary blowers are switch off.
Fig 5-36 Switch box
014
001
013
012 002
011 003
010
004
009
005
008
007
006
Legend
001 Indicator (auxiliary blower No. 2 running) 008 Restart push button
002 Indicator (auxiliary blower No. 2 overload) 009 Ampere meter (auxiliary blower No. 1)
003 Hour counter (auxiliary blower No. 2) 010 Hour counter (auxiliary blower No. 1)
004 Ampere meter (auxiliary blower No. 2) 011 Supply fault indicator
005 Main switch (auxiliary blower No. 2) 012 Indicator (auxiliary blower No. 1 running)
006 Emergency push button 013 Indicator (auxiliary blower No. 1 overload)
007 Main switch (auxiliary blower No. 1) 014 Control voltage indicator

X92-B AA00-6547-00AAA-043A-A
Operation Manual Auxiliary blower switch box

X92-B AA00-6606-00AAA-043A-A
Operation Manual Scavenge air cooler
5.6.5 Scavenge air cooler

The scavenge air cooler (SAC) decreases the temperature of the hot compressed air from the
turbochargers. This increases the density of the air and thus increases the quantity of air that is
supplied to the cylinders.
The cooling water flows constantly through the tubes of the SAC and flows back to the cooling
water system of the plant.
The SAC has a cover (004, Figure 5-37). For maintenance you can remove the cover.
Fig 5-37 Scavenge air cooler (generic)
001
002
004
003
Legend
001 Air flow 003 Cooling water inlet

002 Cooling water outlet 004 Cover
WinGD recommends to regularly clean the scavenge air coolers, refer to section 9.5 Clean the
scavenge air cooler during operation. This prevents or decreases contamination of the scavenge
air coolers and thus increases the time between overhauls.

X92-B AA00-6606-00AAA-043A-A
Operation Manual Scavenge air cooler

X92-B AA00-6708-00AAA-043A-A
Operation Manual Water separator
5.6.6 Water separator

The water separator removes water from the scavenge air. This prevents damage and gives better
combustion in the cylinders. Water occurs when the scavenge air cooler (SAC) decreases the
temperature of wet air. Water also occurs during the wash procedure of the SAC.
The profiles (002, Figure 5-38) hold back the water in the air flow. This water collects at the bottom
of the frame (003) and then flows back to the drain system.
Fig 5-38 Water separator (generic)
001
003
002
Legend
001 Air flow 003 Frame

002 Profile

X92-B AA00-6708-00AAA-043A-A
Operation Manual Water separator

X92-B AA00-7218-00AAA-043A-A
Operation Manual Cylinder lubrication

5.7.1 Cylinder lubrication
For information about the cylinder lubrication oil, refer to section: 12.1 General for operating media
For information about the cylinder oil system in general, refer to section: 4.6 Cylinder oil system

X92-B AA00-7218-00AAA-043A-A
Operation Manual Cylinder lubrication

X92-B AA00-7752-00AAA-043A-A
Operation Manual Integrated electrical balancer (iELBA)
5.7.2 Integrated electrical balancer (iELBA)

The optional integrated ELectrical BAlancer (iELBA) decreases second order vertical mass
moments (M2v) of the engine, refer to Figure 5-39.
NOTE: For the engine itself it is not necessary to install a balancer. But a balancer decreases
the exitation forces of the engine. A calculation of the mass moment M2v shows if a
balancer is necessary for a specified hull design.
Usually there are two iELBAs installed, one at the free end (FE) and one at the driving end (DE)
of the engine. For special designs it is possible to install only one balancer at the free end (FE) or
at the driving end (DE).
Fig 5-39 Effect of second order moments (M2v) of the engine
5.7.2.1 Function
An electric motor operates the two gear wheels (001, Figure 5-40) and thus the counterweights
(002) in opposite directions. The horizontal elements (Fhoriz) of the forces (F) are always canceled.
The vertical elements (Fvert) are always added to a resulting vertical force. This resulting force
operates up and down with the same frequency as the counterweights (002) turn. The resulting
force is transmitted through the bearings (003) to the column (005) and thus to the engine.
The rotating speed (ω) of the counterweights (002) is always two times the engine rotating speed
and is in phase to the engine. Thus the second order vibrations in the hull are decreased.
Engine system oil lubricates the iELBA. The oil flows back to the crankcase.
NOTE: Operate the iELBA only if system oil is available at correct pressure and flow rate.
A brake resistor for each balancer changes the rotating energy of the iELBA to heat in the
conditions that follow:
• If the engine speed changes quickly.
• If there is an emergency stop of the iELBA.
• If there is an energy sink during the phase synchronisation of the iELBA.

X92-B AA00-7752-00AAA-043A-A
Fig 5-40 iELBA - function
Legend
001 Gear wheel 004 Housing

002 Counterweight 005 Column
003 Bearing

X92-B AA00-7752-00AAA-043A-A
5.7.2.2 Control system
Each iELBA has two control cabinets (E38 and E39). The control system monitors the speed of
the electric motor and the rotating speeds and phases of the counterweights (002) and of the
flywheel of the engine. The control system also uses TDC and BDC data of piston #1 of the engine.
A frequency converter controls the electric motor.
When the iELBA is started, there are two states that are indicated on the control cabinet:
• Swing state
The electric motor swings the counterweights back and forward some times until the
counterweights turn fully.
• Run state
The iELBA has started to turn fully. The control system increases the speed of the iELBA
and synchronises it to the engine.
5.7.2.3 Operation
Usually the iELBA operates in the speed range of the engine of 65% to 105% of CMCR in the
AHEAD direction.
NOTE: In heavy sea mode the iELBA does not operate.
The engine can also operate if one or the two balancers do not operate (eg in manual mode or if
a balancer is defective). Then it is possible that there are more vibrations on the hull.
When the power for the iELBA is set to ON, it takes some seconds to complete the initialisation
of the system.
The iELBA operates independently of the engine control system (ECS). The iELBA can be
operated in automatic mode or manual mode:
• Automatic mode
In automatic mode the balancers operate as follows:
○ The iELBA starts if the engine speed is higher than the specified threshold value.
○ The iELBA stops if the engine speed is lower than the specified threshold value.
• Manual mode
In manual mode the balancers operate at a specified speed. Use the manual mode for
troubleshooting only.
NOTE: Use the manual mode only if system oil is available at correct pressure and flow
rate.

X92-B AA00-7752-00AAA-043A-A
5.7.2.4 Control cabinet
Figure 5-41 shows the buttons and indications on the control cabinet of the iELBA.
Fig 5-41 iELBA - control cabinet

X92-B AA00-7752-00AAA-043A-A
Tab 5-1 iELBA - control cabinet
A9 Drive Power Consumption indica- Shows the electric motor current (in Ampere)
tion
S7 Manual Start button Starts the iELBA (in manual mode)
S8 Manual Stop button Stops the iELBA (in manual mode)
H11 Power 24V indicator light Shows if electric power is on
S5/H5 Error reset button Shows and resets iELBA errors, refer to Table 5-2 - iELBA - error
indication
NOTE: If an error occurs, the indicator light shows the related
number of flashes.
NOTE: Only reset an error after you have done the related
procedures.
S6 Mode Auto / Manual switch Changes between automatic and manual mode
H3 Swing / Run indicator light Shows the state of the running iELBA:
• Lamp blinks - iELBA is in swing state
• Lamp is steady - iELBA is in run state
H4 Synch OK indicator light Shows the synchronisation state of the iELBA:

• Lamp is steady - iELBA is synchronised to the engine
• Lamp blinks slowly - iELBA is +/-15° from engine syn-
chronisation
• Lamp blinks quickly - iELBA is +/-30° from engine syn-
chronisation
S1 Emergency stop button Stops the iELBA immediately
S2/H2 Emerg. Stop Reset button Resets an emergency stop to enable iELBA restart
The integrated indicator light shows as follows:
• Lamp is on - an emergency stop is active
• Lamp is off - usual operation
A10 Hour indication Shows the running hours of the electric motor
NOTE: A10 is installed in the control cabinet.

X92-B AA00-7752-00AAA-043A-A
Table 5-2 - iELBA - error indication shows the possible iELBA error indications related to the
number of flashes of the indicator light.
NOTE: The error indications are active in automatic mode and in manual mode.
Tab 5-2 iELBA - error indication
Number of Status iELBA state

flashes
1 Start OK, “Boost to Control Speed Threshold” not OK OFF
2 Start OK, “Setpoint Speed” not OK in 60 s OFF
3 Start OK, speed OK, “Phase Synchronisation” not OK in 60 s OFF
4 Overspeed error OFF
5 Electric motor error OFF
6 The lubricating oil pressure is too low OFF
7 iELBA pickup sensor error OFF
8 TDC pickup sensor error Usual operation
9 BDC pickup sensor error Usual operation

X92-B AA00-8135-00AAA-043A-A
Operation Manual Exhaust waste gate
5.8 Group 8 - Pipes

5.8.1 Exhaust waste gate
The optional exhaust waste gate is a by-pass pipe to the turbine (006, Figure 5-42) of the
turbochargers. The valve (007) in this pipe controls the flow of exhaust gas through the
turbines (006). This controls the compressor (002) of the turbochargers and thus the supply of
scavenge air to the scavenge air receiver (003).
During usual operation the valve (007) is closed and thus all the exhaust gas flows through the
turbines (006).
Fig 5-42 Exhaust waste gate (generic)
001
008
007 002
006
005 003
004
Legend
001 Air inlet 005 Exhaust gas manifold

002 Compressor 006 Turbine
003 Scavenge air receiver 007 Valve
004 Engine 008 Exhaust gas outlet
If the turbochargers deliver too much scavenge air pressure, the ECS opens the valve (007). If
the valve (007) is controllable, the ECS opens it as much as necessary. This decreases the
performance of the turbochargers and thus the pressure of the scavenge air.
If the valve (007) is blocked in the open position, you have to close the exhaust waste gate, refer
to section 10.18 Temporary isolate the exhaust waste gate.

X92-B AA00-8135-00AAA-043A-A
Operation Manual Exhaust waste gate

X92-B AA00-9223-00AAA-043A-A
Operation Manual Crank angle sensor unit

5.9.1 Crank angle sensor unit
The crank angle sensor unit is installed on the supply unit drive at the driving end.
There are two crank angle systems that monitor the teeth on the intermediate wheel. The two sets
of proximity sensors (003, Figure 5-43) operate independently to sense the teeth on the
intermediate wheel (002).
Fig 5-43 Crank angle sensor unit on intermediate wheel (example)
Legend
001 Supply unit 003 Proximity sensor

002 Intermediate wheel

X92-B AA00-9223-00AAA-043A-A
Operation Manual Crank angle sensor unit
Two more proximity sensors (002, Figure 5-44) are used to find the crank angle marks (004) for
TDC and BDC on the flywheel (003).
All proximity sensors are connected as follows:

• First sensor pair to MCM-20 and CCM-20#1
• Second sensor pair from CCM-20#2 to CCM-20#n
• TDC and BDC to all CCM-20
Fig 5-44 Crank angle sensor unit on flywheel (example)
Legend
001 Cover 003 Flywheel

002 Proximity sensor 004 Crank angle mark

X92-B AA00-9313-00AAA-043A-A
Operation Manual Water in oil monitor
5.9.2 Water in oil monitor

The optional water in oil monitor continuously monitors the concentration of water in the oil supply
pipe. The water in oil monitor continuously sends a signal to the alarm and monitoring system
(AMS).
On the display (001, Figure 5-45) you can see the data that follow:
• aw - water activity
• T - temperature in °C
• H2O - water content in ppm
Fig 5-45 Water in oil monitor (generic)
001
002
003
Legend
001 Display 003 Connection points

002 Keypad

X92-B AA00-9313-00AAA-043A-A
Operation Manual Water in oil monitor

X92-B AA00-9314-00AAA-043A-A
Operation Manual Oil mist detector
5.9.3 Oil mist detector

The oil mist detection system continuously monitors the concentration of oil mist in the crankcase,
in the supply unit drive and in the supply unit. If there is a high oil mist concentration, the oil mist
detector activates an alarm. Thus damage to the bearings can be quickly found and explosions in
the crankcase can be prevented.
The system includes the sensors (002, Figure 5-46) and the control unit (003) on the engine.
Fig 5-46 Oil mist detector (example)
001
002
004
003
Legend
001 Data cable 003 Control unit E15.1

002 Sensor 004 Column
Each sensor monitors the concentration of oil mist. Each sensor has a self-test function to make
sure that there are no internal faults.

X92-B AA00-9314-00AAA-043A-A
Fig 5-47 Oil mist detector - schematic diagram (example)
001
009
008
002
007 006 005 004 002 003
Legend
001 Control panel 006 Control unit E15.1

002 Power supply 007 Supply unit
003 Data cable 008 Crankcase and gear box
004 To alarm system 009 Sensor
005 To safety system
Data communication is between the control unit (006, Figure 5-47) and the control panel (001).
The adjustments can be programmed in the display unit (001). The menu-driven software has
three user levels:
• User - Read-only of data
• Operator - Password-protected level for access to most adjustments and functions
• Service - Password-protected level for authorized staff of the manufacturer and service
personnel.
NOTE: Instructions that relate to adjustments, commissioning, troubleshooting, and
maintenance are given in the related documentation of the manufacturer.

X92-B AA00-9314-00AAA-043A-A

X92-B
Operation Manual
6 Control system
6.1 Engine control system WiCE...................................................................................206
6.2 Intelligent combustion control..................................................................................210
6.3 Integrated gas pressure regulation..........................................................................214
6.4 Local display unit (LDU-20) - general......................................................................218
6.5 LDU-20 page - iELBA Control (optional).................................................................220
6.6.1 Operate the manual control panel (MCP)........................................................222
6.6.2 MCP page - MAIN...........................................................................................226
6.6.3 MCP page - Adjust user parameters...............................................................228
6.6.4 MCP page - SYSTEM INFO - Option for WiCE...............................................232
6.6.5 MCP page - TREND - Option for WiCE...........................................................234
6.6.6 MCP page - INSTRUMENTS..........................................................................236
6.6.7 MCP page - FUEL / LUBRICATION SYSTEM................................................238

X92-B AA00-0000-00AAC-043K-A
Operation Manual Engine control system WiCE
6.1 Engine control system WiCE
6.1.1 General
The engine control system (ECS) is an embedded system that has a modular design. Some parts
and functions in the ECS system configuration are optional and are related to the application.
The name of the WinGD engine control system is WinGD integrated Control Electronics (WiCE).
It has the items that follow:
• Cylinder control unit (CCU #1 to #n)
The cylinder control units (CCU #1 to #n) for each cylinder are installed on the rail unit in
the terminal boxes E95.nn. The CCU have different cylinder-related and engine-related
control functions. The CCU also have redundant global functions for the engine control.
• Main control unit (MCU #1 to #3)
The main control units (MCU #1 to #3) are installed in the terminal boxes E27.1 to E27.3.
The MCU have functions for speed control, engine control and common engine functions
(for example starting air shut-off valve).
• Gateway unit (GTU #1 and #2)
The gateway units (GTU #1 and #2) are installed on the rail unit in the terminal box E90.
The GTU transmits data to and from external control systems.
• Manual control panel (MCP)
One manual control panel (MCP) is installed at the local maneuvering stand at the free end.
The other MCP is installed in the engine control room (ECR). External control systems
transmit data to the MCP. The MCP gives the operator a graphical user interface for access
to data and system adjustments.
• Angle calculation module (ACM #1 and #2)
The optional angle calculation modules (ACM #1 and #2) are installed in the terminal boxes
E96.1 and E96.2.
Redundant system buses connect all these modules.
Software updates must be done only with the supervision of a WinGD service engineer and in
accordance with regulations that WinGD has set.

X92-B AA00-0000-00AAC-043K-A
6.1.2 Functions of the engine control system
The main functions of the engine control system are as follows:

• Starting valve control
• Servo oil pressure control
• Exhaust valve control
• Cylinder lubricating control
• Engine speed and crank angle sensor monitoring
• Diesel fuel pressure control
• Diesel fuel injection control
• For a DF engine, also gas injection control

X92-B AA00-0000-00AAC-043K-A
6.1.3 External control systems
The Diesel Engine CoNtrol and OptImizing Specification (DENIS) and the engine control system
(ECS) are designed so that different remote controls can be used. All nodes are fully specified.
The terminal boxes are installed on the engine, to which the cable ends from the control room or
from the bridge can be connected.
The engine control has all the parts necessary to operate and monitor the engine, and for the
safety of the engine.
The ECS supplies the data communications to:

• The propulsion control system (PCS)
• The alarm and monitoring system (AMS).
The standard version of the ECS includes the external communications that follow:
• Two redundant CANBus lines to the PCS
• Three redundant Modbus lines to the AMS.
NOTE: The communications between the systems can be different. See the related
documentation from the approved propulsion control system manufacturer.
6.1.3.1 Propulsion control system
The propulsion control system (PCS) has the subsystems that follow:
• Remote control system
The remote control system (RCS) has the primary functions that follow:
○ Start, stop and reverse
○ Automatic slow turning
Data about the ECS status is available in the RCS. This includes measured values of
sensors, defects and other indications (refer to the documentation of the remote control
manufacturer).
All commands to operate the engine (for example AHEAD or ASTERN) come from the RCS.
• Engine safety system
The engine safety system (ESS) has the primary functions that follow:
○ Emergency stop
○ Overspeed protection
○ Automatic shutdown
○ Automatic slowdown
• Telegraph system
The telegraph system transmits maneuvering signals from the bridge to the ECR and local
control panel.
NOTE: The ESS and telegraph system operate independently and are also fully serviceable if
the RCS is defective.

X92-B AA00-0000-00AAC-043K-A
6.1.3.2 Alarm and monitoring system
The alarm and monitoring system (AMS) is an external system and monitors the engine. The AMS
gives the operator alarms and status data of the engine to make sure of safe and satisfactory
engine operation.
The functions of the AMS are specified in the diesel engine control and optimizing specification
(DENIS). The AMS sends signals to the engine safety system to slow down or shut down the
engine.
For more data, see the documentation of the AMS manufacturer.

X92-B AA00-9308-00AAA-043A-A
Operation Manual Intelligent combustion control
6.2 Intelligent combustion control

The intelligent combustion control (ICC) permanently monitors and automatically controls the
combustion process.
The ICC is part of the engine control system (ECS). All ICC modifications of the engine control
parameters obey the IMO regulations and are related to the IMO certificate of the vessel.
The ICC calculates the best engine control parameters for operation, which balances the
compression and firing pressures in the engine (for example injection time offsets and exhaust
valve closing time for each cylinder).
• This decreases the excessive wear of engine components.
• This decreases the risk of an engine overload.
• This prevents manual adjustment failures.
In the ECS you can set to OFF or ON each individual function of the ICC system. When all ICC
functions are set to OFF, the engine operates in a conventional open-loop control mode.
NOTE: Large differences in the values (for example injection time or exhaust valve operation)
for a cylinder is an indication of possible wear or damage of the cylinder. If necessary,
replace the defective parts.

X92-B AA00-9308-00AAA-043A-A
6.2.1 Pressure calculation
In the ICC system, the compression pressure of each cycle is calculated with the polynomial
formula and the data of the piston position. The ICC uses the values that follow for calculation,
refer to Figure 6-1:
• Compression pressure at TDC (pC)
• Pressure at start of ignition (pI) (001)
• Maximum firing pressure (pF) (002).

NOTE: If ignition is not exactly at TDC, the pressure at start of ignition pI is smaller than the
compression pressure at TDC pC.
The pressure increase is the difference between the maximum firing pressure pF and the pressure
at start of ignition pI. The ICC system sets the limit of this pressure increase related to the shop
test results. This prevents mechanical overload to the engine.
Fig 6-1 ICC - pressure diagram
002
001
Cylinder pressure (bar)
Crank angle (°)
Legend
001 Pressure at start of ignition (pI) 002 Maximum firing pressure (pF)

X92-B AA00-9308-00AAA-043A-A
6.2.2 ICC control
A pressure transmitter is installed on each cylinder cover. The cylinder pressure data of each
cylinder is taken as an analogue input signal from the pressure transmitter into the ECS.
The ECS filters the signals from the sensors and then transmits these signals to a controller. The
measured value is adjusted to the correct setpoint value and is related to the engine load. This
real-time site correction and comparison is done for each engine cycle (refer to Figure 6-2).
Fig 6-2 ICC - control schematic
Measured values
Target values

X92-B AA00-9308-00AAA-043A-A

X92-B AA00-8904-00AAA-043A-A
Operation Manual Integrated gas pressure regulation
6.3 Integrated gas pressure regulation

The integrated gas pressure regulation (iGPR) controls the gas pressure of the gas that is supplied
to the engine inlet. The iGPR control system has also other functions as follows:
• It removes contamination of the supplied gas with a gas filter.
• It measures the gas quantity with a flow meter.
• It measures temperature and pressure of the gas.
Fig 6-3 iGPR - schematic diagram
In the chapters that follow you find a short description of the automatic control functions for the
iGPR control system.
6.3.1 Transfer to gas operation
If you have to change to gas operation, you have to start the gas mode, refer to section [section
not applicable for this engine].
Then the iGPR control system automatically starts the transfer sequence as follows:

X92-B AA00-8904-00AAA-043A-A
• Starts step 1 (FGSS preparation):

○ Waits for the signal FGSS is ready.
NOTE: All valves are in diesel operation position.
○ Activates the FGSS ready signal from PCS to iGPR.
• Starts step 2 (automatic leakage test):

○ Activates the leakage test active signal from iGPR to PCS and ECS.
• Pressurizes the iGPR piping.
• Monitors the pressure drop in the iGPR piping.
○ Activates the leakage test OK signal from iGPR to PCS and ECS.
○ Deactivates the leakage test active signal from iGPR to PCS and ECS.
• Starts step 3 (flushing):

○ Activates the flushing active signal from iGPR to PCS and ECS.
○ Opens the shut-off valve (CV7285C).
○ Closes the vent valve at the engine inlet (CV7289C).
○ Opens the pressure regulating valve (CV7288C).
○ Opens the shut-off valves (CV7291C, CV7292C) and the vent valves (CV7286C,
CV7287C).
○ Activates the flushing OK signal from iGPR to PCS and ECS.
○ Deactivates the flushing active signal from iGPR to PCS and ECS.
• Starts step 4 (pressurization and stabilisation):

○ Activates the pressure stabilisation active signal from iGPR to PCS and ECS.
○ Closes the vent valves (CV7286C, CV7287C)
○ Starts the pressurization and stabilisation.
○ Activates the pressure stabilisation OK signal from iGPR to PCS and ECS.
○ Deactivates the pressure stabilisation active signal from iGPR to PCS and ECS.
○ Activates the transfer preparation OK signal from iGPR to PCS and ECS.
NOTE: The ECS uses this signal to start the GAV operation.
NOTE: If one of the transfer preparation steps is not successful, the iGPR control system
sends a gas trip signal to the PCS and ECS. Then the iGPR control system
changes to degassing state, refer to Para 6.3.3.
6.3.2 Overpressure release state
The iGPR control system automatically starts the steps that follow, if the gas pressure is 0.5 bar
above the setpoint value:
• Opens the vent valve (CV7289C) as long as necessary.
• Controls the pressure regulating valve (CV7288C).
6.3.3 Shutdown on gas operation
The iGPR control system automatically starts different steps related to the conditions.
If you manually start a transfer to diesel operation (refer to section [section not applicable for this
engine]), or if there is a usual gas trip and the ECS parameter “vent valve active mode” is ON, the
iGPR control system automatically starts the steps that follow:

X92-B AA00-8904-00AAA-043A-A
• Closes the shut-off valves (CV7285C, CV7291C, CV7292C).
• Opens the vent valves (CV7289C, CV7286C, CV7287C).
• Opens the pressure regulating valve (CV7288C).

NOTE: The pressure in the engine gas piping decreases to atmospheric pressure.
If there is a usual gas trip and the ECS parameter “vent valve active mode” is OFF, or if there is
a gas trip with automatic inerting request, or if there is an engine shutdown, the iGPR control
system automatically starts the steps that follow:
• Closes the master shut-off valve of the FGSS (controlled by PCS).
• Opens the vent valve of the FGSS (controlled by PCS).

NOTE: The pressure in the engine gas piping and in the iGPR decreases to atmospheric
pressure (degassing state).
• If there is a gas trip with automatic inerting request, the iGPR control system starts the
automatic inerting sequence, refer to Para 6.3.5.
6.3.4 Gas trip with automatic inerting
A gas trip with automatic inerting is necessary in the conditions that follow:
• Emergency gas trip switches are active
• Gas trip from gas detection system is active
• Incorrect gas inlet conditions
• Ventilation failure of the double wall pipes.
In these conditions the iGPR control system automatically starts the steps that follow:
• Closes the master shut-off valve of the FGSS.
• Opens the vent valve of the FGSS.

NOTE: The pressure in the engine gas piping and in the iGPR decreases to atmospheric
pressure.
The automatic inerting sequence then starts, refer to Para 6.3.5.
6.3.5 Automatic inerting sequence
The automatic inerting sequence has the steps that follow:

• The engine safety system (ESS) sends a signal to the iGPR control system.
• The iGPR control system opens the inert valve in the FGSS.
• Inert gas flows through the pipes from the inert valve in the FGSS to the inert gas release
outlet of the engine.

X92-B AA00-8904-00AAA-043A-A
• The inert valve in the FGSS closes again after 25 seconds, when the pipes are filled with
inert gas.
• If the inerting sequence was successful, the iGPR control system activates the inerting
completed signal from iGPR to PCS.
• If the inerting sequence was not successful, the iGPR control system activates the inerting
failed signal from iGPR to PCS.
6.3.6 Engine maintenance
If you have to do maintenance on the engine or on the iGPR or on the supply line, you have to
start the related maintenance mode, refer to section 8.19 Prepare the engine for standstill or for
maintenance.
Then the iGPR control system automatically starts the inerting sequence, refer to Para 6.3.5.

X92-B AA00-0000-00AAA-043H-A
Operation Manual Local display unit (LDU-20) - general
6.4 Local display unit (LDU-20) - general
6.4.1 Local display unit (LDU-20)
The LDU-20 (Figure 6-4) is a multi-purpose module that has an LCD color display (009), ten multi-
function buttons (004 to 008) and a rotary button (003).
The number of LDU-20 installed on the engine is related to the engine control system (ECS) and
to other optional systems.
Fig 6-4 LDU-20 - overview
001
POWER 002
STATUS
009 003
004
PUSH SELECT
005
008 008 008 008 008 008 007 006 00209
Legend
001 Power LED 006 CHECK button (used to accept the action or
enter data)
002 Status LED 007 HOME button (push to show the main page)
003 Rotary button (16 steps in one turn, push to 008 Multi-function buttons (function is shown on the
select) display)
004 BACK button (used to cancel the action or delete009 Color display
data)
005 Failure LIST button (push to show the failure list)

X92-B AA00-0000-00AAA-043H-A
Operation Manual Local display unit (LDU-20) - general
6.4.2 Color display
The color display (009) of the LDU-20 shows different pages for each application. After boot-up,
or when you push the HOME button, the MAIN page is shown.
Some elements are shown on all pages as follows:

• In the top right-hand corner, the system time is shown above the title bar.
• Below the system time, Local or ECR is shown. If the LDU-20 is the active control location,
the indication In Control is shown.
• The bottom of the color display has some space to show the function of the multi-function
buttons.
The color display has the general items that follow, refer to Figure 6-5:
• An orange arrow (001) shows the active item.
• A 3D-rectangle (002) indicates a command button.
• An orange frame (003) indicates the edit mode.
• A black dotted frame (004) around an item shows the position of the cursor.
• A white background (005) shows a parameter, which the operator can adjust.
• A grey background (006) shows a parameter, which the operator cannot adjust.
Fig 6-5 LDU-20 color display - general items
003 004 005 006
002
001
Legend
001 Orange arrow 004 Black dotted frame

002 3D-rectangle 005 White background
003 Orange frame 006 Grey background
For the procedures how to use the LDU-20, eg change a LDU-20 page, refer to section [section

X92-B AA00-9606-42AAA-043B-A
Operation Manual LDU-20 page - iELBA Control (optional)
6.5 LDU-20 page - iELBA Control (optional)

Fig 6-6 iELBA Control
006 007
008
009
001 002 003 004 005

X92-B AA00-9606-42AAA-043B-A
Operation Manual LDU-20 page - iELBA Control (optional)
Tab 6-1 iELBA Control
001 START AST button Starts the engine in astern direction (for reversible engine)
002 STOP button Stops the engine
003 START AHD button Starts the engine in ahead direction
004 CTRL. TR. button Sends a signal for a control transfer to this LDU-20
005 INDEX button Opens the INDEX page
006 Manual / Auto Mode Changes between automatic and manual control mode of the
iELBA
007 Free End ON/OFF In manual mode - starts and stops the iELBA on the related en-
gine end
008 Operator Phase Setpoint In manual mode - manually adjust the crank angle setpoint for
the related engine end in manual mode
009 Auto Phase Setpoint In manual mode - manually adjust the crank angle setpoint for
the related engine end in auto mode

X92-B AA00-4618-00AAC-131A-A
Operation Manual Operate the manual control panel (MCP)

6.6.1 Operate the manual control panel (MCP)
Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• The engine control system must be set to on.

X92-B AA00-4618-00AAC-131A-A
PROCEDURE
Fig 6-7 MCP page - MAIN locked
002
001
Legend
001 UNLOCK button 002 Navigation field
1 To unlock the function buttons, do the steps that follow:

1.1 Touch the UNLOCK button (001, Figure 6-7) with your finger.
1.2 Hold the finger on the button until the green circle is complete.
1.3 Release the finger.
2 To start a function with a function button, shortly touch the related function button.
NOTE: When the function is active, the LED indication comes on.
NOTE: You only can start one function at the same time, also when you touch two or
more function buttons.
3 To change the control location, do the steps that follow:
3.1 Shortly touch the function button for the related control location.
3.2 If necessary, confirm the transfer on the related MCP.
4 To change between MCP pages, do the steps that follow:

4.1 Shortly touch the related button in the navigation menu (002).
4.2 If applicable, shortly touch the related sub menu button.

X92-B AA00-4618-00AAC-131A-A
5 To change the speed command setting, do the steps that follow:

5.1 To increase the speed command setting, turn the fuel dial knob clockwise.
5.2 To decrease the speed command setting, turn the fuel dial knob counterclockwise.
CLOSE UP
• None

X92-B AA00-4618-00AAC-131A-A

X92-B AA00-4618-01AAA-043B-A
Operation Manual MCP page - MAIN
6.6.2 MCP page - MAIN

Fig 6-8 MCP page - MAIN
001
005 002
004 003

X92-B AA00-4618-01AAA-043B-A
Operation Manual MCP page - MAIN
Tab 6-2 MAIN
001 Indication field Shows data for start interlocks and for limiters
Start interlock Info: Turning Gear Engaged, Main Start Air Valve
Closed, Exhaust Venting Request, Shaft Locking Device En-
gaged
Limiter Info: Torque Limiter Active, Scavenge Air Limiter Active,
Torque + Scavenge Air Limiter Active
002 Fuel mode Shows the fuel mode

Shows: Diesel, Transfer, Gas, Gas - DCC Active, Fuel Sharing,
Diesel - Manual
003 Gas System Shows data for the gas system

Shows: Available, Int. Gas Trip, Ext. Gas Trip, Transfer Prep.,
Operational
004 Control Shows the control mode

Shows: Brigde, ECR Remote, ECR Manual, Local
005 Engine Shows the engine status

Shows: Air Run, Slowturning, Start Interlock, Stopped, Shut-
down, Running, Starting, Heavy Start, Angle Determining, Slow-
down

X92-B AA00-4618-05AAA-043B-A
Operation Manual MCP page - Adjust user parameters
6.6.3 MCP page - Adjust user parameters

Fig 6-9 MCP page - Open user parameters
Item Name Effect when touched
001 Navigation field: MENU Opens the sub-navigation fields:

• INFO
• TRENDING
• USER PARAMETERS
002 Sub-navigation field: USER Opens the user parameter options:

PARAMETERS • VIT
• FQS (deg)
• Heavy Sea Mode
• Compressor Balancing
• Firing Balancing
• Firing Control
• Fuel Electrical Heating

X92-B AA00-4618-05AAA-043B-A
Fig 6-10 MCP page - Select user parameter
001 User parameter Makes the related user parameter ad-

justable.

X92-B AA00-4618-05AAA-043B-A
Fig 6-11 MCP page - Adjust user parameter
001 Adjustable user parameter. Makes the related adjustable user pa-
rameter option non-adjustable.
002 User parameter regulators Two possible effects:
• Increase or decrease user pa-
rameter value or
• Set user parameter value to on/
off.
003 Enter field Makes the related adjustable user pa-
rameter option non-adjustable.

X92-B AA00-4618-05AAA-043B-A

X92-B AA00-4618-03AAA-043B-A
Operation Manual MCP page - SYSTEM INFO - Option for WiCE
6.6.4 MCP page - SYSTEM INFO - Option for WiCE

Fig 6-12 MCP page - SYSTEM INFO
001
002
003
Tab 6-3 SYSTEM INFO
001 Engine Shows data for the engine
002 Engine Software Shows data for the engine software
003 NOx Compliance Shows data for the IMO CRC compliance
NOTE: CRC - Cyclic Redundancy Check

X92-B AA00-4618-03AAA-043B-A
Operation Manual MCP page - SYSTEM INFO - Option for WiCE

X92-B AA00-4618-04AAA-043B-A
Operation Manual MCP page - TREND - Option for WiCE
6.6.5 MCP page - TREND - Option for WiCE

Fig 6-13 MCP page - TREND
001
002
Tab 6-4 TREND
001 Selection field Highlights the selected parameters
002 Diagram field Shows the trend of the selected parameters

X92-B AA00-4618-04AAA-043B-A
Operation Manual MCP page - TREND - Option for WiCE

X92-B AA00-4618-02AAA-043B-A
Operation Manual MCP page - INSTRUMENTS
6.6.6 MCP page - INSTRUMENTS

Fig 6-14 MCP page - INSTRUMENTS
001
Tab 6-5 INSTRUMENTS
001 Indication field Shows the values of the displayed instruments

NOTE: The number of the displayed instruments is related to
the engine.
NOTE: If an instrument is unservicable, the background of the

related instrument changes to red.

X92-B AA00-4618-02AAA-043B-A
Operation Manual MCP page - INSTRUMENTS

X92-B AA00-4618-08AAA-043B-A
Operation Manual MCP page - FUEL / LUBRICATION SYSTEM
6.6.7 MCP page - FUEL / LUBRICATION SYSTEM

Fig 6-15 MCP page - FUEL / LUBRICATION SYSTEM
001
011 002
010 003
009 004
008
005
007 006

X92-B AA00-4618-08AAA-043B-A
Tab 6-6 FUEL / LUBRICATION SYSTEM
001 LFO button Changes to LFO (Light Fuel Oil)
002 HFO button Changes to HFO (Heavy Fuel Oil)
003 LOW BN button Changes to low BN cylinder oil
004 HIGH BN button Changes to high BN cylinder oil
005 MANUAL LUBRICATION button Starts the manual cylinder lubrication procedure related to the
set values
006 AUX SO PUMP START/STOP Starts and stops the auxiliary electric servo oil pump (servo oil
service pump)
NOTE: If necessary, start this pump only in engine stop mode.
007 Manual Lub. Cylinder buttons Manually select the cylinder for manual lubrication:
• Set 1 to n for the related cylinder
• Set 0 (zero) for all cylinders
008 Manual Lub. Pulses buttons Manually set the number of injections for lubrication at engine
stop mode (range 0 to 255)
009 Cyl. Lub. Oil Type indication Shows the type of cylinder lubrication oil in use
Shows: Low BN, High BN
010 Cyl. Lubrication Mode indication Shows the status of the cylinder lubrication
Shows: Dry Running, Pre-Lubrication, Speed Dependent, Load
Dependent, Manual Lubrication, Stopped
011 Used Fuel Type indication Shows the fuel in use

Shows: HFO, LFO, GAS, LFO & GAS, HFO & GAS

X92-B AA00-4618-08AAA-043B-A

X92-B
Operation Manual
7 Installation
7.1 Installation...............................................................................................................242

X92-B AA00-0000-00AAA-910A-A
Operation Manual Installation
7.1 Installation
The Marine Installation Manual (MIM) gives data about the installation of the engine on the ship.
The general installation topics in the MIM are as follows:
• Engine dimensions and masses
• Outline views
• Platform arrangement
• Engine seating
• Engine coupling
• Propulsion shaft earthing
• Engine stays
• Extinguishing system
• Auxiliary systems.
NOTE: The latest version of the Marine Installation Manual and the installation drawings are
available on the WinGD website.
https://www.wingd.com/

X92-B
Operation Manual
8 Operation
8.1 Prepare the engine before start - general................................................................244
8.2 Prepare the engine before start...............................................................................246
8.3 Start the engine - general........................................................................................254
8.4 Start the engine.......................................................................................................256
8.5 Do checks during operation - general......................................................................258
8.6 Do checks during operation.....................................................................................260
8.7 Do regular safety checks.........................................................................................264
8.8 Maneuver the ship - general....................................................................................268
8.9 Maneuver the ship...................................................................................................270
8.10 Change-over the diesel fuel - general.....................................................................272
8.11 Change-over the diesel fuel automatically...............................................................276
8.12 Change-over from HFO to MDO manually..............................................................278
8.13 Change-over from MDO to HFO manually..............................................................280
8.14 Stop the engine - general........................................................................................282
8.15 Stop the engine.......................................................................................................284
8.16 Emergency stop the engine - general......................................................................286
8.17 Emergency stop the engine.....................................................................................288
8.18 Prepare the engine after stop - general...................................................................290
8.19 Prepare the engine for standstill or for maintenance...............................................292

X92-B AA00-0000-00AAA-120A-A
Operation Manual Prepare the engine before start - general
8.1 Prepare the engine before start - general

If you have done maintenance work on the engine, make sure that you have done the related
function tests and the engine is ready for operation.
Do checks on the systems that follow to make sure that the engine is ready for engine start.
NOTE: For the specifications of the operating media refer to section 12.1 General for operating
media.
8.1.1 Standard preparation
The systems that follow must be prepared for operation:

• Cooling water system
Make sure that the quality of the cooling water obeys the related specifications.
Make sure that cooling water is available at the engine connections 01 and/or 02 (cylinder
cooling water inlet).
Make sure that the cooling water system is full.
• Wash-water system
Make sure that the quality of the wash-water obeys the related specifications.
Make sure that wash-water is available at the engine connection 11 (water for cleaning plant
turbocharger and SAC inlet).
• System oil system
Make sure that the quality of the system oil obeys the related specifications.
Make sure that main lubricating oil is available at the engine connection 25 (main lubricating
oil inlet).
Make sure that crosshead lubricating oil is available at the engine connection 30 (lubricating
oil crosshead inlet).
Make sure that the lubricating oil system is full.
• Cylinder oil system
Make sure that the quality of the cylinder oil obeys the related specifications.
Make sure that cylinder oil is available at the engine connection 33 (cylinder oil inlet).
Make sure that the cylinder oil system is full.
• Starting air system
Make sure that the quality of the starting air obeys the related specifications in section 12.2
Compressed air.
Make sure that starting air is available at the engine connection 40 (starting air pipe inlet).
• Scavenge air system
Make sure that the quality of the scavenge air obeys the related specifications in section
12.3 Scavenge air.
Make sure that scavenge air is available at the turbocharger inlet.

X92-B AA00-0000-00AAA-120A-A
Operation Manual Prepare the engine before start - general
• Control air system

Make sure that the quality of the control air obeys the related specifications in section 12.2
Compressed air.
Make sure that control air is available at the engine connection 49 (control air supply inlet).
Make sure that the control air system is full.
• Fuel system
Make sure that the quality of the fuel obeys the related specifications.
Make sure that fuel is available at the engine connection 45 (fuel inlet).
Make sure that the fuel system is full and the fuel can flow.
• Exhaust gas system
Make sure that the exhaust gas system is ready for operation.
• Power supply system
Make sure that the power supply system is ready for operation.
• Leakage drain system
Make sure that the leakage drain tanks of the plant have sufficient capacity.
For a DF engine, also the systems that follow must be prepared for operation:
• Gas system
Make sure that the quality of the gas obeys the related specifications in section [section not
Make sure that gas is available at the engine connection 78 (gas supply inlet).
• Pilot fuel system
Make sure that the quality of the pilot fuel obeys the related specifications.
Make sure that pilot fuel is available at the engine connection 76 (supply unit fuel pilot valve
inlet).
Make sure that the pilot fuel system is full and the pilot fuel can flow.
NOTE: You can start a DF engine only in diesel mode.
8.1.2 Preparation if components are defective
You also can operate the engine, if components of the engine are defective and you cannot repair
the fault immediately. You have to do more preparations related to the defective component, refer
to chapter 10 Troubleshooting.
Obey the limits of operation, if components of the engine are not in operation, refer to section 8.3
Start the engine - general.

X92-B AA00-0000-00AAA-121A-A
Operation Manual Prepare the engine before start
8.2 Prepare the engine before start

Periodicity
Description
Engine start
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• Refer to section 8.1 Prepare the engine before start - general

X92-B AA00-0000-00AAA-121A-A
PROCEDURE
1 Make sure that there is no alarm indication.

2 Prepare the control system for operation.
2.1 Set to ON the engine control system (ECS) and the remote control system (RCS).
2.2 Set to ON all circuit breakers in the power supply box E85.
2.3 Set to ON the control box for the cylinder oil filter (refer to the documentation of
the manufacturer).

X92-B AA00-0000-00AAA-121A-A
3 Prepare the cooling water system for operation.

3.1 For an engine with a bypass cooling water system (refer to Figure 8-1), and when
the liner wall temperature is between 60°C and 90°C (for example when the engine
is pre-heated or after engine full stop for a sufficient period), release the unwanted
air with a high flow rate as follows:
Fig 8-1 Cooling water system with bypass cooling
001
002
01
003
05
02
Legend
001 Optional vent valve 01 Connection 01 (cylinder cooling water inlet)

002 Shut-off valve 02 Connection 02 (cylinder liner CW inlet)
003 Shut-off valve 05 Connection 05 (cylinder CW drain outlet)
3.1.1 Close all shut-off valves (002) in the cylinder cover supply pipes (engine
connection 01).
NOTE: This increases the pressure and thus the flow rate at the engine
connection 02.
3.1.2 Let the cooling water flow through the cylinder liners for approximately ten
minutes.
3.1.3 Close the shut-off valves (003) in the cylinder liner supply pipes of the first
half of cylinders (for example cylinder 1 to 3 for a 5 or 6 cylinder engine).
NOTE: This increases again the pressure and thus the flow rate to the
other cylinders.
3.1.4 Let the cooling water flow through the other cylinder liners for
approximately ten minutes.
3.1.5 Open the shut-off valves (003) in the cylinder liner supply pipes of the first
half of cylinders.
3.1.6 Do Step 3.1.3 to Step 3.1.5 again for the second half of cylinders (for
example for cylinder 4 and 5 or for cylinder 4 to 6).
3.1.7 Open all shut-off valves (002) in the cylinder cover supply pipes.
3.1.8 If there is unwanted air in the cooling water and the optional vent valve
(001) is installed, do as follows:
3.1.8.1 Put an applicable container under the vent valve (001).
3.1.8.2 Carefully open the vent valve (001) until only cooling water flows
out of the vent valve (001).
3.1.8.3 Close the vent valve (001).
3.1.8.4 Discard the hot cooling water correctly.

X92-B AA00-0000-00AAA-121A-A
3.2 For an engine without a bypass cooling water system (refer to Figure 8-2), and
when the liner wall temperature is between 60°C and 90°C (for example when the
engine is pre-heated or after engine full stop for a sufficient period), release the
unwanted air with a high flow rate as follows:
Fig 8-2 Cooling water system without bypass cooling
02
001
05
Legend
001 Shut-off valve 05 Connection 05 (cylinder cooling water drain

outlet)
02 Connection 02 (cylinder liner cooling water inlet)
half of cylinders (for example cylinder 1 to 3 for a 5 or 6 cylinder engine).
NOTE: This increases the pressure and thus the flow rate to the other
cylinders.
half of cylinders.
example for cylinder 4 and 5 or for cylinder 4 to 6).

X92-B AA00-0000-00AAA-121A-A
3.3 For an engine with an internal circulation cooling water system (with circulation
pump and temperature control valve, refer to Figure 8-3), and when the liner wall
temperature is between 60°C and 90°C (for example when the engine is pre-
heated or after engine full stop for a sufficient period), release the unwanted air
with a high flow rate as follows:
Fig 8-3 Cooling water system with circulation
02
001
002
003
05
Legend
001 Temperature control valve 02 Connection 02 (cylinder liner cooling water inlet)
002 Circulation pump 05 Connection 05 (cylinder cooling water drain
outlet)
003 Shut-off valve
half of cylinders (for example cylinder 1 to 6 for a 12 cylinder engine).
NOTE: This increases the pressure and thus the flow rate to the other
cylinders.
half of cylinders.
example cylinder 7 to 12 for a 12 cylinder engine).
3.4 Set all valves to their correct positions for operation.
3.5 Release the unwanted air in the cooling water pipes and the scavenge air coolers
at the related vent valves.
3.5.1 Carefully open the first vent valve.
3.5.2 After water that has no air flows out, close the vent valve.
3.5.3 Do Step 3.5.1 and Step 3.5.2 again with the other vent valves.
3.6 Make sure that the values that follow are in the permitted range:
• Pressure in the supply pipe of the cylinder cooling water
• Temperature in the supply pipe of the cylinder cooling water
• Pressure in the cooling water supply pipe of the scavenge air cooler (SAC)
• Temperature in the cooling water supply pipe of the SAC.

X92-B AA00-0000-00AAA-121A-A
4 Prepare the air systems for operation.

4.2 Drain the air system at the related drain valves.
4.2.1 Open the first drain valve.
4.2.2 After no more water flows out from the valve, close the drain valve.
4.2.3 Do Step 4.2.1 and Step 4.2.2 again with the other drain valves.
• Pressure in the supply pipe to the air springs
• Pressure in the supply pipe to the starting air system.
4.4 Set the auxiliary blowers to AUTO.
5 Prepare the lubricating oil systems for operation.

5.2 If it is necessary to have servo oil pressure, set to ON the servo oil service pump.
• Temperature in the oil supply pipes
• Pressure in the oil supply pipes
• Pressure before the torsional vibration damper (if applicable)
• Pressure in the servo oil rail (only pressure of servo oil service pump)
• Pressure in the distributor pipe (mini-rail)
• Pressure at the turbocharger (if applicable)
5.4 Set to ON the cylinder oil system.
6 Prepare the exhaust gas system for operation.

6.1 If necessary (for example after maintenance), do a check of the exhaust valves for
correct function.
6.1.1 Manually open and close the exhaust valve of cylinder No. 1.
6.1.2 Do Step 6.1.1 for a minimum of four times.
6.1.3 Do Step 6.1.1 and Step 6.1.2 again with the other cylinders.
6.1.4 If an exhaust valve does not function correctly, find the cause and repair
the fault.
6.2 Make sure that all exhaust valves are closed.
7 Prepare the fuel system for operation.

7.2 Make sure that the selected fuel supply is in the permitted range.

X92-B AA00-0000-00AAA-121A-A
8 For a DF engine, prepare the gas system for operation.

8.1 Do a visual check of the gas pipes for damage. If damage is found, replace the
defective gas pipes immediately.
8.2 Do the gas related checks. If alarms or failure messages occur, repair the related
item.
8.4 Make sure that the selected gas supply is in the permitted range.
9 For a DF engine, prepare the pilot fuel system for operation.

9.2 Make sure that the selected pilot fuel supply is in the permitted range.
10 Carefully open all indicator valves on the cylinder covers.

NOTE: This makes it possible, that fluids can come out of the cylinder, if the pistons
move. Fluids can be in a cylinder, if there are leaks in the water, oil, or fuel
system.
WARNING
Injury hazard: Before you operate the turning gear, make sure that no personnel are near
the flywheel, or in the engine.
11 Engage and start the turning gear.

12 If the engine has been stopped for more than approximately five days, start a manual pre-
lubrication procedure.
NOTE: This makes sure, that the cylinders get sufficient lubrication before start-up.
13 Turn the engine a minimum of three full turns.
14 If water, oil, or fuel comes out of the indicator valves, do a check of the related components
that follow and repair if necessary:
• Cylinder liner
• Cylinder cover
• Piston
• Injection valve.
15 Do a check of all the running gears for correct operation.
16 Stop and disengage the turning gear and lock the lever.
17 If you have started the servo oil service pump, set to OFF the servo oil service pump.
18 On the starting air shut-off valve turn the hand-wheel to the position AUTO.
19 Close the indicator valves on the cylinder covers.
20 Make sure that all doors on the monoblock column are closed and locked.
21 Start the slowturning of the engine on the local control panel.
NOTE: The engine will slowly turn at approximately 5 rpm to 10 rpm.
22 Tell personnel on the bridge that the engine is prepared for operation.
CLOSE UP
• None

X92-B AA00-0000-00AAA-121A-A

X92-B AA00-0000-00AAA-130A-A
Operation Manual Start the engine - general
8.3 Start the engine - general
8.3.1 Usual start conditions
The engine must be prepared for operation.
All the auxiliary systems must be in correct operation related to section 8.2 Prepare the engine
before start.
You can start the engine from the locations that follow:
• At the bridge or engine control room (ECR) with remote control
• At the backup control panel in the ECR
• At the local control panel of the engine.
Obey the rules for operation related to barred speed ranges:

• Do not continuously operate the engine in a barred speed range.
• If you change the speed, go through the barred speed range as quickly as possible.
NOTE: It is possible that the engine has more than one barred speed range (for example if the
axial vibration damper becomes defective, or one or more cylinders are not in operation).
You can find data about the barred speed ranges near the telegraph on the bridge, near
the local control panel, and in the related documentation of vibration calculations.
8.3.2 Start conditions - limits
With some limits you also can start the engine, if parts of the engine are not prepared for operation,
for example:
• One or more turbochargers are defective.
• One or more cylinders are unserviceable.
• The cooling water flow is decreased.
8.3.2.1 One or more turbochargers are defective
To prevent damage to the engine, make sure that you know the limits that follow:
• For an engine with two turbochargers and one turbocharger is defective:
- Make sure that the exhaust gas temperature at the serviceable turbocharger inlet is
less than the maximum permitted temperature.
- The maximum power output of the engine is approximately 50% related to the power
of the serviceable turbocharger.

X92-B AA00-0000-00AAA-130A-A
Operation Manual Start the engine - general
• For an engine with three turbochargers and one or two turbochargers are defective:
- Make sure that the exhaust gas temperature at the serviceable turbochargers inlet is
less than the maximum permitted temperature.
- If one turbocharger is defective, the maximum power output of the engine is
approximately 66% related to the power of the serviceable turbochargers.
- If two turbochargers are defective, the maximum power output of the engine is
approximately 33% related to the power of the serviceable turbocharger.
- For a DF engine, the engine can operate in diesel mode, gas mode, or fuel sharing
mode.
• If all turbochargers of the engine are defective:
- The maximum power output of the engine is between 10% (as a minimum) to
approximately 15% related to the power of the auxiliary blowers.
8.3.2.2 One or more cylinders are unservicable
Obey the rules for operation, if one or more cylinders are unserviceable:
• Operate the engine only at decreased load.
• It is possible that the turbochargers surge. This makes a loud sound and causes large
differences in the scavenge air pressure. In this condition decrease the load of the engine
sufficiently.
• It is possible that the engine had stopped in a position from which it cannot start. In this
condition start the engine momentarily in the opposite direction to get the crankshaft to a
different position.
8.3.2.3 Cooling water flow is decreased
If the cooling water flow is decreased, operate the engine only at decreased load.

X92-B AA00-0000-00AAA-131A-A
Operation Manual Start the engine
8.4 Start the engine

Periodicity
Description
Engine start
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• Refer to section 8.3 Start the engine - general

X92-B AA00-0000-00AAA-131A-A
Operation Manual Start the engine
PROCEDURE
1 If there is a clutch coupling between engine and propeller, do the steps that follow:
1.1 Engage the clutch coupling.
1.2 Keep the clutch coupling engaged during operation to prevent damage to the
engine.
2 Select the applicable control panel.

3 Start the auxiliary blowers.
4 Set the minimum fuel injection quantity on the related control panel to 30%.
5 Push the button START AHD or START AST to start the engine.
NOTE: The ECS starts an automatic pre-lubrication sequence with a specified number
of pulses.
NOTE: The ECS increases the engine speed.
6 If new cylinder liners or piston rings were installed, do a running-in, refer to section [section
7 If necessary, slowly adjust the fuel injection quantity.
NOTE: The ECS changes the engine speed.
CLOSE UP
• None

X92-B AA00-0000-00AAA-130B-A
Operation Manual Do checks during operation - general
8.5 Do checks during operation - general

During operation, do regular checks of the operating values, refer to section 8.6 Do checks during
operation. This prevents damage to the engine if malfunctions occur.
Compare the values with those given in the acceptance records. This gives a good indication of
the engine performance. If there are unusual differences in the values, find the causes and repair
the faults.
Do not open the covers of the rail unit during engine operation.
NOTE: For data about regular maintenance work refer to the Maintenance Manual.
When the engine is at standstill, do also regular checks of the alarm and safety system, refer to
section 8.7 Do regular safety checks. This prevents damage to the engine if settings have changed
or malfunctions occur.

X92-B AA00-0000-00AAA-130B-A
Operation Manual Do checks during operation - general

X92-B AA00-0000-00AAA-131B-A
Operation Manual Do checks during operation
8.6 Do checks during operation

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• The engine is running.

X92-B AA00-0000-00AAA-131B-A
PROCEDURE
1 Make sure that the engine control system indicates no alarm signals.
2 If there are alarm signals, find the cause and repair the fault.
3 Listen to the engine for unusual noise. If you hear unusual noise, find the cause and repair
the fault.
4 If you cannot find the cause of the unusual noise, stop the engine as soon as possible.
Find the cause and repair the fault.
5 Do daily the checks and the servicing that follow:
5.1 Do a check of the condensation collectors through the sight glasses of the SAC
and the water separator for free flow. If there is a blockage, clean the condensation
collector.
5.2 Release the unwanted air from the cooling water system.
6 Do a check of the exhaust gas for dark smoke. If there is dark smoke, find the cause and
repair the fault.
7 Do regular checks of the items that follow:
• Levels of fuel, oil and water tanks
• Temperatures of oil, cooling water, bearings and exhaust gas
• Pressures of oil, cooling water and control air
• Pressure difference of the oil filter
• For a DF engine, also pressure of gas.
8 If there are unusual operating values, find the cause and repair the fault.
9 Do regular checks of pipes for leaks. If there are leaks, find the cause and repair them.
10 Do a careful check of the dirty oil drain pipes for differences in temperature.
NOTE: Different temperatures show a blockage in the pipes.
11 If there is an unusual temperature difference, remove the blockage of the pipe as soon as
possible.
12 Do weekly the checks and the servicing that follow:
12.1 Do a check of the quality of the cooling water, refer to the instructions of the inhibitor
manufacturer.
12.2 Do a careful check of the temperature of the pipe upstream of the starting air
valves. If a pipe is too hot, repair the related starting air valve.
12.3 Do a check of the fuel pump cover for oil leaks. If necessary, replace the O-ring.
12.4 Drain the bottle of the filter in the control air supply.
12.5 Do a check of the electrical installations, connectors and modules.

X92-B AA00-0000-00AAA-131B-A
13 For a DF engine, do also the checks that follow:

13.1 Do regular checks (leak checks) of the gas piping system, refer to the related data
or documentation.
13.2 Do daily a check of the cylinder compression pressures on the related control
panel.
13.3 If there is a drift that is too high or if there is a related alarm message, clean or
replace the related pressure transmitter, refer to the Maintenance Manual.
13.4 Do daily a check of the cylinder liner wall temperatures on the related control panel.
13.5 If there is a drift that is too high or if there is a related alarm message, release the
unwanted air from the cooling water, for an engine with bypass cooling water
system refer to section [section not applicable for this engine].
CLOSE UP
• None

X92-B AA00-0000-00AAA-131B-A

X92-B AA00-0000-00AAA-340A-A
Operation Manual Do regular safety checks
8.7 Do regular safety checks

Periodicity
Description
Months 3
Unscheduled After maintenance work
Personnel
Support equipment
Pressure calibration hand- 94050 1
pump
Smoke test instrument N/A 1
Ampere meter N/A 1
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
Equipment Hazard: Leaks can cause faults in the engine control systems and damage to
engine components. Leaks that are found during the engine control system checks must
be repaired to prevent damage to equipment.
• The engine must be prepared for operation, refer to section 8.1 Prepare the engine before
start - general
• The engine must be stopped.

X92-B AA00-0000-00AAA-340A-A
PROCEDURE
1 Make sure that the remote control system (RCS), the engine safety system (ESS), and the
alarm and monitoring system (AMS) are set to ON.
2 Do a check of the EMERGENCY STOP buttons:
2.1 On the control panel in the engine control room (ECR), push the EMERGENCY
STOP button.
2.2 Make sure that the pressure control and safety valve 10-5562_E0_5 is electrically
operated (ie the coil is energized).
NOTE: This causes an alarm (M/E Emergency Stop) in the AMS.
2.3 Make sure that the EMERGENCY STOP button is deactivated again.
2.4 Do Step 2.1 to Step 2.3 again with the EMERGENCY STOP buttons on the local
control panel and on the bridge.
3 Do a check of the all the pressure switches.

3.1 Carefully remove the first pressure switch.
NOTE: The stop valve in the connection closes automatically.
3.2 Connect the pressure calibration hand-pump to the pressure switch.
3.3 Operate the pressure calibration hand-pump to increase the pressure to more than
the SHD pressure of the pressure switch. Repeat this step for each pressure
switch.
NOTE: For the related SHD pressure refer to section [section not applicable for
this engine]
3.4 Make sure that the pressure switch opens.
3.5 Decrease the pressure to less than the SHD pressure.
3.6 Make sure that the pressure switch closes at the related pressure.
3.7 If the pressure switch does not close, find the cause and repair the fault.
3.8 Disconnect the pressure calibration hand-pump from the pressure switch.
3.9 Install the pressure switch.
3.10 Do Step 3.1 to Step 3.9 again for the other pressure switches.
3.11 To do a test of the passive failures, temporary disconnect the sockets of the
switches that follow:
• PS1101S
• PS2002S
• PS4341S
• FS2521-nnS
4 Do a function check of the oil mist detector:

4.1 Remove a plug from the junction box, or start the Test Menu in the control unit.
4.2 Connect the smoke test instrument to the test connection of a sensor.
4.3 Simulate oil mist to activate an alarm in the safety system.
4.4 If removed, install the plug on the junction box.
5 For a DF engine, do a calibration and a function check of the gas detectors, refer to the
related documentation of the manufacturer.
6 Do a check of the auxiliary blowers:
6.1 Make sure that main bearing oil is available.
6.2 If applicable, set to ON the turbocharger oil supply.
6.3 Do a check of the applicable lubricating oil pressure, refer to section [section not

X92-B AA00-0000-00AAA-340A-A
6.4 Set to ON the electrical power supply for each auxiliary blower.
6.5 Get control at the local control panel.
6.6 Start the auxiliary blowers.
6.6.1 Make sure that the auxiliary blower 1 starts immediately.
6.6.2 Make sure that the auxiliary blower 2 starts after an interval of between
3 to 6 seconds.
6.7 Make sure that the two auxiliary blowers turn in the correct direction.
6.8 Stop the auxiliary blowers.
6.9 Get control at the control panel in the engine control room (ECR).
6.10 Do Step 6.6 to Step 6.8 again from the control panel in the ECR.
7 Do a check of the auxiliary blowers from the control panel in the engine control room (ECR):
7.1 On the MCM-11, disconnect terminal X33.
7.2 Start the auxiliary blowers.
7.3 Make sure that the command and feedback of auxiliary blowers continue to
operate.
NOTE: If the auxiliary blowers do not operate, do a check of the wiring to the
starter box.
7.5 On the MCM-11, connect terminal X33.
7.6 On the IOM-10, disconnect terminal X11.
7.7 Start the auxiliary blowers. Command and feedback of auxiliary blowers must
continue to operate.
7.8 If the auxiliary blowers do not operate, do a check of the wiring to the starter box.
7.10 On the IOM-10, connect terminal X11.
7.12 Do Step 7.1 to Step 7.10 again from the local control panel.
8 Do a check of the turning gear interlocks:

8.1 Make sure that the turning gear is engaged.
8.2 Make sure that the pressure transmitter PT5017C and the switch ZS5016C do not
operate.
NOTE: The pressure transmitter PT5017C operates at 2.0 bar.
8.3 Make sure that the indication Turning Gear Engaged shows on each control panel
(in the engine control room and at the local maneuvering stand).
8.4 Make sure that no starting air is in the starting air supply pipe:
8.4.1 Make sure that the starting air shut-off valve 30-4325_E0_1 is in the
position AUTO.
8.4.2 Disconnect the plugs on the two solenoid valves CV7013C and CV7014C.
8.4.3 Open the two drain valves in the starting air supply pipe.
8.6 Select the button START AHD.
8.7 Make sure that the indication Turning Gear Engaged is shown on each control
panel.
8.8 Make sure that no start command is released.
8.9 Do Step 8.1 to Step 8.8 again from the locations that follow:
• Control panel in the engine control room (ECR)

X92-B AA00-0000-00AAA-340A-A
• Remote control.
8.10 Make sure that the supply of starting air to the starting air supply pipe is possible:
8.10.1 Close the two drain valves in the starting air supply pipe.
8.10.2 Connect the plugs on the two solenoid valves CV7013C and CV7014C.
8.11 Disengage the turning gear.
NOTE: On each control panel, the indication changes to Turning Gear
Disengaged. The start command is canceled in the remote control.
9 If there is a malfunction, find the cause and repair the fault, before you start the engine.
CLOSE UP
• None

X92-B AA00-0000-00AAA-130C-A
Operation Manual Maneuver the ship - general
8.8 Maneuver the ship - general

Maneuvering is the operation between leaving a port and approaching to port. Maneuvering also
includes all changes during usual operation, for example changing of direction.
The conditions as follows affect the speed of the ship:

• Sailing into strong head winds
• Sailing in heavy seas
• Sailing in shallow water
• Unwanted heavy growth on the hull.
The governor increases the fuel quantity to keep the speed of the ship constant. The increase in
the fuel injection quantity shows on the control panel.
8.8.1 Usual maneuvering
The maneuvering range is the speed range between FULL AHEAD and FULL ASTERN. This range
is usually divided into four maneuvering steps with related given speeds in each direction.
Load changes must be done slowly to let the piston rings adapt the new conditions. This also
prevents increased wear and contamination of the piston rings and the cylinder liners.
The total time to increase the engine load from leaving port to sea speed must not be less than
30 minutes.
The total time to decrease the engine load from sea speed to port approach must not be less then
15 minutes.
Usual time for these two maneuvering operations is between 40 and 45 minutes.
You can do maneuvering operations from the locations that follow:


NOTE: Maneuvering from the local control panel does not decrease the quality or the
safety of the engine operation.

X92-B AA00-0000-00AAA-130C-A
Operation Manual Maneuver the ship - general
8.8.2 Maneuvering at overload
The engine should only be operated at overload (110% of CMCR power) during sea trials and
when there is an authorized representative of the engine builder on board the ship. The limit for
operation of the engine at overload is a maximum of one hour each day (refer also to section 3.3
The relation between engine and propeller).
During operation at overload, you must carefully monitor the engine. If there are unusual
indications, you must decrease the load (power).
The load indication (fuel injection quantity) and the exhaust gas temperature upstream of the
turbocharger show the engine load.
The cooling water temperatures must stay in their usual ranges.
The maximum permitted position of the load indication (fuel injection quantity) is given in the
acceptance records. The adjustments are only permitted to show the CMCR power during sea
trials with an overspeed of 104% to 108% of CMCR power.

X92-B AA00-0000-00AAA-131C-A
Operation Manual Maneuver the ship
8.9 Maneuver the ship

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-0000-00AAA-131C-A
Operation Manual Maneuver the ship
PROCEDURE
1 Select the applicable control console.

2 To change the speed, do the steps that follow:
2.1 Use the rotary button to select the fuel command button.
2.2 Turn the rotary button to set the related fuel injection quantity.
NOTE: Refer to the time limits given in section 8.8 Maneuver the ship -
general.
3 To operate the engine in the opposite direction, do the steps that follow:
3.1 Use the rotary button to select the fuel command button.
3.2 Turn the rotary button to set the fuel injection quantity to approximately 30%.
3.3 Push the related button START AHD or START AST.
NOTE: After some minutes the engine operates in the opposite direction.
CLOSE UP
• None

X92-B AA00-0000-00AAA-130D-A
Operation Manual Change-over the diesel fuel - general
8.10 Change-over the diesel fuel - general

When you change from heavy fuel oil (HFO) to marine diesel oil (MDO) or back, you must keep
the thermal stresses of the related fuel components as low as possible. Thermal stress occurs
because of the large temperature changes. Too fast change of the temperature can cause damage
to the fuel pump plungers and can cause leakages in the fuel pipes.
During the change-over procedure the temperature of the fuel must not change more than 2°C
each minute. This prevents damage to the system, specially when you do the procedure frequently.
The small change rate is also because of the large difference of viscosity between HFO and MDO/
MGO.
You can do a change-over of the fuel only when the engine is running. While the engine has
stopped, there is no fuel flow through the fuel rail. In this situation a change-over is not possible.
8.10.1 Automatic fuel change-over
WinGD recommends the installation and use of an automatic fuel change-over system to prevent
problems during the change-over procedure.
• This system decreases the thermal load of the related fuel components (for example fuel
pump plungers).
• The safety functions decrease the risk of damage because of thermal loads.
• You can do the change-over procedure at a load of up to 100% CMCR.
• The time period for automatic change-over is less than that of a manual change-over.
8.10.2 Manual fuel change-over
When you do a manual change-over of the fuel, you must make sure that the change-over is safe.
Refer to the related procedures.
Make sure that during the procedures HFO never can flow into the MDO tank and pipe system.
NOTE: WinGD recommends to do a manual change-over only, if an automatic change-over
system is not installed or if the automatic change-over system is unserviceable.
8.10.3 Recommended viscosity at the inlet of the fuel pumps
For the temperature necessary to make sure that the fuel upstream of the inlet to the fuel pumps
is at the correct viscosity, refer to the Viscosity / Temperature Diagram in the related specification,
refer to section 12.1 General for operating media. The viscosity for MDO must not be less than 2
cSt.
A viscosimeter measures the viscosity and thus controls the temperature of the fuel.
Make sure that you monitor the viscosity and the temperature of the fuel.

X92-B AA00-0000-00AAA-130D-A
8.10.4 Cylinder oil
When you do a change-over of the fuel, you must make sure that you change to the correct cylinder
oil at the same time. This prevents damage of the piston running system because of an incorrect
BN. For more data refer to the related procedures.
8.10.4.1 Engine with iCAT
If the engine has an iCAT system (integrated Cylinder lubricant Auto Transfer system), WinGD
recommends as follows, when you change-over the fuel:
• If the iCAT system is in auto mode, the iCAT system automatically changes-over the cylinder
oil at the correct time.
• If the iCAT system is in manual control (no iCAT functionality mode), you have to manually
change-over the cylinder oil at the same time as the diesel fuel change-over.
8.10.4.2 Engine without iCAT
If the engine has no iCAT system (integrated Cylinder lubricant Auto Transfer system), WinGD
recommends to monitor the change-over of the cylinder oil. Do a calculation of the cylinder
lubricant quantity and make sure that you know the cylinder lubricating feed rate, refer to Figure
8-4.
1 Make sure that you know the cylinder lubricant quantity that is between the change-over
valve and the lubricating quills including the measurement tube.
2 Calculate the related lead time that the cylinder oil has to get to the lubricating quills.
3 Use this lead time to have the correct timing for the change-over of the cylinder oil.
NOTE: When you change from MDO to HFO, WinGD recommends to start the change-over of
the cylinder oil from low BN to high BN already inside the ECA zone. This prevents
operation with high sulphur fuel and low BN cylinder oil.

X92-B AA00-0000-00AAA-130D-A
Fig 8-4 Cylinder lubricant quantity
Cylinder lubricant quantity in piping and measuring tank:
2 ∗
Volume piping: ∑ = ∑
4
∗ [ ]= 3 [ ]= []=
Mass: = ∗ [ ]= [ ]= 3
[ ]= 3
The density of the cylinder lubricant can be found in the technical data sheet. If not
available, an average value of 920 3 is suitable for this purpose.
Lead time until new lubricant is in use:
∗
=
1000
= [ ]= ℎ [ ]=
[ ]= [ ]= [ ]=
ℎ ℎ
00595

X92-B AA00-0000-00AAA-130D-A

X92-B AA00-0000-00AAA-131E-A
Operation Manual Change-over the diesel fuel automatically
8.11 Change-over the diesel fuel automatically

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• WinGD recommends to always do this automatic change-over procedure when possible.

There is no load limit of the engine to do an automatic fuel change-over.

X92-B AA00-0000-00AAA-131E-A
Operation Manual Change-over the diesel fuel automatically
PROCEDURE
1 Start the automatic change-over procedure, refer to the instructions of the manufacturer.
CLOSE UP
• None

X92-B AA00-0000-00AAA-131D-A
Operation Manual Change-over from HFO to MDO manually
8.12 Change-over from HFO to MDO manually

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• WinGD recommends to do a manual change-over only, if an automatic change-over system

is not installed or if the automatic change-over system is unserviceable.

X92-B AA00-0000-00AAA-131D-A
Operation Manual Change-over from HFO to MDO manually
PROCEDURE
1 Make a full time schedule for the change-over to obey the ECA rules.
2 If you operate the engine with MDO for a long period, you must change the cylinder oil to
the applicable BN at the related time, refer to section 8.10 Change-over the diesel fuel -
general.
3 Set to OFF the trace heating of the fuel pipes and fuel rail approximately one hour before
the change-over. The correct time is related to the pipe diameter and the waste heat in the
system.
4 Set the viscosimeter to 17 cSt to decrease the temperature of the fuel.
5 Set to OFF all heating sources in the system (for example fuel heaters) some minutes
before the change-over.
6 Decrease the load of the engine to max. 50% CMCR. The decrease of the engine power
is related to the total quantity of fuel that flows in the system (for example the larger the
mixing tank, the less decrease in load is necessary).
7 Follow the instructions of the plant to slowly change-over the fuel supply from HFO to MDO.
Make sure that you decrease the fuel temperature a maximum of 2°C each minute.
8 If the temperature changes too much, wait until the fuel temperature is stable. Then you
can continue the procedure. Try to decrease the temperature as linearly as possible.
9 When the temperature of the fuel is near the applicable value, you can start the cooler
slowly to give a linear and smooth temperature change at minimum viscosity.
NOTE: The viscosity of the fuel must not be less than 2 cSt.
10 Do a check of the temperature, viscosity and pressure of the supplied fuel.
11 If the temperature, viscosity, or pressure is not correct, find the cause and repair the fault.
12 If you have to collect the MDO from the leakage and return pipes, do as follows:
12.1 Wait until the system is completely flushed with MDO.
NOTE: This prevents contamination of the MDO with HFO.
12.2 If also a MDO leakage tank is installed, move the 3-way valve in the pipe from the
outlet of the fuel leakage fuel pump and injection control to the MDO leakage tank.
12.3 If the fuel return of the pressure control valve goes into the HFO service tank, set
the valve positions to have the fuel return go into the MDO service tank.
13 If you have to stop the engine, wait until the change-over procedure is fully completed.
NOTE: This prevents problems during the subsequent engine start because of a mixture
of HFO and MDO in the system.
CLOSE UP
• None

X92-B AA00-0000-00AAA-131H-A
Operation Manual Change-over from MDO to HFO manually
8.13 Change-over from MDO to HFO manually

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• WinGD recommends to do a manual change-over only, if an automatic change-over system

is not installed or if the automatic change-over system is unserviceable.

X92-B AA00-0000-00AAA-131H-A
Operation Manual Change-over from MDO to HFO manually
PROCEDURE
1 Make a full time schedule for the change-over to obey the ECA rules.
2 Make sure that you have changed the cylinder oil to the applicable BN, refer to section
8.10 Change-over the diesel fuel - general.
3 Set to ON the trace heating of the fuel pipes and fuel rail.
4 If the engine room is cold, after a minimum of one hour make sure to get correct heating.
5 Make sure that HFO cannot flow into the MDO system.
5.1 If also a MDO leakage tank is installed, move the 3-way valve in the pipe from the
outlet of the fuel leakage fuel pump and injection control to the HFO leakage tank.
5.2 If the fuel return of the pressure control valve goes into the MDO service tank, set
the valve positions to have the fuel return go into the HFO service tank.
6 Close all covers on the rail unit.

7 Decrease the load of the engine to max. 75% CMCR. The decrease of the engine power
is related to the total quantity of fuel that flows in the system (for example the larger the
mixing tank, the less decrease in load is necessary).
8 Set the viscosimeter to 13 cSt to increase the temperature of the fuel.
NOTE: The viscosimeter controls the end-heater, which keeps the fuel temperature at
the necessary viscosity.
9 Follow the instructions of the plant to slowly change-over the fuel supply from MDO to
HFO. Make sure that you increase the fuel temperature a maximum of 2°C each minute.
NOTE: Sudden temperature changes can stop the movement of the fuel pump plungers.
10 If the temperature changes too much, wait until the fuel temperature is stable. Then you
can continue the procedure.
11 Do a check of the temperature, viscosity and pressure of the supplied fuel.
12 If the temperature, viscosity, or pressure is not correct, find the cause and repair the fault.
13 If you have to stop the engine, wait until the change-over procedure is fully completed.
NOTE: This prevents problems during the subsequent engine start because of a mixture
of HFO and MDO in the system.
CLOSE UP
• None

X92-B AA00-0000-00AAA-130G-A
Operation Manual Stop the engine - general
8.14 Stop the engine - general

You can stop the engine from the locations that follow:
Related to the situation and to the planned tasks after engine shutdown, WinGD recommends to
operate the engine with marine diesel oil (MDO) for some time before you stop the engine, refer
to section 8.12 Change-over from HFO to MDO manually.
For a DF engine that operates in gas mode are the procedures related to the conditions as follows:
• The operator pushes the STOP button
When the operator pushes the STOP button, the ECS starts the procedures that follow:
○ The ECS changes to stop mode, thus the related control system stops the gas supply
and releases the pressure in the gas inlet pipes.
○ The ECS de-energizes the solenoid valve on the gas admission valves (GAV), thus
the gas flow to the cylinders stops.
○ The ECS stops the operation of the pilot fuel valves after the crankshaft has turned
360°, thus makes sure that all gas in the combustion chambers burns.
NOTE: If the crankshaft cannot turn 360°, the ECS sends a signal for an exhaust
ventilation request.
• The ESS or ECS sends a cancelable shutdown signal
The engine safety system (ESS) or the ECS sends a cancelable shutdown signal, when a
related failure or defect occurs. The procedures are as follows:
○ The ECS changes to diesel mode, thus the related control system stops the gas
supply and releases the pressure in the gas inlet pipes.
○ The engine continues to operate in diesel mode until the shutdown signal becomes
active.
○ If the operator cancels the shutdown signal within the specified period, the engine
continues to operate in diesel mode.
• The ESS or ECS sends a non-cancelable shutdown signal
The ESS or the ECS sends a non-cancelable shutdown signal, when a related failure or
defect occurs. The procedures are as follows:
○ The ECS changes to diesel mode, thus the related control system stops the gas
supply and releases the pressure in the gas inlet pipes.
○ The ECS de-energizes the solenoid valve on the gas admission valves (GAV), thus
the gas flow to the cylinders stops.
○ The ECS stops the engine.
○ The ECS sends a signal for an exhaust ventilation request.

X92-B AA00-0000-00AAA-130G-A
Operation Manual Stop the engine - general

X92-B AA00-0000-00AAA-131G-A
Operation Manual Stop the engine
8.15 Stop the engine

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• Refer to section 8.14 Stop the engine - general

X92-B AA00-0000-00AAA-131G-A
Operation Manual Stop the engine
PROCEDURE
1 Select the applicable control panel.

2 Decrease the engine load to the minimum.
3 On the control panel push the STOP button.
NOTE: The ECS shuts down the engine in a controlled manner.
4 For a DF engine, start the exhaust ventilation sequence, if there is a ventilation request.
CLOSE UP
• None

X92-B AA00-0000-00AAA-140A-A
Operation Manual Emergency stop the engine - general
8.16 Emergency stop the engine - general

To stop the engine in an emergency, do the procedure given in section 8.17 Emergency stop the
engine.

X92-B AA00-0000-00AAA-140A-A
Operation Manual Emergency stop the engine - general

X92-B AA00-0000-00AAA-141A-A
Operation Manual Emergency stop the engine
8.17 Emergency stop the engine

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• In some conditions the ECS starts an automatic shutdown.

X92-B AA00-0000-00AAA-141A-A
Operation Manual Emergency stop the engine
PROCEDURE
1 In the control room (control console), or on the local control panel, push the EMERGENCY
STOP button.
NOTE: The ECS stops the engine immediately.
2 For a DF engine, start the exhaust ventilation sequence, if there is a ventilation request.
3 To make the engine ready for restart after an emergency stop, you must reset the
EMERGENCY STOP button.
CAUTION
Damage Hazard. Do this step only as a last alternative selection, if the EMERGENCY STOP
button is not working. Damage to the engine can occur.
4 In the power supply boxes E85.1 to E85.#, set to OFF the electrical power to the ECS.
5 Find the cause of the emergency stop and repair the fault.
CLOSE UP
• None

X92-B AA00-0000-00AAA-150A-A
Operation Manual Prepare the engine after stop - general
8.18 Prepare the engine after stop - general

After a decrease of the engine speed to less than 8% the ECS automatically starts the post-
lubrication of the cylinders.
NOTE: The water and oil pumps must operate for a minimum of 20 minutes after the engine has
stopped. This is to make sure that when the engine temperature has decreased, the
temperature of engine parts become as stable as possible.
For a short period after an engine stop of one week or less, usually you keep the auxiliary systems
in operation, refer to section [section not applicable for this engine].
For a long period after an engine stop of more than one week or for maintenance of the engine,
you do the steps in section 8.19 Prepare the engine for standstill or for maintenance. If you have
to do maintenance, you have to make a decision about which steps of the procedure are necessary
for the specified maintenance tasks.

X92-B AA00-0000-00AAA-150A-A
Operation Manual Prepare the engine after stop - general

X92-B AA00-0000-00AAA-151B-A
Operation Manual Prepare the engine for standstill or for maintenance
8.19 Prepare the engine for standstill or for maintenance

Periodicity
Description
Unscheduled
Personnel
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• The engine must be stopped. Refer to section 8.18 Prepare the engine after stop - general

X92-B AA00-0000-00AAA-151B-A
PROCEDURE
1 Open the indicator valves in the cylinder covers.

2 Engage the turning gear.
3 Stop the fuel supply to the engine as follows:
3.1 Stop the fuel supply system from the plant.
3.2 Close the shut-off valve at engine connection 49 (fuel inlet).
3.3 Release the pressure in the fuel system.
3.4 Drain the fuel system.
3.5 Close the shut-off valve at engine connection 50 (fuel return outlet).
4 Drain the exhaust gas manifold and the exhaust gas pipe.
5 Stop the air supply to the engine as follows:
5.1 Stop the air supply systems from the plant.
5.2 Close the shut-off valves at engine connection 40 (starting air pipe inlet).
5.3 Turn the hand-wheel of the starting air shut-off valve to the position CLOSED.
5.4 Drain the air systems of the engine.
5.5 Release the pressure in the air pipes.
6 Stop the lubricating oil supply to the engine as follows:

6.1 Stop the oil supply systems from the plant.
6.2 Close the shut-off valves to the engine at engine connection 33 (cylinder oil inlet).
6.3 Set to OFF the control box for the automatic filter.
6.4 If installed, close the shut-off valves to the engine upstream of engine connection
25 (main lubricating oil inlet) and of engine connection 30 (lubricating oil crosshead
inlet).
6.5 Release the pressure in the oil pipes and the oil rail.
6.6 Drain the oil systems of the engine.
7 Stop the cooling water supply to the engine as follows:

7.1 Stop the cooling water supply system from the plant.
7.2 If installed, close the shut-off valves upstream of engine connections 01 and/or 02
(cylinder cooling water inlet).
7.3 Release the pressure in the cooling and wash-water pipes.
7.4 Drain the water systems of the engine.

X92-B AA00-0000-00AAA-151B-A
8 For a DF engine, stop the gas system.

8.1 If you have to do maintenance downstream of the block valve (CV7285), do as
follows:
8.1.1 Make sure that the valve positions are in degassing state.
8.1.2 On the iGPR cabinet switch the button S8 to maintenance to activate the
maintenance mode.
8.1.3 On the LDU-20 iGPR page, make sure that all conditions are satisfactory.
8.1.4 On the LDU-20 iGPR page, push the Engine Inerting button to start the
engine inerting sequence.
8.1.5 Make sure that the indication in progress shows on the LDU-20.
NOTE: The iGPR control system does the engine inerting sequence.
8.1.6 Wait until the indication passed shows on the LDU-20.
8.1.7 On the iGPR cabinet push the button S7 to degas the system.
8.2 If you have to do maintenance on a component downstream of the master shut-
off valve, do as follows:
8.2.1 Make sure that the valve positions are in degassing state.
8.2.2 On the iGPR cabinet switch the button S8 to maintenance to activate the
maintenance mode.
8.2.3 On the LDU-20 iGPR page, make sure that all conditions are satisfactory.
8.2.4 On the LDU-20 iGPR page, push the Supply Line Inerting button to start
the supply line inerting sequence.
8.2.5 Make sure that the indication in progress shows on the LDU-20.
NOTE: The iGPR control system does the supply line inerting sequence.
8.2.6 Wait until the indication passed shows on the LDU-20.
8.2.7 On the iGPR cabinet push the button S7 to degas the system.
9 For a DF engine, stop the pilot fuel supply to the engine as follows:
9.1 Stop the pilot fuel supply from the plant.
9.2 Close the shut-off valve at engine connection 76 (pilot fuel inlet).
9.3 Release the pressure in the pilot fuel system.
9.4 Drain the pilot fuel system.
9.5 Close the shut-off valve at engine connection 77 (pilot fuel return outlet).

X92-B AA00-0000-00AAA-151B-A
10 Stop the control system from the engine as follows:

10.1 Set to OFF all circuit breakers in the power supply box E85.
10.2 Set to OFF the engine control system (ECS) and the remote control system (RCS).
11 Do a check of the rail unit as follows:

11.1 Open the covers.
11.2 Make sure that there is no condensation or corrosion.
11.3 If you find condensation or corrosion, do the steps that follow:
11.3.1 Clean the related part.
11.3.2 Find the cause and repair the fault.
11.4 If necessary, apply anti-corrosion oil to give protection.
11.5 Close the covers.
12 Do a check of the supply unit as follows:

12.1 Make sure that there is no condensation or corrosion.
12.2 If you find condensation or corrosion, do the steps that follow:
12.2.1 Clean the related part.
12.2.2 Find the cause and repair the fault.
12.3 If necessary, apply anti-corrosion oil to give protection.
13 If the engine must have preservation for a long period, speak to or send a message to
WinGD for the applicable preservation procedures.
CLOSE UP
• None

X92-B AA00-0000-00AAA-151B-A

X92-B
Operation Manual

9.1 Do an analysis of the system oil..............................................................................298
9.2 Do an analysis of the cylinder oil.............................................................................300
9.3 Replace the filter element of the duplex filter..........................................................304
9.4 Clean the turbocharger during operation.................................................................306
9.5 Clean the scavenge air cooler during operation......................................................308
9.6 Do a test of the exhaust waste valve.......................................................................312

X92-B AA00-0000-00AAA-371B-A
Operation Manual Do an analysis of the system oil
9.1 Do an analysis of the system oil

Periodicity
Description
Working hours 3000
Working hours 6000
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
Sample bottles A/R
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
Injury Hazard: The system oil is hot. Put on gloves and safety goggles to prevent injuries.
Do the work carefully.
• The oil pump is running.
• The system oil has operating temperature.
• The periodicity of 3000 working hours applies for regular oil analysis.
• The periodicity of 6000 working hours applies for FZG and particle count analysis.

X92-B AA00-0000-00AAA-371B-A
Operation Manual Do an analysis of the system oil
PROCEDURE
1 Flush the sample pipe.

NOTE: Use the sample point related to the engine as follows:
• For an engine with servo oil filter, do as follows:
○ Get a sample from the sample point at the engine inlet.
○ If the analysis shows unusual values, get a sample from the sample
point after the servo oil filter.
• For an engine without servo oil filter, get the sample from the sample point
at the engine inlet.
1.1 Put an applicable container under the sample valve.
1.2 Slowly open the sample valve to flush out oil and possible dirt.
1.3 Close the sample valve.
1.4 Discard the oil correctly.
2 Get an oil sample.

2.1 Put the sample bottle under the sample valve.
2.2 Slowly open the sample valve to fully fill the sample bottle.
NOTE: The necessary quantity of oil is as follows:
• 100 ml for regular oil analysis
• 5 l for FZG and particle count analysis.
2.3 Close the sample valve.
2.4 Close the sample bottle tight.
3 Write the data that follows on the sample bottle:

• Name of the ship
• Type and serial number of the engine
• Date of the sampling
• Location of the sample point
• Operating hours of the oil and of the engine
• Brand and type of the oil.
4 If applicable, do Step 1 to Step 3 again for the other sample point.
5 Send the sample bottles in an applicable package to a laboratory for analysis.
6 Do the procedures related to the results, refer to section [section not applicable for this
engine] or to the document “Lubricants” on the WinGD website (https://www.wingd.com/).
CLOSE UP
• None

X92-B AA00-0000-00AAA-371A-A
Operation Manual Do an analysis of the cylinder oil
9.2 Do an analysis of the cylinder oil

Periodicity
Description
Weeks 1
Unscheduled After a fuel change
Unscheduled After a cylinder oil change
Unscheduled After a feed rate change
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
Sample bottles A/R
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
Injury Hazard: The cylinder oil is hot. Put on gloves and safety goggles to prevent injury.
Do the work carefully.
• The engine must be in stable operation for a minimum of 12 hours.
• The duration of the procedure is related to the number of cylinders.

X92-B AA00-0000-00AAA-371A-A
PROCEDURE
Fig 9-1 Location of ball valves - dirty oil samples
001
Closed
003
002 001 001

Open Open
002
Closed
002
00010
1 Do this procedure at a minimum of one time each week, and do it also in the conditions
that follow:
• After a fuel change
• After a cylinder oil change
• After a feed rate change.
2 Flush the sample pipe of the related cylinder.
2.1 Close the ball valve (002, Figure 9-1) for approximately 30 minutes to 60 minutes.
NOTE: Some parts can look different.
2.2 Put an applicable container under the oil sample valve (001).
2.3 Slowly open the oil sample valve (001) to flush out oil and possible dirt.
2.4 Close the oil sample valve (001).
2.5 Open the ball valve (002) to drain the remaining oil from the dirty oil pipe (003).
2.6 Close the ball valve (002).
3 Get a sample of the drain oil.

3.1 Make sure that the label on the sample bottle refers to the related cylinder.
3.2 Wait approximately 10 to 60 minutes.
3.3 Put the sample bottle under the oil sample valve (001).
3.4 Slowly open the oil sample valve (001) to fill the sample bottle.
3.5 Close the oil sample valve (001).
3.6 Open the ball valve (002) to drain the oil in the dirty oil pipe (003).
4 Do Step 2 and Step 3 again for each cylinder.

X92-B AA00-0000-00AAA-371A-A
5 Write the applicable data on the oil analysis form (for example operation conditions, fuel
parameters, cylinder lubricating feed rate).
6 Do an oil analysis of the samples on-board. The oil analysis must include the data that
follows:
• Residual BN
• Iron (Fe) content (if possible).
7 If necessary, do the applicable recommended procedures, refer to section [section not
applicable for this engine] or to the document “Lubricants” on the WinGD website (https://
www.wingd.com/).
8 Send the oil samples to a laboratory for an oil analysis.
8.1 Make sure that the sample bottles are tightly closed.
8.2 Put the sample bottles in an applicable package.
9 Compare the oil analysis from the laboratory with the oil analysis from on-board.
10 If the oil analyses are different, do the applicable recommended procedures related to the
oil analysis from the laboratory, refer to section [section not applicable for this engine] or
to the document “Lubricants” on the WinGD website (https://www.wingd.com/).
CLOSE UP
• None

X92-B AA00-0000-00AAA-371A-A

X92-B AA00-7200-00AAA-200A-A
Operation Manual Replace the filter element of the duplex filter
9.3 Replace the filter element of the duplex filter

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
Filter element HA1-59-9613-01 -002 pc 1
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-7200-00AAA-200A-A
Operation Manual Replace the filter element of the duplex filter
PROCEDURE
1 Change over to the clean filter chamber.

2 Drain the clogged filter chamber.
3 Remove the cover of the clogged filter chamber.
4 Remove the filter element from the filter chamber.
5 Clean the filter chamber.
6 Clean the filter element or take a new filter element.
7 Install the new filter element into the filter chamber.
8 Install the cover on the filter chamber.
9 Make sure that the cleaned filter chamber has no leaks.
CLOSE UP
• None

X92-B AA00-6500-00AAA-200A-A
Operation Manual Clean the turbocharger during operation
9.4 Clean the turbocharger during operation

Periodicity
Description
Weeks 1
Personnel
Support equipment
None
Supplies
Description QTY
Cleaning fluid A/R
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
Damage Hazard: For an engine with LP SCR system, do not do this procedure, if there is
gas flow through the LP SCR reactor. This could cause damage to the components of the
SCR system.
• None

X92-B AA00-6500-00AAA-200A-A
Operation Manual Clean the turbocharger during operation
PROCEDURE
1 Decrease the engine power to approximately 25 to 85%.

2 Clean the compressor of the turbocharger, refer to the documentation of the manufacturer.
3 Clean the turbine of the turbocharger, refer to the documentation of the manufacturer.
CLOSE UP
• None

X92-B AA00-6600-00AAA-200A-A
Operation Manual Clean the scavenge air cooler during operation
9.5 Clean the scavenge air cooler during operation

Periodicity
Description
Weeks 1
Personnel
Support equipment
None
Supplies
Description QTY
Cleaning fluid A/R
Spare Parts
None
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-6600-00AAA-200A-A
PROCEDURE
Fig 9-2 SAC - clean during operation (example)
08 PLANT
11 12 07 ENGINE
009
001 002
008
TE TE
1381A 1371A
PT
Turbocharger
007 1361A
PI
1361L
Washing
Plant SAC
006
004 005
003
TI TI
1381L 1371L
Scavenge
Air Cooler
18
Aux Aux
Blower Blower
LS LS
4075A 4071A
16
13
ENGINE
PLANT
00520

X92-B AA00-6600-00AAA-200A-A
1 Decrease the engine power to approximately 45%.

2 Make sure that compressed air is available at the shut-off valve (001, Figure 9-2) and fresh
water is available at the shut-off valve (009).
NOTE: The schematic diagram in Figure 9-2 is an example and is used for reference.
Some parts can look different.
3 Fill the tank (006, Figure 9-2) through the funnel (008) with fresh water and the specified
quantity of cleaning fluid (max. 30 liters).
3.1 Open the vent valve (002) and the valve (007) of the tank (006).
3.2 Carefully open the shut-off valve (009) in the water supply pipe and fill the
tank (006).
NOTE: You can also use a hand-held container filled with cleaning fluid mixed
with fresh water to put into the funnel. When you use this method, make
sure that the shut-off valve in the supply pipe stays closed.
3.3 Close the shut-off valve (009) in the water supply pipe.
3.4 Close the vent valve (002) and the valve (007) of the tank (006).
4 Open the shut-off valve (001) in the compressed air supply pipe to pressurize the
tank (006).
5 Clean the scavenge air cooler (005) as follows:
5.1 Open the shut-off valve (003).
5.2 After no more cleaning water comes out, close the shut-off valve (003).
6 Close the shut-off valve (001) in the compressed air supply pipe.
7 Open the vent valve (002) to release the pressure in the tank (006).
8 After 10 minutes, do Step 2 to Step 7 again with fresh water (no cleaning fluid).
9 Do a check of the water separator for dirt.
10 If the water separator is dirty, clean the water separator (refer to the Maintenance Manual).
CLOSE UP
• None

X92-B AA00-6600-00AAA-200A-A

X92-B AA00-8135-00AAA-320A-A
Operation Manual Do a test of the exhaust waste valve
9.6 Do a test of the exhaust waste valve

Periodicity
Description
Weeks 1
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• This procedure is only applicable, if the engine has operated for a long period at low load
with the exhaust waste valve closed.
• The engine load must be less than 70%, or the engine can be stopped.

X92-B AA00-8135-00AAA-320A-A
PROCEDURE
1 On the related control panel manually open the exhaust waste valve.
2 Make sure that the exhaust waste gate is open.
3 Close the exhaust waste valve.
4 If the check is incorrect, find the cause and repair the fault.
CLOSE UP
• None

X92-B AA00-8135-00AAA-320A-A

X92-B
Operation Manual
10 Troubleshooting and Special running

condition
10.1 Troubleshooting - general data................................................................................316
10.2 Malfunctions of systems and components...............................................................318
10.3 Failures and defects of UNIC-flex components.......................................................338
10.4 Examine the supply unit for servo oil leakage.........................................................340
10.5 Examine the supply unit for fuel leakage.................................................................344
10.6 Examine the rail unit for leakage.............................................................................348
10.7 Examine the FLV or fuel pipes for fuel leakage.......................................................350
10.8 Temporary cut out a defective injection valve.........................................................354
10.9 Temporary cut out a defective exhaust valve drive.................................................356
10.10 Temporary isolate a cylinder with cooling water leakage........................................358
10.11 Servo oil pump - troubleshooting.............................................................................362
10.12 Servo oil pump - Calibration for Dynex pump..........................................................364
10.13 Servo oil pump - Calibration for Bosch pump..........................................................366
10.14 Servo oil pump - Calibration for Hawe pump...........................................................368
10.15 Fuel pump - cutting out............................................................................................370
10.16 Fuel pump - cutting in..............................................................................................376
10.17 Temporary isolate a defective turbocharger............................................................380
10.18 Temporary isolate the exhaust waste gate..............................................................384
10.19 Isolate a defective engine at twin engine installation...............................................388
10.20 WiCE - Gateway Unit (GTU) replace.......................................................................390
10.21 WiCE - Main Control Unit (MCU) replace................................................................392
10.22 WiCE - Cylinder Control Unit (CCU) module replacement......................................394
10.23 WiCE - Angle Control Unit (ACM20) module replacment........................................396
10.24 WiCE - Manual Control Panel (MCP) replacement.................................................398
10.25 WiCE module - troubleshooting...............................................................................400
10.26 Special running condition: Turbocharger cut out.....................................................402
10.27 Special running condition: Cylinder cut out.............................................................410

X92-B AA00-0000-00AAA-410B-A
Operation Manual Troubleshooting - general data
10.1 Troubleshooting - general data

If the AMS shows trigger value signals, do a check of the data that follow:
• Make sure that all shut-off valves to the instruments are open.
• Make sure that all shut-off valves are in the correct operation position.
• Make sure that the instruments are serviceable.
• Make sure that the cables are connected correctly to the instruments.
• Make sure that there are no leaks.
Before you look for other causes repair defects immediately. For the procedures to replace
defective components, refer to the Maintenance Manual.
The tables in section 10.2 Malfunctions of systems and components show how to repair
malfunctions on the engine. The tables give the data that follow:
• Title of the table
The title of the table gives the description of the malfunction.
• Indication
This list specifies the number of the signal related to the value. The list can also contain text
or be empty.
• Possible cause
This list gives possible causes that have activated the alarm, or have started the malfunction.
Refer to the specified sequence to find faults.
• Procedure
This list gives data about the related malfunction. Refer to the specified sequence during
troubleshooting. For repair work refer to the related section of the Maintenance Manual. If
you cannot repair the malfunction, speak to or send a message to WinGD.

X92-B AA00-0000-00AAA-410B-A
Operation Manual Troubleshooting - general data

X92-B AA00-0000-00AAA-410C-A
Operation Manual Malfunctions of systems and components
10.2 Malfunctions of systems and components
10.2.1 Table of malfunctions
Malfunctions of the water systems (XX10NN to XX19NN)

• Table 10-1 - Supply pressure of the cylinder cooling water is too low
• Table 10-2 - Supply temperature of the cylinder cooling water is too low
• Table 10-3 - Cylinder cooling water temperature downstream of a cylinder is too high
• Table 10-4 - Supply pressure of the cooling water to the SAC is too low
• Table 10-5 - Supply temperature of the cooling water to the SAC is too low
• Table 10-6 - Temperature of the cooling water downstream of the SAC is too high
Malfunctions of the oil systems (XX20NN to XX31NN)

• Table 10-7 - Lubricating oil supply pressure at the engine inlet is too low
• Table 10-8 - Lubricating oil supply pressure upstream of the injectors is too low
• Table 10-9 - Lubricating oil supply temperature at the engine inlet is too high
• Table 10-10 - Lubricating oil supply pressure upstream of the crossheads is too low
• Table 10-11 - Servo oil pressure in the distributor pipe (mini rail) is not in the permitted range
• Table 10-12 - Servo oil leakage flow from the servo oil supply unit is too high
• Table 10-13 - Servo oil flow at a servo oil pump inlet is too low
• Table 10-14 - Bearing oil temperature at a bearing outlet is too high
• Table 10-15 - Oil mist concentration is too high
• Table 10-16 - Piston cooling oil temperature downstream of a piston is too high
• Table 10-17 - Piston cooling oil flow to a piston is not in the permitted range
• Table 10-18 - TC bearing oil temperature at a turbocharger outlet is too high
• Table 10-19 - TC bearing oil supply pressure upstream of a turbocharger is too low
• Table 10-20 - TC bearing oil temperature at a turbocharger inlet is too high (external oil
supply)
• Table 10-21 - Damper oil supply pressure upstream of the torsional vibration damper is too
low
• Table 10-22 - Damper oil supply pressure upstream of the axial vibration damper is too low
• Table 10-23 - Cylinder oil supply pressure is too low
• Table 10-24 - Cylinder oil flow is too low
Malfunctions of the fuel system (XX34NN)

• Table 10-25 - Fuel supply temperature is not in the permitted range
• Table 10-26 - Fuel supply pressure at the engine inlet is too low
• Table 10-27 - Fuel leakage flow from the fuel supply unit is too high
• Table 10-28 - Temperature difference of the fuel outlet of the two fuel pumps is too high (for
X35/-B or X40/-B engine)

X92-B AA00-0000-00AAA-410C-A
• Table 10-29 - Leakage flow from the rail unit is too high
• Table 10-30 - Fuel leakage flow from fuel rail items is too high (engine with FLV)
• Table 10-31 - Fuel leakage flow from fuel rail items is too high (engine with ICU)
• Table 10-32 - Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine)
• Table 10-33 - Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine)
Malfunctions of systems for DF engine (XX33NN to XX39NN)

• Table 10-34 - Gas concentration in piston underside is too high
• Table 10-35 - Difference pressure of pilot fuel filter is too high
• Table 10-36 - Gas supply pressure is too low
Malfunctions of the exhaust gas system (XX37NN)

• Table 10-37 - Exhaust gas temperature downstream of a cylinder is too high
• Table 10-38 - Exhaust gas temperature difference downstream of all cylinders is too high
• Table 10-39 - Exhaust gas temperature upstream of a turbocharger is too high
• Table 10-40 - Exhaust gas temperature downstream of a turbocharger is too high
• Table 10-41 - Exhaust valve does not operate, unwanted noise
• Table 10-42 - Smoke is too dark
Malfunctions of the air systems (XX40NN to XX44NN)

• Table 10-43 - Scavenge air temperature in the receiver is too high
• Table 10-44 - Scavenge air temperature in the receiver is too low
• Table 10-45 - Scavenge air pressure is too high
• Table 10-46 - Scavenge air pressure is too low
• Table 10-47 - Condensation flow at a water separator is too high
• Table 10-48 - Condensation flow upstream of a water separator is too high
• Table 10-49 - Scavenge air temperature in the piston underside is too high
• Table 10-50 - Starting air supply pressure is too low
• Table 10-51 - Pressure of the air spring air supply is too high
• Table 10-52 - Pressure of the air spring air supply is too low
• Table 10-53 - Oil leakage flow in the collector for leakage oil from the air spring is too high
• Table 10-54 - Control air supply pressure is too low (usual supply)
• Table 10-55 - Control air supply pressure is too low (stand-by supply)
• Table 10-56 - Control air supply pressure is too low (safety supply)
Miscellaneous malfunctions (XX45NN to XX52NN)

• Table 10-57 - Temperature of a thrust bearing pad is too high
• Table 10-58 - Cylinder liner wall temperature is too high
• Table 10-59 - A fuel pump actuator has a failure
• Table 10-60 - Power supply to the power supply box E85 has a failure

X92-B AA00-0000-00AAA-410C-A
• Table 10-61 - Unwanted engine speed decrease
• Table 10-62 - Unwanted engine stop

X92-B AA00-0000-00AAA-410C-A
10.2.2 Malfunctions of the water systems (XX10NN to XX19NN)
Tab 10-1 Supply pressure of the cylinder cooling water is too low
Indication Possible cause Procedure
PT1101A The cooling water supply system is • Find the cause and repair the fault.
defective
There are leaks in the cooling water • Find the cause and repair the fault.
system (for example cracks in a
cylinder liner)
For X92DF, the booster pump is • Repair the booster pump.

defective
Tab 10-2 Supply temperature of the cylinder cooling water is too low
TE1111A The cooling water supply system is • Find the cause and repair the fault. Adjust
defective the cooling water temperature slowly. This
prevents damage caused by sudden tem-
perature change.
Tab 10-3 Cylinder cooling water temperature downstream of a cylinder is too high
TE1121-nnA This is a result of the malfunction in • Do the repair shown there.

Table 10-1 - Supply pressure of the
cylinder cooling water is too low
The cooling water supply tempera- • Find the cause and repair the fault.
ture is too high
A cylinder liner, cylinder cover or • Find the cause and repair the fault.
exhaust valve cage is defective
A piston ring is defective • As a temporary procedure, cut out the injec-

tion of the related cylinder.
• As a temporary procedure, increase the
feed rate of the cylinder oil of the related
cylinder.
• Repair or replace the piston rings.
Tab 10-4 Supply pressure of the cooling water to the SAC is too low
PT1361A The cooling water supply system is • Find the cause and repair the fault.
defective

X92-B AA00-0000-00AAA-410C-A
Tab 10-5 Supply temperature of the cooling water to the SAC is too low
TE1371A The cooling water supply system is • Find the cause and repair the fault.
defective
Tab 10-6 Temperature of the cooling water downstream of the SAC is too high

cooling water to the SAC is too low
This is a result of the malfunction in • Do the repair shown there.

Table 10-5 - Supply temperature of
the cooling water to the SAC is too
low

X92-B AA00-0000-00AAA-410C-A
10.2.3 Malfunction of the oil systems (XX20NN to XX31NN)
Tab 10-7 Lubricating oil supply pressure at the engine inlet is too low
PT2001A The oil supply system is defective • Find the cause and repair the fault.
PT2012A (if applica-
ble)
Tab 10-8 Lubricating oil supply pressure upstream of the injectors is too low
PT2003A If applicable: the injector oil valve • Open the shut-off valve 8423_E0_2.
8423_E0_1 is defective Repair the injector oil valve.
•
If injector oil valve 8423_E0_1 is • Open the shut-off valve 8423_E0_2.
not applicable: shut-off valve
8423_E0_2 is closed
An injection valve is defective or a • Find the cause and repair the fault.
pipe is clogged
The alarm has no effect at engine standstill.
Tab 10-9 Lubricating oil supply temperature at the engine inlet is too high
TE2011A The oil supply system is defective • Find the cause and repair the fault.
TE2012A (if applica-
ble)
Tab 10-10 Lubricating oil supply pressure upstream of the crossheads is too low
PT2021A The crosshead oil supply system is • Decrease the engine load.
defective Find the cause and repair the fault.
•
Tab 10-11 Servo oil pressure in the distributor pipe (mini rail) is not in the permitted range
PT2041A There is an incorrect setting of the • Set the pressure reducing valve to the cor-
pressure reducing valve rect value.
There is an incorrect setting of the • Set the safety valve to the correct value.
safety valve
The filter or the opening in the ex- • Clean the filter or the exhaust valve control
haust valve control unit is clogged unit.
A servo oil pump or the servo oil • Repair the defective pumps.
service pump is defective

X92-B AA00-0000-00AAA-410C-A
Tab 10-12 Servo oil leakage flow from the servo oil supply unit is too high
LS2055A The servo oil unit or a servo oil pipe • Find the cause and repair the fault, refer to
is defective section 10.4 Examine the supply unit for ser-
vo oil leakage.
Tab 10-13 Servo oil flow at a servo oil pump inlet is too low
FS2061-nnA The related servo oil pump is de- • Replace the defective servo oil pump as
fective soon as possible.
The alarm has an effect only above 30% of engine load.
Tab 10-14 Bearing oil temperature at a bearing outlet is too high

Table 10-7 - Lubricating oil supply
TE2201-nnA
pressure at the engine inlet is too
TE2301-nnA low
A bearing is defective • Find the cause and repair the fault.
The oil does not have the specified • Use correct oil.
properties
Tab 10-15 Oil mist concentration is too high
AE2401-nnA The oil supply system is defective • Find the cause and repair the fault.
(crankcase)
Parts that move have become too • As a temporary procedure, decrease the en-
AE2415A
hot gine load.
(gearcase)
• Stop the engine.
AE2421-nnA (fuel
• Wait a minimum of 20 minutes to let the en-
supply unit)
gine temperature decrease.
• Find the cause and repair the fault.

X92-B AA00-0000-00AAA-410C-A
Tab 10-16 Piston cooling oil temperature downstream of a piston is too high

temperature at the engine inlet is
too high
A piston ring is defective • As a temporary procedure, cut out the injec-

tion of the related cylinder.
cylinder.
Tab 10-17 Piston cooling oil flow to a piston is not in the permitted range
FS2521-nnA This is a result of the malfunction in • Do the repair shown there.

low
A lever is defective • Repair the defective lever.
Tab 10-18 TC bearing oil temperature at a turbocharger outlet is too high

temperature at the engine inlet is
too high
A turbocharger is defective • Refer to the turbocharger manual.
Tab 10-19 TC bearing oil supply pressure upstream of a turbocharger is too low
PT2611-nnA This is a result of the malfunction in • Do the repair shown there.

low
There is an incorrect setting of the • Set the adjustable orifice to the correct val-
adjustable orifice ue.
Tab 10-20 TC bearing oil temperature at a turbocharger inlet is too high (external oil supply)
TE2621A The external oil supply system is • Find the cause and repair the fault.
defective

X92-B AA00-0000-00AAA-410C-A
Tab 10-21 Damper oil supply pressure upstream of the torsional vibration damper is too low
PT2711A There is an incorrect setting of the • Set the throttle valve to the correct value.
throttle valve
An oil supply pipe is defective • Replace the oil supply pipe.
Tab 10-22 Damper oil supply pressure upstream of the axial vibration damper is too low
PT2721A A sealing ring is defective • Replace the defective sealing ring.

PT2722A
Tab 10-23 Cylinder oil supply pressure is too low
PT3124A A filter element is clogged • Change over to the other filter chamber.
• Replace or clean the clogged filter element.
The cylinder oil tank is empty • Fill the cylinder oil tank.
Tab 10-24 Cylinder oil flow is too low

Table 10-23 - Cylinder oil supply
pressure is too low

Table 10-11 - Servo oil pressure in
the distributor pipe (mini rail) is not
in the permitted range
There is air in the cylinder oil sys- • Release the unwanted air from the cylinder
tem oil system.
Lubricating quills are blocked • Clean or replace defective parts.

X92-B AA00-0000-00AAA-410C-A
10.2.4 Malfunction of the fuel system (XX34NN)
Tab 10-25 Fuel supply temperature is not in the permitted range
TE3411A The fuel supply system is defective • Find the cause and repair the fault.
Tab 10-26 Fuel supply pressure at the engine inlet is too low
PT3421A The fuel supply system is defective • Find the cause and repair the fault.
The fuel does not have the speci- • Use correct fuel.
fied properties
Tab 10-27 Fuel leakage flow from the fuel supply unit is too high
LS3426-27A An HP fuel pipe or a fuel pump is • Find the cause and repair the defective item,
defective refer to section 10.5 Examine the supply unit
for fuel leakage.
Tab 10-28 Temperature difference of the fuel outlet of the two fuel pumps is too high (for X35/-B or
X40/-B engine)
TE3431-nnA Flow control valve of a fuel pump is • Clean or replace the defective flow control
defective valve.
One of the two fuel pumps is de- • Replace the defective fuel pump.
fective As a temporary procedure, close the 3/2-
•
way valve 10-8752_E0_3-4 in the HP fuel
pipe of the defective fuel pump.
Tab 10-29 Leakage flow from the rail unit is too high
LS3444-nnA An item of the rail unit is defective • Find the cause and repair the defective item,
refer to section 10.6 Examine the rail unit for
leakage.
Tab 10-30 Fuel leakage flow from fuel rail items is too high (engine with FLV)
LS3446A A flow limiting valve (FLV), a injec- • Find the cause and repair the defective item,
tor or a pipe is defective refer to section 10.7 Examine the FLV or fuel
pipes for fuel leakage.
NOTE: The leakage flow from the FLV is related to the viscosity of the used fuel.

X92-B AA00-0000-00AAA-410C-A
Tab 10-31 Fuel leakage flow from fuel rail items is too high (engine with ICU)
LS3446-nnA An injection control unit (ICU) or a • Find the cause and repair the defective item,
pipe or a connecting pipe (if appli- refer to section [section not applicable for
cable) is defective this engine].
Tab 10-32 Fuel pressure in the fuel rail is too high (for X35/-B or X40/-B engine)
PT3461-62C Control signal is missing or wrong • Find out the applicable flow control valve.
• Related to the necessary engine power
close the 3/2-way valve 10-8752_E0_3-4 in
the HP fuel pipe of the related fuel pump.
Flow control valve of a fuel pump is • Clean or replace the defective flow control
defective valve.
Tab 10-33 Fuel pressure in the fuel rail is too low (for X35/-B or X40/-B engine)
PT3461-62C Control signal is missing or wrong • Find out the applicable flow control valve.
• Disconnect the cable of the applicable flow
control valve (The related fuel pump sup-
plies the maximum fuel quantity. The pres-
sure control valve of the fuel rail or the other
fuel pump then controls the fuel pressure).
Flow control valve of a fuel pump is • Clean or replace the defective flow control
defective valve.
A fuel pump is defective • Replace the defective fuel pump.

X92-B AA00-0000-00AAA-410C-A
10.2.5 Malfunctions of systems for DF engine (XX33NN to XX39NN)
Tab 10-34 Gas concentration in piston underside is too high
AE3315C There is a leakage in the gas sys- • Find the cause and repair the defective item.
tem
Tab 10-35 Difference pressure of pilot fuel filter is too high
PS3464A The pilot fuel filter is clogged • Replace the filter element.
Tab 10-36 Gas supply pressure is too low
PT3901C The gas supply is defective • Find the cause and repair the fault.
The gas filter is clogged • Clean or replace the gas filter. For the filter
of the iGPR refer to [section not applicable
for this engine].

X92-B AA00-0000-00AAA-410C-A
10.2.6 Malfunctions of the exhaust gas system (XX37NN)
Tab 10-37 Exhaust gas temperature downstream of a cylinder is too high
TE3701-nnA The scavenge air flow is too low • Clean the turbocharger.
• Clean the air flaps in the scavenge air re-
ceiver.
• Clean the scavenge ports.

Table 10-3 - Cylinder cooling water
temperature downstream of a
cylinder is too high
There is air in the cooling water • Open the vent valves of the cooling water
system system.
An injection nozzle is defective • Repair or replace the defective injection

nozzle.
The injection time is too long • Find the cause and repair the fault.
There are leaks in the cooling water • Find the cause and repair the fault.
system (for example cracks in a
cylinder liner)
There is a fire in the piston under- • Do the procedure in section 2.3 Fire-fighting
side in the scavenge air space.
Tab 10-38 Exhaust gas temperature difference downstream of all cylinders is too high
TE3701-nnA An injection nozzle is defective • Repair or replace the defective injection

nozzle.
The fuel supply system is defective • Find the cause and repair the fault.
An exhaust valve is defective • Repair or replace the defective exhaust

valve.
Tab 10-39 Exhaust gas temperature upstream of a turbocharger is too high

Table 10-37 - Exhaust gas temper-
ature downstream of a cylinder is
too high

X92-B AA00-0000-00AAA-410C-A
Tab 10-40 Exhaust gas temperature downstream of a turbocharger is too high
TE3731-nnA A turbocharger surges • As a temporary procedure, decrease the en-

gine load.
• If applicable, open the exhaust waste gate
valve.
• Refer to the turbocharger manual.
Tab 10-41 Exhaust valve does not operate, unwanted noise
Refer to the display The air spring air pressure is too • Find the cause and repair the fault.
of a control panel low
The opening oil pressure is too low • Find the cause and repair the fault.
An exhaust valve is defective (pis- • Repair the exhaust valve.

ton cannot move, or a piston is de-
fective)
Tab 10-42 Smoke is too dark
The engine has too much load • Decrease the fuel injection quantity.
There is unwanted material in the • Find the cause and remove the unwanted
scavenge air material.
The fuel does not have the speci- • Use fuel with the specified properties.
fied properties

X92-B AA00-0000-00AAA-410C-A
10.2.7 Malfunction of the air systems (XX40NN to XX44NN)
Tab 10-43 Scavenge air temperature in the receiver is too high

cooling water to the SAC is too low
There is air in the cooling water • Release the unwanted air from the cooling
system water system.
The SAC is dirty • Clean the SAC on the air side, refer to sec-
tion 9.5 Clean the scavenge air cooler dur-
ing operation.
The SAC is defective • Repair or replace the SAC.
Tab 10-44 Scavenge air temperature in the receiver is too low

Table 10-5 - Supply temperature of
the cooling water to the SAC is too
low
Tab 10-45 Scavenge air pressure is too high
PT4043-nnC A turbocharger surges • As a temporary procedure, decrease the en-

gine load.
• If applicable, open the exhaust waste gate
valve.
• Refer to the turbocharger manual.
A safety valve is defective • Repair or replace the defective safety valve.
Tab 10-46 Scavenge air pressure is too low
PT4043-nnC The silencer, SAC or water sepa- • Remove the blockage and clean the item.
rator is clogged
The auxiliary blowers do not oper- • Start or repair the auxiliary blowers.
ate at low load

X92-B AA00-0000-00AAA-410C-A
Tab 10-47 Condensation flow at a water separator is too high
LS4071-nnA The filter in the return pipe is • Clean the filter.

clogged
The opening in the return pipe is • Clean the return pipe.

clogged
There are leaks in the SAC • Find the cause and repair the fault.
Tab 10-48 Condensation flow upstream of a water separator is too high
LS4075-nnA The filter in the return pipe is • Clean the filter.

clogged
The opening in the return pipe is • Clean the return pipe.

clogged
There are leaks in the SAC • Find the cause and repair the fault.
Tab 10-49 Scavenge air temperature in the piston underside is too high
TE4081-nnA There is fire in the piston underside • Refer to section 2.3 Fire-fighting in the scav-
enge air space.
A piston ring is defective • As a temporary procedure, decrease the

load and cut out the injection of the related
cylinder.
cylinder.
The engine has too much load • Decrease the fuel injection quantity.
Tab 10-50 Starting air supply pressure is too low
PT4301-nnC The starting air supply system is • Find the cause and repair the fault.
defective
Tab 10-51 Pressure of the air spring air supply is too high
PT4341A There is an incorrect setting of the • Set the control air supply to the correct val-
control air supply ue.

X92-B AA00-0000-00AAA-410C-A
Tab 10-52 Pressure of the air spring air supply is too low
PT4341A There is an incorrect setting of the • Set the control air supply to the correct val-
There is an incorrect setting of the • Set the safety valve to the correct value.
safety valve
The control air supply is defective • Repair or replace the defective item of the
control air supply.
Tab 10-53 Oil leakage flow in the collector for leakage oil from the air spring is too high
LS4351-52A The collector for leakage oil from • Clean the collector for leakage oil from the
the air spring is clogged air spring.
The float control is defective • Repair the float control.
Tab 10-54 Control air supply pressure is too low (usual supply)
PT4401A The control air supply system is de- • Find the cause and repair the fault.
fective
There is an incorrect setting of the • Set the control air supply to the correct val-
Tab 10-55 Control air supply pressure is too low (stand-by supply)
PT4411A The starting air supply system is • Find the cause and repair the fault.
defective
There is an incorrect setting of the • Set the control air supply to the correct val-
Tab 10-56 Control air supply pressure is too low (safety supply)
PT4421A This is a result of the malfunction in • As a temporary procedure, stop the engine.
Table 10-54 - Control air supply Do the repair shown there.
•
pressure is too low (usual supply)
and in Table 10-55 - Control air
supply pressure is too low (stand-
by supply)
The drain valve of the air tank is • Close the drain valve of the air tank.
open

X92-B AA00-0000-00AAA-410C-A
10.2.8 Miscellaneous malfunctions (XX45NN to XX52NN)
Tab 10-57 Temperature of a thrust bearing pad is too high
TE4521A This is a result of the malfunction in • Do the repair shown there.

low
The thrust bearing is defective • Find the cause and repair the fault.
The oil does not have the specified • Use correct oil.
properties
Tab 10-58 Cylinder liner wall temperature is too high
TE4801-nnC The cylinder oil system is defective • Find the cause and repair the fault.
TE4841-nnC
An injection nozzle is defective (for • Repair or replace the defective injection

example wrong spray angle, too nozzle.
long spray period)

cylinder cooling water is too low or
in Table 10-3 - Cylinder cooling wa-
ter temperature downstream of a
cylinder is too high
There is air in the cooling water • Release the unwanted air from the cooling
system water system, for an engine with bypass
cooling water system refer to section [sec-
tion not applicable for this engine].
There are exhaust gas leaks into • Find the cause and repair the fault.
the cooling water system (for ex-
ample valve seat area)
Tab 10-59 A fuel pump actuator has a failure
XS5046A The fuel does not have the speci- • Use correct fuel.
fied properties
A fuel pump actuator is defective • Repair the fuel pump actuator.

X92-B AA00-0000-00AAA-410C-A
Tab 10-60 Power supply to the power supply box E85 has a failure
XS5056A The power supply is set to OFF • Set to ON the power supply.
The power supply system is defec- • Repair the power supply system.
tive
Tab 10-61 Unwanted engine speed decrease
The speed setting from the speed • Do a check of the speed control system.
control system is decreased or is
not in the specified limits
The fuel injection quantity from the • A procedure is not necessary because the
speed control system is decreased control system prevents too much load in
heavy sea.
The fuel injection system is defec- • Find the cause and repair the fault.
tive
Tab 10-62 Unwanted engine stop
The fuel injection system is defec- • Find the cause and repair the fault.
tive

Table 10-61 - Unwanted engine
speed decrease
There is heavy sea • Set to ON the heavy sea mode.

X92-B AA00-0000-00AAA-410C-A

X92-B AA00-0000-00AAC-410C-A
Operation Manual Failures and defects of UNIC-flex components
10.3 Failures and defects of UNIC-flex components

Failures and defects of UNIC-flex components cause failure messages, which are transmitted to
the alarm and monitoring system (AMS).
10.3.1 Failure messages
The UNIC-flex engine control system (ECS) constantly does internal integrity checks and monitors
the connected sensors. UNIC-flex records each unusual condition and makes an event.
• The system software level does the checks for basic sensor failures.
• The software application level gives the level of the created event.
Related to the severity of the event there are three levels of messages:
• Minor failures
This category contains failures that will not cause to decrease the engine load (slowdown)
or to stop the engine (shutdown). But you have to do a check of the message. If necessary
correct the fault as soon as possible.
• Major failures
This category contains failures that will cause to decrease the engine load (slowdown) and/
or to stop the engine (shutdown). Major failures are divided in the two sub-groups SLD
(slowdown) and SHD (shutdown):
○ The SLD sub-group contains failures that cause one cylinder to cut off. The AMS
sends a slowdown signal to the ECS.
○ The SHD sub-group contains failures that prevent an engine operation. The engine
safety system (ESS) sends a shutdown signal to the ECS. UNIC-flex stops the fuel
injection.
These two sub-groups are not shown in internal or external interfaces. Thus they are only
used on the application level.
If a major failure occurs, the AMS sends a signal to the ECS for a slowdown or shutdown
command. Usually the ECS automatically sets the related setpoint for a slowdown or
shutdown of the engine, refer also to Para 10.3.2.
• Info logs
This category contains messages which describe engine operation conditions or give more
data to other failures. Related to the functional description only the most important
messages are sent to the AMS.
The table that follows shows some examples of failure messages.
Tab 10-63 Examples of failure messages
ID Failure text Failure type
3 Gear Wheel Sensor A Signal Fail Minor
46 Crank Angle Measurement Fail CCM #2 to #n Major / SHD
48 Crank Angle Measurement Fail CCM #1 Major / SLD
250 Remote Start Interlock - Main Start Air Valve Manually Closed Info

X92-B AA00-0000-00AAC-410C-A
Operation Manual Failures and defects of UNIC-flex components
For the complete list of failure messages refer to the document - Modbus to AMS signal list - of
the engine.
10.3.2 Special failures
WinGD has specified a few special failures (refer to Table 10-64 - Special failures) that makes it
necessary to start other steps.
Tab 10-64 Special failures
ID Failure text Failure type
45 Crank Angle Measurement Fail CCM #1 & MCM Major / SLD
47 Crank Angle Measurement Fail MCM Minor
96 Module Fail MCM Minor
If one of these special failures occur, the ECS automatically does the steps that follow:
• The ECS changes the active control location to “ECR manual”.
• The ECS changes to the “Fuel command mode”.
In this condition the ECS cannot set a setpoint for a command. Thus obey the rules that follow:
• If failure 45 occurs the operator must set the fuel command setpoint for slowdown manually.
• If failure 47 or 96 occurs the operator can set the fuel command setpoint if necessary.
10.3.3 Troubleshooting of UNIC-flex failures
If there is an indication of a UNIC-flex failure, use the data that follows to find the failure and to
repair it:
• Use the failure ID to find the related system or item.
• If applicable, compare the indicated values with the values on the local instruments.
• Make sure that the related items are mounted correctly and can operate correctly.
• Make sure that the related shut-off valves are in the correct operation positions.
• Do a check of the related cable connections.
• Do a check of the related cable or plugs for damage.
• Do a check of the related item for damage.
• Use a multimeter to do a check of the power supply.
• Use a multimeter to do a check of the sensor signal.
• Use a multimeter to do a check for a short circuit or a ground fault.
• If applicable, do a check of the terminating resistors for correct connection.
• Repair the faults, or temporarily repair defective cables with insulation tape.
• If necessary, replace damaged items.
If you cannot repair a fault, speak to or send a message to WinGD.

X92-B AA00-0000-00AAA-311A-A
Operation Manual Examine the supply unit for servo oil leakage
10.4 Examine the supply unit for servo oil leakage

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None

X92-B AA00-0000-00AAA-311A-A
PROCEDURE
1 Do a check of the level switch LS2055A for free flow. If necessary, clean the bore of the
pipe of the level switch.
2 Carefully do a check of the temperature of the oil leakage pipe of each servo oil pipe to
find the leakage pipe that has an oil flow.
NOTE: There is an oil flow in the leakage pipe that has a higher temperature than the
other leakage pipes.
3 Do a check of the related servo oil pipe at the highest inspection point for oil flow.
3.1 Carefully loosen the screw plug (003, Figure 10-1) a maximum of two turns and
look for oil flow.
3.2 If there is an oil flow, repair the cause of the leaks as soon as possible. Refer to
the Maintenance Manual.
3.3 Tighten the screw plug (003).
Fig 10-1 Example of inspection point
001
002
003
Legend
001 Servo oil pipe 003 Screw plug

002 Flange
4 Do Step 3 again for the other inspection points.

NOTE: Step 5 to Step 8 are only applicable for an X82 engine.
5 Do a check of the level switch LS2076A (if applicable also LS2077A) for free flow. If
necessary, clean the bore of the pipe of the level switch.
6 Carefully do a check of the temperature of the oil leakage pipe of each valve control unit
(VCU) to find the leakage pipe that has an oil flow.
NOTE: There is an oil flow in the leakage pipe that has a higher temperature than the
NOTE: As an alternative you can carefully loosen and tighten the screw plug of the
inspection point of each flange a maximum of two turns to find the leakage pipe
that has an oil flow.
7 Cut out the injection of the related cylinder and replace the defective oil pipe, refer to the
Maintenance Manual.

X92-B AA00-0000-00AAA-311A-A
8 If there is no oil flow from none of the leakage pipes, find (if applicable) the connecting pipe
that has a leakage as follows:
8.1 Carefully loosen the screw plug of the inspection point of the first connecting pipe
a maximum of two turns.
8.2 Do a check for oil flow.
8.3 If there is an oil flow, shut-off the related connecting pipe an repair it at the next
occasion, refer to the Maintenance Manual.
8.4 Tighten the screw plug.
8.5 Do Step 8.1 to Step 8.4 again for the other connecting pipe.
CLOSE UP
• None

X92-B AA00-0000-00AAA-311A-A

X92-B AA00-0000-00AAA-311B-A
Operation Manual Examine the supply unit for fuel leakage
10.5 Examine the supply unit for fuel leakage

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
Injury Hazard: Always put on gloves and safety goggles when you do work on hot or
pressurized components. When you open the screw plugs, fuel can come out as a spray
and cause injury.
• None

X92-B AA00-0000-00AAA-311B-A
PROCEDURE
2 Carefully do a check of the temperature of the fuel leakage pipe (002, Figure 10-2) of each
fuel pump (001) to find the leakage pipe that has a fuel flow.
NOTE: There is a fuel flow in the leakage pipe that has a higher temperature than the
3 Continue with Step 4 to find the location of the leakage at the related fuel pump and its HP
fuel pipes.
4 Do a check of the HP fuel pipe (005) at the highest inspection point (004) for leaks.
4.1 Carefully loosen the screw plug a maximum of two turns.
4.2 Do a check for fuel flow.
4.3 If there is fuel flow, repair the cause of the fuel flow as soon as possible, refer to
the Maintenance Manual 8752-1.
NOTE: The fuel system has high pressure. Replace a defective HP fuel pipe only
when the engine has stopped and the pressure in the system is released.
4.4 Tighten the screw plug.
Fig 10-2 Supply unit (example) and example of inspection point
001
002
003
005 004
Legend
001 Fuel pump 004 Inspection point

002 Fuel leakage pipe 005 HP fuel pipe
003 Supply unit

X92-B AA00-0000-00AAA-311B-A
5 Do Step 4 again for the other inspection points.

6 If the related HP fuel pipes are tight, a fuel pump is defective. Thus do an overhaul of the
fuel pump, refer to the Maintenance Manual 5556-1.
NOTE: If the defective HP fuel pipe cannot be replaced immediately (or the engine must
continue to operate), the related fuel pump must be cut out.
CLOSE UP
• None

X92-B AA00-0000-00AAA-311B-A

X92-B AA00-0000-00AAA-311E-A
Operation Manual Examine the rail unit for leakage
10.6 Examine the rail unit for leakage

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
pressurized components. Fuel can come out as a spray and cause injury.
• None

X92-B AA00-0000-00AAA-311E-A
Operation Manual Examine the rail unit for leakage
PROCEDURE
2 Carefully look into the rail unit to find the cause of the leakage.
NOTE: Possible causes can be a defective pipe to the exhaust valve, a defective flange
or an other defective item.
3 Repair the defective item.
CLOSE UP
• None

X92-B AA00-0000-00AAA-311C-A
Operation Manual Examine the FLV or fuel pipes for fuel leakage
10.7 Examine the FLV or fuel pipes for fuel leakage

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
CAUTION
pressurized components. When you open the screw plugs, fuel can come out as a spray
and cause injury.
• None

X92-B AA00-0000-00AAA-311C-A
PROCEDURE
Fig 10-3 Leakage on FLV and pipes (example)
001
002
008
003
004
007
006 005
Legend
001 HP fuel pipe to injection valve 005 Fuel rail

002 Screw 006 Fuel leakage pipe
003 Screw-in union 007 Screw-in union
004 Fuel leakage pipe 008 Flow limiting valve (FLV)
1 Do a check of the level switch LS3446A for free flow. If necessary, clean the bore of the
pipe of the level switch.
2 Carefully do a check of the temperature of the fuel leakage pipe (004, Figure 10-3) of each
flow limiting valve (FLV) (008) to find the leakage pipe that has a fuel flow.
NOTE: There is a fuel flow in the leakage pipe that has a higher temperature than the
NOTE: As an alternative you can carefully open and close the screw-in union (003) of
each FLV a maximum of two turns to find the leakage pipe that has a fuel flow.
3 If there is a leakage pipe (004) that has a fuel flow, do as follows:
3.1 Make sure that the screws (002) are tightened correctly, refer to the Maintenance
Manual 8733-1.
3.2 On the fuel leakage pipe (004), carefully loosen the screw-in union (003) a
maximum of two turns.
3.3 Do a check for fuel flow.
3.4 If fuel continues to flow from the screw-in union (003), do as follows (an HP fuel
pipe (001) is defective):
3.4.1 Stop the engine.
3.4.2 Remove each of the HP fuel pipes (001) until you find the defective HP fuel
pipe (refer to the Maintenance Manual 8733-1).
3.4.3 Do a check for damage on the sealing face of the defective HP fuel pipe
(001). If you find damage, grind the sealing face (refer to the Maintenance
Manual 8733-1).
3.4.4 If the HP fuel pipe is defective, cut out the injection of the related cylinder
and replace the defective HP fuel pipe, refer to the Maintenance Manual.
3.4.5 Tighten the screw-in union (003).
3.4.6 Start the engine.
3.5 If no fuel flows from the screw-in union (003), tighten the screw-in union (003).

X92-B AA00-0000-00AAA-311C-A
4 If none of the leakage pipes (004) have a leakage, find the FLV that has a fuel flow more
than usual (compared to the amount of leakage from the other FLV) as follows:
4.1 Put an oil tray under the screw-in union (007, Figure 10-3) of the fuel leakage pipe
(006) to collect the usual fuel flow.
4.2 Carefully loosen the screw-in union (007) a maximum of two turns.
4.3 Do a check of the fuel flow.
4.4 If fuel flows from the screw-in union (007) more than usual (compared to the
amount of leakage from the other FLV), the piston rod is defective. Replace the
defective piston rod (refer to the Maintenance Manual 5564-1).
4.5 Tighten the screw-in union (007).
4.6 Do Step 4.1 to Step 4.5 again for the other FLV.
CLOSE UP
• None

X92-B AA00-0000-00AAA-311C-A

X92-B AA00-0000-00AAA-662A-A
Operation Manual Temporary cut out a defective injection valve
10.8 Temporary cut out a defective injection valve

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-0000-00AAA-662A-A
Operation Manual Temporary cut out a defective injection valve
PROCEDURE
1 Cut out the injection of the related cylinder.

NOTE: If possible, the exhaust valve must always operate.
2 For an engine with direct controlled injection valves, disconnect the electrical connection
from the injection valve.
3 For an engine with conventional injection valves, disconnect the electrical connection from
the injection control unit (ICU).
4 If it is necessary to operate the engine with the injection cut out for an extended period, do
as follows:
4.1 Record the settings of the cylinder oil feed rate.
4.2 Decrease the cylinder oil feed rate for the related cylinder to the minimum setting.
5 Repair the fault as soon as possible, refer to the Maintenance Manual.
CLOSE UP
• None

X92-B AA00-0000-00AAA-662D-A
Operation Manual Temporary cut out a defective exhaust valve drive
10.9 Temporary cut out a defective exhaust valve drive

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None

X92-B AA00-0000-00AAA-662D-A
Operation Manual Temporary cut out a defective exhaust valve drive
PROCEDURE
1 Cut out the defective cylinder from the injection, refer to section 10.8 Temporary cut out a
defective injection valve.
2 Disconnect the electrical connection to the related exhaust valve control unit (VCU).
CLOSE UP
• The engine can be started and operated at decreased load, refer to section 8.3 Start the
engine - general

X92-B AA00-0000-00AAA-662B-A
Operation Manual Temporary isolate a cylinder with cooling water leakage
10.10 Temporary isolate a cylinder with cooling water leakage

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
Pressure element 94259 A/R
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None

X92-B AA00-0000-00AAA-662B-A
PROCEDURE
1 Isolate the defective cylinder from the cooling water system.

2 Make sure that there is no air spring air pressure.
3 Lock the exhaust valve in the open position as follows:
3.1 Remove the damper (002, Figure 10-4) from the top housing (001).
3.2 Make sure that you do not lose the shim(s) (004).
NOTE: The shim(s) must stay in position when the pressure element is installed.
3.3 Apply a thin layer of oil to the thread of the pressure element (003).
3.4 Install the pressure element (003).
Fig 10-4 Exhaust valve with pressure element
002 003
001
004
Legend
001 Top housing 003 Pressure element

002 Damper 004 Shim
4 Cut out the defective cylinder from the injection, refer to section 10.8 Temporary cut out a
defective injection valve.
5 Disconnect the electrical connection to the related exhaust valve control unit (VCU).
6 Disconnect the control signal connection from the related starting air valve.

X92-B AA00-0000-00AAA-662B-A
CLOSE UP
• The engine can be started and operated at decreased load, refer to section 8.3 Start the
engine - general

X92-B AA00-0000-00AAA-662B-A

X92-B AA00-5551-00AAA-410A-A
Operation Manual Servo oil pump - troubleshooting
10.11 Servo oil pump - troubleshooting

To troubleshoot the flow sensor, refer to the following instructions:
10.11.1 Flow sensor check
To resolve a flow sensor alarm, refer to the following instructions:

1 Disconnect the sensor from the connector.
2 Wait for 10 seconds to connect the sensor to the connector.
3 Monitor the following conditions:
Condition 1: If 2 LEDs glow orange and 1 LED glows green at the same time, then the sensor
is OK.
Condition 2: If only 1 LED glows green, then the sensor is faulty.
Condition 3: If no LEDs glow, then there is no power supply to the sensor.

NOTE: If the sensor is OK, then check the servo oil pump operation.
10.11.2 Servo oil pump operation check
To check for the servo oil pump operation, refer to the following instructions:
1 Engine must be at low load.
2 Remove the solenoid connector from the servo oil pump.
NOTE: Do no remove the solenoid connector from the servo oil pump which gives a flow
alarm.
3 The servo oil pump which gives a flow alarm must now supply the servo oil in full capacity.
4 The flow alarm stops.
5 Wait for a minute to monitor the following conditions:
Condition 1: If the flow alarm stops, then the servo oil pump is operational and only needs
calibration.
Condition 2: If the flow alarm does not stop, the servo oil pump must be removed from the
engine.

X92-B AA00-5551-00AAA-410A-A
Operation Manual Servo oil pump - troubleshooting

X92-B AA00-5551-00AAA-273A-A
Operation Manual Servo oil pump - Calibration for Dynex pump
10.12 Servo oil pump - Calibration for Dynex pump

To calibrate the Dynex servo oil pumps, refer to the following instructions.
10.12.1 Calibration procedure of the Dynex servo oil pump
To calibrate the Dynex servo oil pumps, refer to the following instructions.
1 Locate the pressure adjustment screw on the servo oil pump.

2 Remove the protection cap.
3 Put marks on the initial position of the setting screw.
4 Loosen the locknut.
5 Turn the setting screw 22.5 degrees.
6 Tighten the locknut
7 Monitor if there is a change in flow alarm indication for 10 minutes.
NOTE: If the flow alarm indication remains, repeat steps 4 to 7.
NOTE: Do no turn the setting screw more than 90 degrees in total.
NOTE: The calibration of the servo oil pump can show another kind of alarm: the controller
limit alarm.
If this happens, turn the setting screw 22.5 degrees back to its initial position.

X92-B AA00-5551-00AAA-273A-A
Operation Manual Servo oil pump - Calibration for Dynex pump

X92-B AA00-5551-00AAB-273A-A
Operation Manual Servo oil pump - Calibration for Bosch pump
10.13 Servo oil pump - Calibration for Bosch pump

To calibrate the Bosch servo oil pumps, refer to the following instructions.
10.13.1 Calibration procedure of the Bosch servo oil pump
To calibrate the Bosch servo oil pumps, refer to the following instructions.

2 Remove the plastic cover from the adjustment screw.
5 Turn the setting screw in clockwise direction for 22.5 degrees.
6 Tighten the locknut.
7 Monitor the condition for 5 minutes on the pump angle indicators.
NOTE: If the pump angle indicators show different angles, an adjustment of the pump
angles is required.
8 Put the plastic cover on the adjustment screw.
limit alarm.

X92-B AA00-5551-00AAB-273A-A
Operation Manual Servo oil pump - Calibration for Bosch pump

X92-B AA00-5551-00AAC-273A-A
Operation Manual Servo oil pump - Calibration for Hawe pump
10.14 Servo oil pump - Calibration for Hawe pump

To calibrate the Hawe servo oil pumps, refer to the following instructions.
10.14.1 Calibration procedure of the Hawe servo oil pump
To calibrate the Hawe servo oil pumps, refer to the following instructions.

NOTE: A small leakage can occur, it will stop when it is tightened.
4 Turn the setting screw in clockwise direction for 22.5 degrees.
5 Tighten the locknut.
6 Monitor the condition for 5 minutes on the pump angle indicators.
NOTE: If the pump angle indicators show different angles, an adjustment of the pump
angles is required.
limit alarm.

X92-B AA00-5551-00AAC-273A-A
Operation Manual Servo oil pump - Calibration for Hawe pump

X92-B AA00-5556-00AAB-510B-A
Operation Manual Fuel pump - cutting out
10.15 Fuel pump - cutting out

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
Flange 94569 1
Flange 94569A 1
Roller lifting tool 94430 1
Pre-tensioner 94430A 1
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
WARNING
Injury hazard: The cutting out procedure can only be done when the engine is stop.
WARNING
the flywheel or the engine.
CAUTION
Damage hazard: When the fuel pump is unserviceable, repair the fault immediately. If the
fault cannot be repaired, because the engine must operate, it becomes necessary to cut
out the unserviceable fuel pump. This will prevent damage hazard.

X92-B AA00-5556-00AAB-510B-A
CAUTION
Damage hazard: Do not operate the engine with the fuel pump removed. This will decrease
the oil supply, i.e. there could be a decrease of lubrication to the other fuel pumps.
NOTE: There can be a limitation in available engine power, based on engine configuration and
rating. Power can be increased to that, when the fuel rail pressure starts to drop.

X92-B AA00-5556-00AAB-510B-A
PROCEDURE
Fig 10-5 Location of flanges
1 Release the pressure of the fuel supply unit to 0 bar.

X92-B AA00-5556-00AAB-510B-A
2 Release the pressure of the servo oil supply unit to 0 bar.

3 Remove the HP fuel pipe (001, Figure 10-5) from the defective fuel pump (003). Refer to
the Maintenance Manual for more information.
4 Install the flange (002) to the fuel pump (003).
5 Install the flange (007) to the intermediate piece (006).
6 Remove the applicable cover (005) from the supply unit casing (004).
NOTE: Make sure that the applicable supply unit cam is at TDC and if not do Step 7.
Fig 10-6 Roller lifting tool assembly
7 Operate the turning gear to turn the supply unit cam at TDC to push the roller (001, Figure
10-6) of the guide piston (002) at the highest position.
8 Tighten the elastic bolt (003) with the pad (004).
9 Tighten the round nut (005) until it touches the pad (004).
10 Make sure that the pad (004) touches the guide piston (002).

X92-B AA00-5556-00AAB-510B-A
Fig 10-7 Pre-tensioner install
11 Install the pre-tensioner (005, Figure 10-7) on to the elastic bolt (002).
12 Make sure that the pre-tensioner (005) touches the pad (003).
13 Use the pre-tensioner (005) to adjust the tension of the elastic bolt (002).
14 Remove the pre-tensioner (005). Refer to the Maintenance Manual for more information.
15 Make sure that the roller (007) is approximately 3.0 mm above the cam (006).
16 Install the cover (006, Figure 10-6).
NOTE: For the torque values and lubrication of the screws, refer to the Maintenance
Manual tightenings instruction.
CLOSE UP
• None

X92-B AA00-5556-00AAB-510B-A

X92-B AA00-5556-00AAB-730B-A
Operation Manual Fuel pump - cutting in
10.16 Fuel pump - cutting in

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
Flange 94569 1
Flange 94569A 1
Roller lifting tool 94430 1
Pre-tensioner 94430A 1
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
WARNING
Injury hazard: The cutting in procedure can only be done when the engine is stop.
WARNING
the flywheel or the engine.
CAUTION
Damage hazard: Do not operate the engine with the fuel pump removed. This will decrease
the oil supply, i.e. there could be a decrease of lubrication to the other fuel pumps.

X92-B AA00-5556-00AAB-730B-A

X92-B AA00-5556-00AAB-730B-A
PROCEDURE
Fig 10-8 Location of flanges
1 Release the pressure of the fuel supply unit to 0 bar.

X92-B AA00-5556-00AAB-730B-A
2 Release the pressure of the servo oil supply unit to 0 bar.

3 Remove the flange (002. Figure 10-8) from the fuel pump (003).
4 Remove the flange (007) from the intermediate piece (006).
5 Install the HP fuel pipe (001) on to the fuel pump (003). Refer to the Maintenance Manual
for more information.
6 Remove the applicable cover (005) from the supply unit (004).
NOTE: Make sure that the applicable supply unit cam is at TDC and if not do Step 7.
Fig 10-9 Assembly of roller lifter tool
7 Operate the turning gear to turn the supply unit cam at TDC to push the roller (007, Figure
10-9) of the guide piston (001) is at the highest position.
8 Install the pre-tensioner (005) on to the elastic bolt (004).
9 Make sure that pre-tensioner (005) touches the pad (003).
10 Use the pre-tensioner (005) to loosen the elastic bolt (003). Refer to the Maintenance
Manual for more information.
11 Remove the pre-tensioner(005).
12 Remove the round nut (004), the elastic bolt (002) and the pad (003).
13 Attach the round nut (004) to the elastic bolt (002) on the pad (003) manually.
14 Install the cover (005, Figure 10-8).
15 Make sure that the fuel pump (003) operates correctly.
16 Make sure that the HP fuel pipe (001) has no leaks.
CLOSE UP
• None

X92-B AA00-6500-00AAA-662A-A
Operation Manual Temporary isolate a defective turbocharger
10.17 Temporary isolate a defective turbocharger

Periodicity
Description
Unscheduled
Personnel
Support equipment
Cover 94653A A/R
Cover 94653B A/R
Cover 94653C A/R
Cover 94653D A/R
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-6500-00AAA-662A-A
PROCEDURE
1 Stop the engine.

2 If not all turbochargers are defective, isolate the defective turbocharger from the exhaust
gas system and from the scavenge air system.
NOTE: This step is only applicable for an engine with more than one turbocharger, and
if one ore two turbochargers are serviceable.
2.1 Lock the rotor of the defective turbocharger (refer to the turbocharger manual).
2.2 Remove the expansion joint (007, Figure 10-10) between the defective
turbocharger and the exhaust gas manifold.
2.3 Install the covers 94653A and 94653B (001 and 002).
2.4 Remove the expansion joint (005) between the defective turbocharger air outlet
and the diffusor.
2.5 Install the covers 94653C and 94653D (003 and 004).
NOTE: You only have to install the covers (003), if the turbochargers are
connected to a suction duct.
Fig 10-10 Not all turbochargers are defective (example)
Legend
001 Cover 94653A 005 Expansion joint

002 Cover 94653B 006 Turbocharger
003 Cover 94653C 007 Expansion joint
004 Cover 94653D

X92-B AA00-6500-00AAA-662A-A
3 If all turbochargers are defective, isolate the defective turbochargers from the scavenge
air system.
NOTE: This step is applicable for an engine with one, two, or three turbochargers, and
none of the turbochargers are serviceable.
3.1 Lock the rotor of the defective turbochargers (refer to the turbocharger manual).
3.2 Remove the expansion joint (005, Figure 10-11) between the defective
turbochargers air outlet and the diffusor.
3.3 Install the covers 94653C (001).
NOTE: You only have to install the covers (001), if the turbochargers are
connected to a suction duct.
3.4 Open the covers (003 and 004) on the scavenge air receiver.
3.5 Set to ON the auxiliary blowers.
Fig 10-11 All turbochargers are defective (example)
Legend
001 Cover 94653C 004 Cover

002 Cover 94653D 005 Expansion joint
003 Cover 006 Turbocharger
4 Make sure that the air supply to the engine room is satisfactory.
5 Make sure that the oil supply pressure to the serviceable turbochargers is satisfactory.
6 Start the engine with the given limits, refer to section 8.3 Start the engine - general.
CLOSE UP
• None

X92-B AA00-6500-00AAA-662A-A

X92-B AA00-8135-00AAA-662A-A
Operation Manual Temporary isolate the exhaust waste gate
10.18 Temporary isolate the exhaust waste gate

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-8135-00AAA-662A-A
PROCEDURE
Fig 10-12 Exhaust waste gate (example)
Legend
001 Exhaust gas manifold 006 Indicator

002 Cardan rod 007 Ball valve 50-8135_E0_3 (air spring air)
003 Positioner and feedback with EMC module 008 Flange
004 Actuator 009 Valve
005 Plate

X92-B AA00-8135-00AAA-662A-A
1 Stop the engine.

2 Loosen the screws of the flange (008, Figure 10-12), but do not loosen one of the two
middle screws.
3 Turn the flange (008) to close the exhaust waste gate.
4 Tighten the screws to attach the flange (008).
5 Start the engine.
CLOSE UP
• None

X92-B AA00-8135-00AAA-662A-A

X92-B AA00-0000-00AAA-662C-A
Operation Manual Isolate a defective engine at twin engine installation
10.19 Isolate a defective engine at twin engine installation

Periodicity
Description
Unscheduled
Personnel
Engine crew Basic 1
Support equipment
None
Supplies
Description QTY
None
Spare Parts
None
SAFETY PRECAUTIONS
• None
• None

X92-B AA00-0000-00AAA-662C-A
Operation Manual Isolate a defective engine at twin engine installation
PROCEDURE
1 Engage the shaft locking device of the defective engine. Refer to the related documentation
of the manufacturer.
NOTE: This prevents the windmilling effect on the propeller of the defective engine (shaft
movement), when you operate the other engine.
2 If installed, disengage the shaft clutch of the defective engine. Refer to the related
documentation of the manufacturer.
3 If the shaft locking device and the shaft clutch are unserviceable, make sure that you
operate the auxiliary systems.
4 If installed, change the pitch of the controllable propeller (CPP) to the lowest resistance.
WARNING
Injury Hazard: Do not go near movable parts of the engine unless you are sure, that in each
condition, no part can move.
5 Obey the procedure to get access to the engine spaces, refer to section 2.6 Access to
engine spaces.
6 If possible, find the cause and repair the fault.
CLOSE UP
• None

X92-B AA00-0000-00AAA-200A-A
Operation Manual WiCE - Gateway Unit (GTU) replace
10.20 WiCE - Gateway Unit (GTU) replace
10.20.1 Gateway Unit (GTU) replacement

NOTE: Do not set OFF the complete control system to replace a single control module. A new
module must be connected to control system which is in operation to start the correct
software and configuration image update. The other Gateway Control Unit (GTU) and
Main Control Unit (MTU) must be in operation to get update with the new installed control
module.
1 Stop the engine, if required.

2 Get control at E90 terminal box.
NOTE: Do not disconnect any wire from the terminal plugs. Always remove the complete
terminal plug. Refer to Step 4 for removal of terminal plug. Each terminal plug has
an unique number and the same number is printed on the top of the applicable
control module.
3 Loosen the two screws of terminal plug.
4 Disconnect the terminal plug from the control module.
5 Disconnect the X11 plug to set OFF the control module (006, Figure 10-13).
6 Disconnect the X12-X14 and X22-X24 plugs (005).
7 If applicable, disconnect the X31 USB port (001).
8 If applicable, disconnect the X41-X43 Ethernet ports (002).
NOTE: Make sure that there are labels attached to the cables.
9 Loosen the cables fixing rail from the module housing (003).
10 Loosen the six screws (006).
NOTE: Make sure that you do not remove them completely.
11 Remove the control module carefully (007).
12 Attach a “Faulty” label to the control module.
NOTE: If the part need to be returned to WinGD service station, fill the return sheet
attached to the box of the spare control module.
13 Install the new control module (007).
14 Tighten the six screws (006) to attach the control module to the back plate.
15 Tighten the cable fixing rail to the module housing.
NOTE: Do not tighten the cable fixing rail too much.
16 If applicable, connect X41-X43 Ethernet ports (002) to the control module.
17 If applicable, connect X31 USB port (001) to the control module.
18 Connect the X12-X14 and X22-X24 plugs (005) to the control module.
NOTE: Connect the X11 power supply plug to the power supply junction carefully .
19 Connect the X11 plug to control module and tighten all connectors with two screws.
20 The control module must boot-up.
21 If there is an automatic download, it will show on the control module display.
22 Start the engine from the remote-control system.

X92-B AA00-0000-00AAA-200A-A
Operation Manual WiCE - Gateway Unit (GTU) replace
23 Do a function test of the new control module e.g. connection to sub-systems, DCM and
remote control system.
Tab 10-65 GTU - Control module configuration
Software image download Configuration image download Normal Boot up without download
B:RI: ethernet ring initiated B:RI: ethernet ring initiated B:RI: ethernet ring initiated
U:CK: software and config im- U:CK: software and config image U:CK: software and config image check
age check initiated check initiated initiated
U:PU: pull update check initi- U:PU: pull update check initiated U:PU: pull update check initiated
ated
U:SI: push single update initi- U:SI: push single update initiated SM:I: USM state "Initialization"
ated
U:SW: software update initiat- U:CF: config update initiated SM:R: USM state "Ready"
ed
Reboot Reboot Blank
Fig 10-13 WiCE - Gateway Unt (GTU) replacement
002 003 004

001
007
006
005

X92-B AA00-0000-00AAA-200B-A
Operation Manual WiCE - Main Control Unit (MCU) replace
10.21 WiCE - Main Control Unit (MCU) replace
10.21.1 Main Control Unit (MCU) replacement

NOTE: Do not set OFF the complete control system to replace a single control module. A new
module must be connected to control system which is in operation to start the correct
software and configuration image update. The other Gateway Control Unit (GTU) and
Main Control Unit (MTU) must be in operation to get update with the new installed control
module.

2 Get control at E90 terminal box.
NOTE: Do not disconnect any wire from the terminal plugs. Always remove the complete
terminal plug. Refer to Step 5 for removal of terminal plug. Each terminal plug has
an unique number and the same number is printed on the top of the applicable
control module.
3 Loosen the two screws from the control module.
5 Disconnect the X11 and X21 plugs to set OFF the control module (002, Figure 10-14).
6 Disconnec thet X12-X15, X22-X25 and X31-X35 plugs (001).
7 If applicable, disconnect theX41 Ethernet port (003).
NOTE: Make sure do not remove them completely.
10 Remove the control module carefully (006).
15 If applicable, connect the X41 Ethernet ports (003) to the control module.
16 Connect the X12-X15, X22-X25 and X31-X35 plugs (001) to the control module.
17 Connect the X11 and X21 plugs to control module.
NOTE: Tighten all connectors with two screws.
18 Make sure that the control module must boot-up correctly.
21 Do a function test of the new control module e.g. speed controller, sensor input failures,
crank angle failures, etc.

X92-B AA00-0000-00AAA-200B-A
Operation Manual WiCE - Main Control Unit (MCU) replace
Tab 10-66 MCU - Control module configuration
U:CK: software and config im- U:CK: software and config image U:CK: software and config image check
age check initiated check initiated initiated
U:PU: pull update check initiat- U:PU: pull update check initiated U:PU: pull update check initiated
ed
U:SI: push single update initiat- U:SI: push single update initiated SM:I: USM state “Initialization”
ed
U:SW: software update initiated U:CF: config update initiated SM:R: USM state “Ready”
Reboot Reboot Blank
Fig 10-14 WiCE - Main Control Unit (MCU) module replacement
001 002
003
004
005
006

X92-B AA00-0000-00AAA-200C-A
Operation Manual WiCE - Cylinder Control Unit (CCU) module replacement
10.22 WiCE - Cylinder Control Unit (CCU) module replacement
10.22.1 Cylinder Control Unit (CCU) replacement

NOTE: If the Cylinder Control Unit (CCU) failure occurs, the related cylinder is cut-out and will
have no cylinder lubrication.
1 Stop the engine.

2 Get control to related E95.xy terminal box.
3 Set to OFF the two circuit breakers (005, Figure 10-15).
NOTE: Do not disconnect any wires from the terminal plugs. Always remove the complete
terminal plug, refer Step 5.Each terminal plug has an unique number and the same
number is printed on the top of its applicable control module.
4 Loosen the two screws and disconnect the terminal plug from the control module.
6 Disconnect the X11-X14, X21-X23, X31-X33, and X41-X43 terminal plugs (004).
7 If applicable, disconnect the X51 Ethernet port (003).
NOTE: Make sure you do not remove them completely.
10 Remove the control module (006) carefully.
15 If applicable, connect the X51 Ethernet port (003) to control module.
16 Connect the X11-X14, X21-X23, X31-X33, and X41-X43 terminal plugs (004) to the control
module.
17 Set to ON both circuit breakers (005).
18 Make sure that the control module must boot-up correctly.
21 Do a function test of the new control module e.g. cylinder related injection, sensor input
failures, etc.
Tab 10-67 CCU control module configuration

X92-B AA00-0000-00AAA-200C-A
Operation Manual WiCE - Cylinder Control Unit (CCU) module replacement
U:PU: pull update check initiat- U:PU: pull update check initiated U:PU: pull update check initiated
ed
U:SI: push single update initiat- U:SI: push single update initiated SM:I: USM state “Initialization”
ed
U:SW: software update initiated U:CF: config update initiated SM:R: USM state “Ready”
Reboot Reboot Blank
Fig 10-15 WiCE - Cylinder Control Unit (CCU) module replacement
006
005
004
003
001
002

X92-B AA00-0000-00AAA-200E-A
Operation Manual WiCE - Angle Control Unit (ACM20) module replacment
10.23 WiCE - Angle Control Unit (ACM20) module replacment
10.23.1 Angle Control Module (ACM-20) replacement.
1 Get control to the E96.x* terminal box.

NOTE: Do not disconnect any wires from the terminal plugs. Always remove the complete
terminal plug, refer to Step 3.Each terminal plug has an unique number and the
same number is printed on the top of its applicable control module.
2 Loosen the two screws from the control module.
4 Disconnect the X1 and X3 plugs (002,Figure 10-16 ).
NOTE: Make sure you do not remove them completely.
7 Remove the control module (004) carefully.
12 Connect the X1 plug to the power supply junction.
13 Connect the X1 and X3 (002) plugs to the control module.
14 Tighten all connectors with two screws.
15 Make sure that the control module must boot-up corrctly.
17 Do a function test of the new control module e.g. valid angle display, related reference pick-
up etc.
18 Make sure that the related reference pickup sensor must go through the new ACM-20
module.

X92-B AA00-0000-00AAA-200E-A
Operation Manual WiCE - Angle Control Unit (ACM20) module replacment
Fig 10-16 WiCE - Angle Control Unit (ACM20) module replacement
001 002 003
004

X92-B AA00-0000-00AAA-200F-A
Operation Manual WiCE - Manual Control Panel (MCP) replacement
10.24 WiCE - Manual Control Panel (MCP) replacement
10.24.1 Manual Control Panel (MCP) replacement

NOTE: The Manual Control Panel (MCP) local and Manual Control Panel (MCP) ECR are fully
interchangeable items. New control panels are supplied with pre-installed application
software.

2 Open the cover of the E26 control box (002,Figure 10-17), to get control on the rear of the
Manual Control Panel (MCP) (001).
3 Disconnect the C1 plug (003, Figure 10-18) from the Manual Control Panel (MCP).
4 Disconnect the C2 plug (002) from the Manual Control Panel (MCP).
5 If applicable disconnect the C3 plug (004) from the Manual Control Panel (MCP).
6 Loosen the screws (001) from the bracket.
NOTE: Make sure the display unit does not fall.
7 Remove the Manual Control Panel (MCP) from the bracket.
9 Attach new MCP, either to E26 or in the ECR.
10 Install the bracets on the new Manual Control Panel (MCP).
11 Tighten the brackets with the screws (001).
12 Connect the C2 plug (002) to the Manual Control Panel (MCP).
13 Connect the C1 plug (003) to the Manual Control Panel (MCP).
14 If applicable, connect the C3 plug (004) to the Manual Control Panel (MCP).
15 Close the cover of the control box E26 or ECR.
16 Do a function test to make sure that the Manual Control Panel (MCP) operates correctly.
• Operating application is functional.
• CAN bus connection is operational.
17 Make sure to operate the engine as quickly as possible (latest at save ship position) with
the new Manual Control Panel (MCP).

X92-B AA00-0000-00AAA-200F-A
Operation Manual WiCE - Manual Control Panel (MCP) replacement
Fig 10-17 WiCE - Manual Control Panel (MCP) replacement - E26
001
002
Fig 10-18 WiCE - Manual Control Panel (MCP) replacement - Back Cover
004
003
002
001

X92-B AA00-0000-00AAA-410A-A
Operation Manual WiCE module - troubleshooting
10.25 WiCE module - troubleshooting

Tab 10-68 WiCE module warning indication on the LDU-20 panel
Indication Possible trouble Procedure
E:L2 Ethernet ring 2 left link down Re-establish the wiring of the Ethernet Ring #2. TRX-L2
to the adjacent control module.
E:R2 Ethernet ring 2 right link down Re-establish the wiring of the Ethernet Ring #2. TRX-R2
E:L1 Ethernet ring 1 left link down Re-establish the wiring of the Ethernet Ring #1. TRX-L1
E:R1 Ethernet ring 1 right link down Re-establish the wiring of the Ethernet Ring #1. TRX-R1

X92-B AA00-0000-00AAA-410A-A
Operation Manual WiCE module - troubleshooting

X92-B AA00-0000-00AAB-100A-A
Operation Manual Special running condition: Turbocharger cut out
10.26 Special running condition: Turbocharger cut out

The engine is designed to run with all its turbochargers working. If a turbocharger stops working,
it must be repaired as soon as possible. However, if it is impossible to repair the not working
turbocharger, then the engine can still be run, even with 2 turbochargers not working. This is called
turbocharger cut out operation and it is considered a special running condition.
NOTE: If during one of the procedures mentioned in this chapter, an auxiliary blower becomes
inoperative, it will automatically be cut out thanks to the built in non-return valve.
WARNING
Running the engine under a special running condition will impact the following parameters
negatively:
• Increase of Thermal load
• Increase of exhaust temperature
• Increase of torsional vibrations
• Increase of stress on the Crankshaft
• Reduction of engine revolutions
• Reduction of load limit
• occurance of surging
WARNING
Running the engine under special running conditions for more than 2-5 days can damage
the engine. If the engine is run under special running conditions for more than that, contact
the engine builder to obtain advice.
A turbocharger can be manually taken out of operation. The main reasons to do so are:
• Heavy turbocharger vibrations
• Bearing failure
• Malfunction of the turbocharger
The turbocharger can be taken out of operation while keeping the vessel maneuverable. For this,
reduce the load until the turbocharger vibrations are gone.
If reducing the load doesn’t help and the turbocharger has problems running even at reduced load,
then proceed like this:
WARNING
Taking the turbocharger out of operation while keeping the vessel maneuverable should
only be done if it isn’t possible to run for an extended period with a turbocharger out of
operation.
A.) For engines with one turbocharger:

1 Stop the engine
2 Open the cover (E)
3 Lock the rotor of the faulty turbocharger (check your turbocharger manual for details)

X92-B AA00-0000-00AAB-100A-A
4 Remove the compensator (1) between the compressor outlet and the scavenge air duct.
5 Remove the expansion piece (2) for the air outlet of the turbocharger (F)
6 If there is oil loss, plug the turbocharger
7 Switch on the manual mode of the auxiliary blower
8 Make sure you are within the load restriction
9 Verify the maximum firing pressure
The turbocharger has been cut out successfully. The engine is now running under a special running
condition.
B.) For engines with two or more turbochargers:

1 Stop the engine
6 Insert an orifice plate (3, 4) in the compressor outlet
7 If there is oil loss, plug the turbochargers
NOTE: The load restriction for 1 out of 2 turbochargers is 40%. The load restriction for 1 out of
3 turbochargers is 55%. The load restriction can be increased considerably, if an orifice
plate is also inserted in the turbine inlet.
NOTE: If reducing the load doesn’t help and the turbocharger has problems running even at
reduced load, then consult the turbocharger manual for further advice.
condition.
If it is possible to run for an extended period of time with a turbocharger out of operation, then
proceed like this:
C.) For engines with one turbocharger and the exhaust bypass option:
1 Stop the engine
4 Remove the blanking plate (T1, T2, T3, T4) from the exhaust bypass pipe

X92-B AA00-0000-00AAB-100A-A

condition.
D.) For engines with one turbocharger but without the exhaust bypass option:
1 Stop the engine
4 Insert the blanking plate (T1, T2, T3, T4) according to your turbocharger manual
condition.
E.) For engines with two or more turbochargers:

1 Stop the engine
4 Remove the blanking plate (T1, T2, T3, T4) from the exhaust bypass pipe
condition.
Turbochargers can be repaired during the voyage. If this is necessary, proceed like this:
E.) For engines with one turbocharger:

1 Stop the engine

X92-B AA00-0000-00AAB-100A-A
F.) For engines with two or more turbochargers:

1 Stop the engine
Fig 10-19 Turbocharger cut out procedure: Illustration 1

X92-B AA00-0000-00AAB-100A-A

X92-B AA00-0000-00AAB-100A-A

X92-B AA00-0000-00AAB-100A-A

X92-B AA00-0000-00AAB-100A-A
NOTE: If during the one of the procedures mentioned in this chapter, an auxiliary blower
becomes inoperative, it will automatically be cut out thanks to the built in non-return
valve. This will restrict the operation of the engine.

X92-B AA00-0000-00AAA-100A-A
Operation Manual Special running condition: Cylinder cut out
10.27 Special running condition: Cylinder cut out

The engine is designed to run with all its cylinders working. If a cylinder stops working, it must be
repaired as soon as possible. However, if it is impossible to repair the not working cylinder, then
the engine can still be run as long as only 1 or 2 cylinders are not working. This is called cylinder
cut out operation and it is considered a special running condition.
WARNING
The special running condition of the cylinder cut out is only available in diesel mode.
WARNING
Running the engine under a special running condition will impact the following parameters
negatively:
• Increase of Thermal load
• Increase of exhaust temperature
• Increase of torsional vibrations
• Increase of stress on the Crankshaft
• Reduction of engine revolutions
• Reduction of load limit
• Occurance of Surging
WARNING
If 2 or more cylinders are misfiring, Contact WinGD immediately.
WARNING
Running the engine under special running conditions for more than 2-5 days can damage
the engine. If the engine is run under special running conditions for more than that, contact
the engine builder to obtain advice.
NOTE: If only the fuel for the respective cylinders is cut off, while the same time, the starting air
connections remain intact, then the engine remains fully maneuverable.
NOTE: If the starting air supply is cut off to some cylinders, the engine might not start from all
crankshaft positions. This can be resolved by starting the engine in reverse it or by using
the turning gear to change the starting position.
There are 5 different procedures of cutting a single cylinder out of operation. If it is needed, each
procedure can be repeated to cut of a second cylinder. The correct procedure depends on the
circumstances of under which the cylinder is underperforming, so chose the procedure best fitting
for the circumstances. The 5 procedures are:
• A.) Cylinder cut out while the piston and exhaust valve are still working and the compression
is still on
• B.) Cylinder cut out while the piston and exhaust valve are still working and the compression
is off
• C.) Cylinder cut out while the piston is still moving but the exhaust valve is closed and the
compression is on

X92-B AA00-0000-00AAA-100A-A
• D.) Cylinder cut out while the piston and crosshead are suspended and the connecting rod
is out
• E.) Cylinder cut out while the piston, piston rod, crosshead and connecting rod are all totally
out
NOTE: If the crosshead and crankpin bearings are operative, the oil inlet to the crosshead must
remain free.
NOTE: For procedures B, D and E, always contact WinGD for a case specific calculation of
allowable ouput and possible barred speed range.
A.) Cylinder cut out while the piston and exhaust valve are still working and the compression is
still on:
1 On the LDU, access the “Fuel Injection Adjust Page”.
2 On the page, turn off the fuel injection for the corresponding cylinder
3 Disconnect the electrical plugs for the fuel injectors of the corresponding cylinder
4 Check if the exhaust valve remains in operation
The cylinder is now cut out and the engine performs under special running conditions.
NOTE: A malfunctional or out of operation exhaust valve may cause the turbochargers to surge.
B.) Cylinder cut out while the piston and exhaust valve are still working and the compression is off
2 On the page, turn off the fuel injection for the corresponding cylinder
4 Shut off the air supply to the exhaust valve and stop the lube oil pumps
5 Put the exhaust valve out of operation and lock it in open position.
6 Dismantle the block and the actuator oil pipe
7 Restart the lube oil pumps
8 Close the cooling water inlet and outlet valves for the cylinder. If necessary, drain the cooling
water spaces completely
9 Dismantle the starting air pipe and blank off the main pipe and the control air pipe for the
corresponding cylinder
10 After 15 minutes of running, open the crankcase and check:
• The bearings
• The temporarily secured parts
• The oil flow through bearings
• The tightness of blanked-off openings

• The bearings

X92-B AA00-0000-00AAA-100A-A
WARNING
When operating in this manner, the engine speed must stay 55% of the maximum
continuous rating speed. Additionally, the over-speed level of the engine must be lowered
to 80% of the continuous rating speed.
NOTE: During maneuvers, the engine speed can be raised for 10 minutes to 80% of the
continuous rating speed.
C.) Cylinder cut out while the piston is still moving but the exhaust valve is closed and the
compression is on
1 Stop the engine
3 On the page, turn of the fuel injection for the corresponding cylinder
5 On the LDU, on the exhaust valve control page, make sure there are no error indications
shown
6 Make sure that the exhaust valve is completely closed
7 If the exhaust valve isn’t completely closed, disconnect the plug for the cylinder starting
valve
• The bearings

• The bearings
WARNING
The cylinder cooling water and piston cooling oil must not be cut off.
NOTE: A malfunctional or out of operation exhaust valve may cause the turbochargers to surge.
D.) Cylinder cut out while the piston, piston rod and crosshead are suspended in the engine and
the connecting rod is out
1 Stop the engine

X92-B AA00-0000-00AAA-100A-A
shown
7 If the exhaust valve isn’t completely closed, disconnect the plug for the cylinder starting air
valve
8 Dismantle the starting air pipe
9 Blank off the main pipe and the control air pipe for the relating cylinder
10 Remove the oil supply lever.
11 Blank off the oil supply with the blind flange.
12 Set the cylinder lubricator for the corresponding cylinder to zero delivery.
• The bearings

• The bearings
E.) Cylinder cut out while the piston, piston rod, crosshead and connecting rod are all totally out
1 Stop the engine
shown
7 If the exhaust valve isn’t completely closed, disconnect the plug for the cylinder starting air
valve
8 Dismantle the starting air pipe
9 Blank off the main pipe and the control air pipe for the relating cylinder
10 Remove the oil supply lever.
11 Blank off the oil supply with the blind flange
12 Blank off the stuffing box opening with two plates
13 Set the cylinder lubricator for the corresponding cylinder to zero delivery.

X92-B AA00-0000-00AAA-100A-A
• The bearings

• The bearings
Fig 10-24 Allowed load during cylinder cut out

X92-B
Operation Manual
11 Technical data
11.1 Engine data.............................................................................................................416
11.2 List of usual values and safeguard settings - general.............................................418
11.3 List of usual values and safeguard settings.............................................................422
11.4 Section views...........................................................................................................434

X92-B AA00-0000-00AAA-030A-A
Operation Manual Engine data
11.1 Engine data

The standard data of the X92B engine is given in Table 11-1 - General data.
Tab 11-1 General data
Item Value Unit
Cylinder bore 920 mm
Piston stroke 3468 mm
Speed range 70 to 80 rpm
Stroke / bore ratio 3.77 -
Available number of cylinders 6 to 12 -

Number of pulses for cylinder pre-lubrication 245 -
Table 11-2 - Rated power gives the data that follow:

• Rating point
For the rating points refer to Figure 11-1.
• Speed
This list gives the speed of the crankshaft in rpm.
• Power
The power in kW for each cylinder refers to the ISO standard reference conditions:
○ Total barometric pressure is 1.0 bar
○ Suction air temperature is 25°C
○ Relative humidity is 30%
○ Cooling water temperature at the engine inlet is 25°C.
• BSFC
This list gives the Brake Specific Fuel Consumption (BSFC) for fuel of lower heating value
42.7 MJ/kg (10 200 kcal/kg) and standard tuning.
• Mean piston speed
This list gives the mean piston speed in m/s.
• MEP
This list gives the Mean Effective Pressure (MEP) in the combustion chamber in bar.
• Firing pressure
This list gives a guide value for the firing pressure in the combustion chamber in bar. The
firing pressure can be lower than the guide values in the table.

X92-B AA00-0000-00AAA-030A-A
Operation Manual Engine data
Tab 11-2 Rated power
Rating point Speed Power BSFC Mean pis- MEP Firing pres-
ton speed sure
[rpm] [kW/cyl.] [g/kWh] [m/s] [bar] [bar]
R1 80 6450 161.8 9.3 21 180
R2 80 4650 154.8 9.3 15.1 180
R3 70 5650 160.8 8.1 21 180
R4 70 4070 155.8 8.1 15.1 180
Fig 11-1 Operating range
P
R1 R1+
R3
R4
R2 R2+
R4
S
Legend
R1 Highest power at highest speed R3 Highest power at lowest speed

R1+ Highest power at highest speed (extended) R4 Lowest power at lowest speed
R2 Lowest power at highest speed P Power
R2+ Lowest power at highest speed (extended) S Speed

X92-B AA00-0000-00AAA-030K-A
Operation Manual List of usual values and safeguard settings - general
11.2 List of usual values and safeguard settings - general

For each system of the engine the tables in the chapter that follows give the values for usual
operation and the trigger values for safeguard settings.
11.2.1 Tables - identification
The tables give the data that follow:

• Description
This list gives the description of the object or of the system.
• Medium / physical value / location
This list gives the data that follow:
○ Medium that is monitored
○ Physical parameter and unit
○ Location of the measurement
• Usual operation (value or range)

This list gives the setpoint or the approximate range for usual operation. During operation
the current values can have small differences to the given values.
• Signal number
This list gives the signal number as follows (refer also to Para 11.2.2):
○ First two letters (XX) - Function code
○ Four digit number of the signal (for example 10NN)
• First two numbers - Function group
• Second two numbers - Running number
○ -nn - If more than one signal of the same type is applicable (for example TE2501-nnA
is TE2501A, TE2502A, TE2503A)
○ Last letter - Applied system
• Function
This list gives one of the functions that follow:
○ ALM - Alarm
○ GTrip - Gas Trip (the ECS changes to diesel mode)
○ SLD - Slowdown
○ SHD - Shutdown
• Level
This list gives one of the levels that follow:
○ D - Deviation
○ H - High
○ L - Low

X92-B AA00-0000-00AAA-030K-A
• Trigger value
This list gives the value at which the related safeguard function starts.
For the analysis elements (AE) of concentration:
○ max - maximum concentration
For the level switches (LS) and flow switches (FS):

○ min - minimum or no flow
○ max - maximum flow
• Delay
This list gives the delay of the action (in seconds) after the trigger value occurs.

X92-B AA00-0000-00AAA-030K-A
11.2.2 Signal codes - identification
An example of a signal code is shown in Figure 11-2.
Fig 11-2 Signal codes
PT 1012 C
001 002 003 004
00207
Legend
001 Function code 003 Running number

002 Function group 004 Applied system
Tab 11-3 Function code
Code First position Second position
A Analysis n/a
C Control Control
E n/a Element
F Flow n/a
G Gauge n/a
H Hand n/a
I n/a Indication
J Power n/a
L Level n/a
P Pressure n/a
S Speed Switch
T Temperature Transmitter
V n/a Valve
X Unclassified Unclassified
Y Vibration Relay
Z Position (binary) n/a

X92-B AA00-0000-00AAA-030K-A
Tab 11-4 Function group
Code Signal type System
10 to 19 Signals from the engine Cooling water
20 to 29 Signals from the engine System oil, cooling oil
31 Signals from the engine Cylinder lubrication
33 Signals from the engine Fuel gas
34 Signals from the engine Fuel oil
37 Signals from the engine Exhaust gas
40 to 49 Signals from the engine Air systems
50 to 59 Signals from the engine Miscellaneous
60 to 69 Signals from the engine Spare
70 to 79 Signals to the engine Miscellaneous
Tab 11-5 Applied system
Code Description
A Alarm and monitoring system
C Control system
L Local
M Measured indication, Local control panel
S Safety system
W Wrong way alarm
X Miscellaneous

X92-B AA00-0000-00AAA-033B-A
Operation Manual List of usual values and safeguard settings
11.3 List of usual values and safeguard settings

On the pages that follow you find the values for usual operation and the trigger values for safeguard
settings as follows:
• Table 11-6 - Cooling water systems (XX10NN to XX19NN)
• Table 11-7 - Oil systems (XX2NNN, part 1)
• Table 11-9 - Oil systems (XX2NNN, part 3 (turbocharger bearing oil))
• Table 11-11 - Fuel system (XX34NN)
• Table 11-12 - Exhaust gas system (XX37NN)
• Table 11-13 - Air systems (XX40NN to XX44NN)
• Table 11-14 - Miscellaneous items (XX45NN to XX52NN)

X92-B AA00-0000-00AAA-033B-A
Tab 11-6 Cooling water systems (XX10NN to XX19NN)
Description Usual oper- Safeguard setting

ation (value
Medium / physical value / location or range) Signal number Func- Le- Trigger De-
tion vel value lay
Cylinder liner, cylinder cover
HT cylinder cooling water / pressure [bar] / 2.2 to 4 PT1101A ALM L ≤ 2.0 0

engine inlet connection 02
SLD L ≤ 1.8 60
- PS1101S SHD L ≤ 1.5 60
HT cylinder cooling water / temperature [°C] / 62 to 80 TE1111A ALM L ≤ 60 0

HT cylinder cooling water / temperature [°C] / 90 +/-2 1

TE1121-nnA ALM H ≥ 95 0
outlet each cylinder (engine outlet connec- 2
90 +/-4 SLD H ≥ 97 60
tion 03)
Scavenge air cooler (SAC)
SAC LT cooling water / pressure [bar] / en- 2.5 to 4 PT1361A ALM L ≤ 2.0 0
gine inlet connection 07
SAC LT cooling water / temperature [°C] / 25 to 36 3

TE1371A ALM L ≤ 21 0
SAC LT cooling water / temperature [°C] / 25 to 75 TE1381-nnA ALM H ≥ 80 0

outlet each SAC
1 This value is applicable for stable operation condition.
2 This value is applicable for transient operation condition.
3 WinGD recommends a setpoint value of 25°C. 36°C is only permitted if the seawater temperature is
32°C.

X92-B AA00-0000-00AAA-033B-A
Tab 11-7 Oil systems (XX2NNN, part 1)

ation (value
tion vel value lay
Lubricating oil supply - system side
Main lubricating oil / pressure [bar] / engine 4.2 to 5 PT2001A ALM L ≤ 4.0 0
inlet connection 25
SLD L ≤ 3.8 60
- PS2002S SHD L ≤ 3.3 10
Main lubricating oil / temperature [°C] / en- 45 +/-2 1

TE2011A ALM H ≥ 50 0
gine inlet connection 25 2
45 +/-4 SLD H ≥ 55 60
If applicable: external oil / pressure [bar] / in- 4.2 to 5 PT2012A ALM L ≤ 4.0 0
let fuel pump
SLD L ≤ 3.8 60
- PS2012S SHD L ≤ 3.3 10
If applicable: external oil (SAE 30) / temper- 45 +/-2 1

TE2012A ALM H ≥ 50 0
ature [°C] / inlet fuel pump 2
45 +/-4 SLD H ≥ 55 0
If applicable: external oil (SAE 40) / temper- 50 +/-2 1

TE2012A ALM H ≥ 55 0
ature [°C] / inlet fuel pump 2
50 +/-4 SLD H ≥ 60 0
External crosshead bearing oil / pressure 10.2 to 13 PT2021A ALM L ≤ 10.0 3

10
[bar] / engine inlet connection 30
SLD L ≤ 9.0 3
60
Bearing oil
Main bearing oil / temperature [°C] / outlet 45 to 60 TE2101-nnA ALM H ≥ 65 0

each main bearing (optional)
SLD H ≥ 70 60
Crank bearing oil / temperature [°C] / outlet 45 to 60 TE2201-nnA ALM H ≥ 65 0

each crank bearing (optional)
SLD H ≥ 70 60
Crosshead bearing oil / temperature [°C] / 45 to 60 TE2301-nnA ALM H ≥ 65 0

outlet each crosshead bearing (optional)
SLD H ≥ 70 60
1 This value is applicable for stable operation condition.
2 This value is applicable for transient operation condition.
3 The trigger value is only applicable above 40% engine load.

X92-B AA00-0000-00AAA-033B-A

ation (value
tion vel value lay
Servo oil
1
Servo oil / flow / inlet each servo oil pump - FS2061-nnA ALM L min 0
ALM H max 0
Servo oil leakage / flow / servo oil supply unit - LS2055A ALM H max 10
Oil mist
Oil mist / concentration / crankcase (each - AE2401-nnA ALM H max 0

cylinder) 2
AS2401-02A ALM H max 0
- AS2401S SLD H max 60
Oil mist / concentration / gearcase - AE2415A ALM H max 0
Oil mist / concentration / fuel supply unit - AE2421-22A ALM H max 0
Piston cooling oil
Piston cooling oil / temperature [°C] / outlet 45 to 75 TE2501-nnA ALM H ≥ 80 0

each cylinder
SLD H ≥ 85 60
Piston cooling oil / flow [l/min] / outlet each - FS2521-nnS SHD L min 15
cylinder
1 The trigger values are only applicable above 30% engine load.
2 The concentration is related to the lower explosive level (LEL).

X92-B AA00-0000-00AAA-033B-A
Tab 11-9 Oil systems (XX2NNN, part 3 (turbocharger bearing oil))

ation (value
tion vel value lay
Bearing oil turbocharger ABB A100/200-L with internal oil
TC bearing oil / pressure [bar] / inlet each 1.5 to 5.0 PT2611-nnA ALM L ≤ 1.0 5
turbocharger
SLD L ≤ 0.8 60
- PS2611-nnS SHD L ≤ 0.6 5
TC bearing oil / temperature [°C] / outlet each 45 to 100 TE2601-nnA ALM H ≥ 110 0
turbocharger
SLD H ≥ 120 60
Bearing oil turbocharger ABB A100/200-L with external oil
turbocharger
SLD L ≤ 1.1 60
- PS2611-nnS SHD L ≤ 0.9 5
TC bearing oil / temperature [°C] / inlet tur- 45 to 80 TE2621A ALM H ≥ 85 0

bocharger
SLD H ≥ 90 60
turbocharger
SLD H ≥ 140 60
Bearing oil turbocharger MHI MET with internal oil
turbocharger
SLD L ≤ 0.6 60
- PS2611-nnS SHD L ≤ 0.4 5

turbocharger
SLD H ≥ 90 60
Bearing oil turbocharger MHI MET with external oil
turbocharger
SLD L ≤ 0.6 60
- PS2611-nnS SHD L ≤ 0.4 5
TC bearing oil / temperature [°C] / inlet tur- 45 to 50 TE2621A ALM H ≥ 60 0

bocharger
SLD H ≥ 65 60

turbocharger
SLD H ≥ 90 60

X92-B AA00-0000-00AAA-033B-A

ation (value
tion vel value lay
Damper oil
Damper oil / pressure [bar] / inlet torsional vi- 2.8 to 5.0 PT2711A ALM L ≤ 2.2 0
bration damper 1
Damper oil / pressure [bar] / axial vibration 1.8 to 5.0 PT2721A ALM L ≤ 1.7 60
damper space aft side
Damper oil / pressure [bar] / axial vibration 1.8 to 5.0 PT2722A ALM L ≤ 1.7 60
damper space fore side
Cylinder oil
Cylinder oil / pressure [bar] / cylinder oil rail ≥ 0.4 PT3124A ALM L ≤ 0.1 30
2
Cylinder oil / temperature [°C] / engine inlet 35 to 50 - - - - -
1 The setpoint and trigger values can be different. For the applicable values, refer to the specification of
the damper manufacturer.
2 This value is only applicable if the engine has no iCAT.

X92-B AA00-0000-00AAA-033B-A
Tab 11-11 Fuel system (XX34NN)

ation (value
tion vel value lay
Fuel supply - system side
High viscosity fuel which requires heating 13 to 17 - 1

ALM H ≥ 20 0
(HFO, excluding RMA10) / viscosity [cSt] /
engine inlet connection 49 ALM L ≤ 10 0
Low viscosity fuel which requires no heating 3 to 14 - 1

ALM H ≥ 17 0
(distillates, RMA10, most ULSFO) / viscosity
[cSt] / engine inlet connection 49 ALM L ≤2 0
Fuel supply unit
Fuel / pressure [bar] / inlet fuel supply unit 7.5 to 10 2

PT3421A ALM L ≤7 0
Fuel / temperature [°C] / inlet fuel supply 20 to 150 TE3411A ALM H ≥ 50 to 160 0
unit 3
ALM L ≤ 20 to 130 0
Fuel leakage / flow / outlet fuel supply unit - LS3426A ALM H max 10
Fuel leakage / flow / outlet fuel rail items - LS3446-47A ALM H max 10
Rail unit
Leakage / flow / outlet rail unit - LS3444-45A ALM H max 10
1 This measurement is not included in the standard engine supply (the viscometer is a yard supply item).
2 When the engine has stopped, the setpoint is 10 bar. The value decreases when the engine load in-
creases.
3 The values are related to the fuel viscosity.

X92-B AA00-0000-00AAA-033B-A
Tab 11-12 Exhaust gas system (XX37NN)

ation (value
tion vel value lay
Exhaust pipe / manifold
Exhaust gas / temperature [°C] / outlet each - TE3701-nnA ALM H ≥ 515 0

cylinder
ALM D ≥ 50 0
SLD H ≥ 530 60
SLD D ≥ 70 60
Exhaust gas / temperature [°C] / inlet each - TE3721-nnA ALM H ≥ 515 0

turbocharger
SLD H ≥ 530 60
Exhaust gas / temperature [°C] / outlet each - TE3731-nnA ALM H ≥ 340 0

turbocharger
SLD H ≥ 380 60

X92-B AA00-0000-00AAA-033B-A
Tab 11-13 Air systems (XX40NN to XX44NN)

ation (value
tion vel value lay
Scavenge air receiver
Scavenge air / temperature [°C] / outlet each 28 to 55 TE4031-nnA ALM L ≤ 25 0

air cooler
ALM H ≥ 60 0
SLD H ≥ 70 60
Scavenge air / temperature [°C] / piston un- 28 to 55 TE4081-nnA ALM H ≥ 80 0

derside each cylinder
SLD H ≥ 120 60
Condensation water / flow / at each water - LS4071-nnA ALM H max 10

separator
SLD H max 60
Condensation water / flow / upstream each - LS4075-nnA ALM H max 10

water separator
SLD H max 60
Starting air supply
Starting air supply / pressure [bar] / engine 20 to 30 - - - - -

inlet connection 40
Control air supply unit
Control air supply / pressure [bar] / engine 7 to 9 - - - - -

inlet connection 45
Control air / pressure [bar] / outlet usual sup- 6.5 PT4401A ALM L ≤ 6.0 0
ply
Control air / pressure [bar] / outlet stand-by 6.0 PT4411A ALM L ≤ 5.5 0
supply
Control air / pressure [bar] / air tank for safety 6.5 or 6.0 PT4421A ALM L ≤ 5.0 15
supply
Air spring
Air spring air / pressure [bar] / supply to air 6.5 or 6.0 PT4341A ALM H ≥ 7.5 0
spring
ALM L ≤ 5.5 0
SLD L ≤ 5.0 60
- PS4341S SHD L ≤ 4.5 0
Oil leakage / flow / air spring at driving end - LS4351A ALM H max 5
Oil leakage / flow / air spring at free end - LS4352A ALM H max 5

X92-B AA00-0000-00AAA-033B-A
Tab 11-14 Miscellaneous items (XX45NN to XX52NN)

ation (value
tion vel value lay
Thrust bearing
Pad / temperature [°C] / thrust bearing 45 to 75 TE4521A ALM H ≥ 80 0

(AHEAD)
SLD H ≥ 85 60
- TS4521S SHD H ≥ 90 60
Cylinder liner
Wall / temperature [°C] / each cylinder liner ≤ 240 TE4801-nnC ALM H ≥ 260 0
aft side
SLD H ≥ 290 60
Wall / temperature [°C] / each cylinder liner ≤ 240 TE4841-nnC ALM H ≥ 260 0
fore side
SLD H ≥ 290 60
Powertrain
Crankshaft / speed [% of CMCR] / crankshaft - ST5111-12S SHD H ≥ 110 0
Tachometer turbocharger (if signal is available as alarm)
Impeller shaft / overspeed [rpm] / each ABB - ST5201-nnA ALM H refer to 0

turbocharger (TC) note 1
Impeller shaft / overspeed [rpm] / each MHI - ST5201-nnA ALM H refer to 0

turbocharger (TC) note 2
1 For ABB TC the alarm value is 0.97 x nMax on rating plate (nMax usually referred to as nMmax in 1/
s).
2 For MHI TC the alarm value is 0.95 x nMax on rating plate (nMax usually referred to as overspeed in
rpm).

X92-B AA00-0000-00AAA-033B-A
Some items are continuously monitored for correct function. If an item becomes defective, the
AMS sends a message to the ship alarm system, refer to Table 11-15 - Failure messages.
Tab 11-15 Failure messages
Medium / location Signal number Delay
Failure of oil mist detector XS2411A 0
Failure of fuel heating XS3463A 0
Failure of fuel pump actuator XS5046A 0

X92-B AA00-0000-00AAA-033B-A

X92-B AA00-0000-00AAA-034A-A
Operation Manual Section views
11.4 Section views

X92-B
Operation Manual
12 Operating media
12.1 General for operating media....................................................................................436
12.2 Compressed air.......................................................................................................438
12.3 Scavenge air............................................................................................................440
12.4 Diesel engine fuels..................................................................................................442

X92-B AA00-0000-00AAA-018M-A
Operation Manual General for operating media
12.1 General for operating media

WinGD has specified the requirements of the operating media for the engine.
On the WinGD website (https://www.wingd.com/) the latest versions of the specifications are
available for the operating media that follow:
• Fuel
• Lubricants
• Water
NOTE: On the WinGD website go to your engine type, then to “OPERATION &
MAINTENANCE”, then to “FUEL LUBRICANTS WATER”.
On the pages that follow the specifications are available for the operating media that follow:
• Compressed air
• Scavenge air
• Gas (if applicable)

X92-B AA00-0000-00AAA-018M-A
Operation Manual General for operating media

X92-B AA00-0000-00AAA-030E-A
Operation Manual Compressed air
12.2 Compressed air

Compressed air has the functions that follow:
• Compressed air is used as starting air for the starting air system.
• Compressed air is used as control air for the control air system.
12.2.1 Requirements for compressed air
The compressed air must have the basic properties that follow:
• Clean and dry
• Purity class 2-4-2 (ISO 8573-1).
12.2.2 Recommended procedures for compressed air
WinGD recommends to regularly do the procedures that follow to prevent explosions:

• Regularly drain the starting air bottles to remove condensation.
• Regularly clean the starting air pipes to remove oil that can come from the air compressors.
• Regularly do the maintenance work for the air compressors to keep the compressed air as
clean as possible.

X92-B AA00-0000-00AAA-030E-A
Operation Manual Compressed air

X92-B AA00-0000-00AAA-030D-A
Operation Manual Scavenge air
12.3 Scavenge air

The turbocharger compresses the air from the engine room or from outside for the scavenge air.
The air must be as clean as possible to keep the wear of cylinder liner, piston rings, turbocharger
compressor etc to a minimum. Silencers are installed to the suction part. The silencers have filter
mats in them, which help to keep the air clean.
The filter mats must be serviced and/or cleaned regularly. For this data, refer to the turbocharger
manual.

X92-B AA00-0000-00AAA-030D-A
Operation Manual Scavenge air

X92-B AA00-0000-00AAA-030A-A
Operation Manual Diesel engine fuels
12.4 Diesel engine fuels
12.4.1 General
Almost all hydrocarbon residual, distillate and some renewable fuels can be burned in a diesel
engine if applicable procedures are done. The type and quality of the fuel will have an effect on
the frequency of overhauls and the work necessary to prepare the fuel. It is the primary economic
considerations that according to the type, size and speed of the engine and its application, gives
the fuel quality margins.
Gas oils and diesel oils (distillates) can be used in all WinGD engines with some limits. WinGD 2-
stroke diesel engines are designed to operate on up to 700 mm2/s (cSt) at 50°C viscosity heavy
fuel oil (ISO 8217:2017 RMK 700 grade) if sufficient fuel heating and treatment is done.
Heavy fuel oil must have treatment in an applicable fuel treatment plant on board. When bunkering,
it is possible that the fuel suppliers will report only some of the values given in the Quality
Specifications. Frequently, only the density and maximum viscosity is given. This makes the full
understanding of the properties of the fuels very difficult, thus it is important to get a full certificate
of analysis with each bunker.
The supplier must guarantee the stability of the fuel and thus the resistance to the formation of
sludge. Also, the fuel must not have a corrosive effect on the injection equipment and must not
contain used lubricating oil, chemical waste or other foreign matter.
Fuels from different bunkers must not be mixed because there is a risk that the fuels have different
compositions. This can cause fouling of filters or too much sludge, which will overload the fuel
preparation equipment. Fresh bunkers must always be put into empty tanks and not added to old
bunkers.

X92-B AA00-0000-00AAA-030A-A
12.4.2 Heavy fuel oil
Fuels used in marine diesel engines are blended using many different products from the petroleum
refinery process that can include fuels such as HFO and gas oil. To get the necessary viscosity
as specified by the supply specifications, the heavier oil stocks are blended with lighter, less
viscous components. Modern refineries also apply a secondary conversion process, such as
viscosity breaking (visbreaking) and catalytic cracking to get a higher yield of lighter products. The
remaining products are mixed to get HFO.
Viscosity is usually used to identify diesel engine fuels. The viscosity is shown in mm2/s, referred
to as centistokes (cSt) and measured at 50°C. The fuels are classified in accordance with
ISO 8217:2017 (Sixth Edition dated from March 2017).
Viscosity is not a quality criterion. To make an analysis of the fuel quality (to make sure that the
fuel is applicable for use in a diesel engine), refer to the properties given in Table 12-1 -
Specifications for HFO.
Very good supervision, engine maintenance and on board fuel treatment equipment is necessary,
especially when the properties of the fuel in use is near the permitted maximum and minimum
limits. Poor quality fuels or insufficient or inadequate preparation can give problems in handling
and/or combustion. Thus higher maintenance requirements, shorter service intervals and possibly
shorter service life of various components of the equipment can be possible.
In Table 12-1 - Specifications for HFO, the values in the column Bunker limit (ISO 8217:2017
RMK700) show the minimum quality of heavy fuel as supplied and bunkered to the ship/installation.
Good operation results come from commercially available fuels that are in the ISO 8217:2017
limits. But the use of fuel with lower metal, ash and carbon contents and a lower density can have
a positive effect on overhaul periods. This can improve combustion and exhaust gas composition
and can decrease the wear.
The fuel as bunkered must be processed before it goes into the engine. It is recommended that
you refer to the related specifications of WinGD for the design of the fuel treatment plant. The
minimum separator capacity is 1.2 x CMCR x BSFC / 1000 (liters/hour), which is related to
0.21 l ⁄ kW. The fuel treatment must remove sludge and decrease catalyst fines and water to the
recommended engine inlet limits.
Unwanted substances such as used oil or chemical waste must not be added to the fuel (refer to
ISO 8217:2017). These unwanted substances can cause damage to the fuel system components,
to the fuel injection equipment, to pistons, piston rings or cylinder liners. Contamination of the
turbocharger, the exhaust system or the boiler can also occur because of poor fuel quality. Thus
WinGD recommends a sample of the bunkered fuel is tested by a laboratory. If the analysis shows,
that the fuel does not obey the specifications, you must do the related procedures.
The specifications of the fuel quality at the engine inlet uses the latest ISO 8217:2017 specification,
refer to Table 12-1 - Specifications for HFO. You can get the ISO standards from the ISO Central
Secretariat, Geneva, Switzerland (www.iso.ch).

X92-B AA00-0000-00AAA-030A-A
Tab 12-1 Specifications for HFO
Parameter Bunker limit At engine inlet Unit Test method
Kinematic viscosity Maximum 700 13 to 17 1 (not related mm2/s [cSt] 2 ISO 3104
at 50°C to temperature)
Density at 15°C Maximum 1010 3 Maximum 1010 kg/m3 ISO 3675/12185
CCAI Maximum 870 Maximum 870 - Calculated
Sulphur 4 Statutory specifica- Maximum 3.5 mass % ISO 8754/14596

tions
Flash point Minimum 60 Minimum 60 °C ISO 2719
Hydrogen sulphide 5 Maximum 2.0 Maximum 2.0 mg/kg [ppm] IP 570
Acid number Maximum 2.5 Maximum 2.5 mg KOH/g ASTM D 664
Total sediment, Maximum 0.1 Maximum 0.1 mass % ISO 10307-2

aged
Carbon residue: mi- Maximum 20 Maximum 20 mass % ISO 10370

cro method
Pour point (upper) 6 Maximum 30 Maximum 30 °C ISO 3016
Water Maximum 0.5 Maximum 0.2 volume % ISO 3733
Ash Maximum 0.15 Maximum 0.15 mass % ISO 6245
Vanadium Maximum 450 Maximum 450 mg/kg [ppm] ISO 14597/IP501/

IP470
Sodium Maximum 100 Maximum 30 mg/kg [ppm] IP501/IP470
Aluminum plus Sili- Maximum 60 Maximum 15 mg/kg [ppm] ISO 10478/IP501/

con IP470
Used lubricating oils ULO shows if: Ca>30 Do no use if: Ca>30 mg/kg [ppm] IP501 or IP470 or
(ULO) must not be and Zn>15 or Ca>30 and Zn>15 or Ca>30 IP500
present: Calcium and P>15 and P>15
(Ca) and zinc (Zn)
1 For Generation X, X-DF and RT-flex engines, the fuel viscosity at the engine inlet must be
in the range between 10 mm2/s and 20 mm2/s, but WinGD recommends a fuel viscosity at
the engine inlet in the range between 13 mm2/s and 17 mm2/s. The maximum permitted
temperature is 150°C.
2 1 mm2/s = 1 cSt (Centistoke)
3 The maximum density limit is 991 kg/m3 if the fuel treatment plant cannot remove water from
high-density fuel.
4 In ISO 8217:2017 sulphur limits are not given for HFO. Sulphur limits are related to statutory
specifications.
5 The hydrogen sulphide limit is applicable from 1st July 2012.
6 Purchasers must make sure that the equipment on board can always keep the fuel at a
temperature above the pour point, specially in cold climates.
It is very important that the fuel is fit for purpose in the related engine application.

X92-B AA00-0000-00AAA-030A-A
NOTE: From 1st January 2015 fuel with less than 0.1% sulphur content must be used in
Emission Control Areas (ECA). As an alternative you can burn LNG (Liquefied Natural
Gas) or in some areas you can use SOX scrubbers to decrease the content of sulphur
oxides in the exhaust gas.
NOTE: Related to the MARPOL annex VI the maximum permitted sulphur content in fuel is 3.5%.
• LSFO (Low Sulphur Fuel Oil) has a maximum of 1.0% sulphur content
• VLSFO (Very Low Sulphur Fuel Oil) has a maximum of 0.5% sulphur content
• ULSFO (Ultra Low Sulphur Fuel Oil) has a maximum of 0.1% sulphur content.
NOTE: From 1st January 2020 fuel with less than 0.5% sulphur content must be used outside
of ECA zones. As an alternative you can burn LNG or in some areas you can use SOX
scrubbers to decrease the content of sulphur oxides in the exhaust gas.
12.4.3 Data about heavy fuel oil specifications
The paragraphs that follow give more data about the specifications for HFO.
12.4.3.1 Viscosity
WinGD recommends a viscosity range at the engine inlet between 13 mm2/s (cSt) and 17 mm2/s
(cSt). You get the necessary temperature for a given nominal viscosity from the data in Figure
12-1.
The maximum permitted viscosity of the fuel that can be used in an engine installation is related
to the heating and fuel preparation facilities available. The flow rate and the temperature of the
fuel that flows through the separators must be adjusted in relation to the viscosity to get good
separation. The temperature of the fuel must not be increased to more than 150°C to get the
recommended viscosity at the engine inlet. This is because the fuel can start to decompose, form
particles and the temperature can be above the flash point.

X92-B AA00-0000-00AAA-030A-A
Fig 12-1 Viscosity / Temperature diagram
Recommended viscosity range for Generation X, X-DF and RT-flex engines
Required viscosity range for Generation X, X-DF and RT-flex engines
00099

X92-B AA00-0000-00AAA-030A-A
12.4.3.2 Density
The composition of the fuel gives the density. A high density shows a high aromatic content. It is
not always possible to use conventional methods to measure the density at 15°C. Thus, the
measurement is made at a higher temperature and then converted and adjusted to the reference
temperature. Usually the maximum density of fuel is 1010.0 kg/m3 related to the ISO 8217:2017
RMK specifications. If you use a fuel with a density higher than 991.0 kg/m3, you must make sure
that an equipment is available on board that can treat such fuels.
12.4.3.3 Calculated Carbon Aromaticity Index (CCAI)
The ignition and combustion properties of the fuel in a diesel engine are related to the specific
engine design, load profile and fuel properties.
The CCAI is a calculated value of the ignition properties or ignition delay of the fuel related to the
viscosity and density. The CCAI gives no indication of the combustion properties. The CCAI limit
is useful to examine fuels with unusual density-viscosity relations.
12.4.3.4 Sulphur
Sulphur limits are not specified in ISO 8217:2017 because statutory specifications put a limit on
this value. WinGD 2-stroke engines are designed to operate with high and low sulphur fuels, if:
• You select the alkalinity (base number (BN)) of the cylinder oil in relation to the sulphur
content of the fuel in use.
• You use the necessary equipment related to the statutory specifications.
12.4.3.5 Flash point
The flash point is an important safety and fire hazard parameter for diesel fuels. Fuel is always a
fire hazard. There can be flammable vapors in the air space above the remaining fuel in the tanks.
Take care if you increase the temperature of the remaining fuel above the flash point, as flammable
vapor can occur.
12.4.3.6 Hydrogen sulphide (H2S)
Hydrogen Sulphide (H2S) is a very toxic gas and exposure to high concentrations is dangerous
and can kill you. Be careful when tanks or fuel lines are opened because there can be H2S vapor.
At low concentrations H2S smells almost the same as rotten eggs. You cannot sense H2S at
moderate concentrations. H2S causes nausea and dizziness.
12.4.3.7 Acid number
Fuels with high acid numbers can cause damages to fuel injection systems. Most fuels have a low
acid number, which is not dangerous, but an acid number above 2.5 mg KOH/g, can cause
problems. Some naphthenic fuels can have an acid number of more than 2.5 mg KOH/g, but still
be permitted. Only a full laboratory analysis can measure the strong acid number.
12.4.3.8 Sediment, Carbon and Asphaltenes
High quantities of sediment, carbon and asphaltenes decrease the ignition and combustion quality
of the fuel. These materials also increase wear and damage to engine components. Asphaltenes
also have an effect on the stability of blended fuels and can cause too much sludge in the

X92-B AA00-0000-00AAA-030A-A
separators and filters. If the blended fuel is not stable, particles can collect on the bottom of the
tank.
To keep risks to a minimum, make sure that bunkers from different suppliers and sources are not
mixed in the storage tanks on board. Also be careful when HFO is blended on board to decrease
the viscosity. Paraffinic distillate, when added to an HFO of low stability, can cause the asphaltenes
to collect, which causes heavy sludge.
HFO can contain up to 14% asphaltenes and will not cause ignition and combustion problems in
2-stroke engines if the fuel preparation equipment is adjusted correctly.
12.4.3.9 Pour Point
The operation temperature of the fuel must be kept between approximately 5°C and 10°C above
the pour point to make sure that the fuel can flow easily.
12.4.3.10 Water
The separator and the correct configuration of drains in the settling and service tanks are used to
decrease the water quantity in the fuel. A complete removal of water is highly recommended to
decrease the quantity of hydrophilic catalytic fines (cat fines) and sodium in the fuel. Sodium is
not a natural oil component, but diesel engine fuel often has sea water contamination, which has
sodium. A content of 1.0% sea water in the fuel is related to 100 ppm sodium.
To get a good separation effect, the flow rate and temperature of the fuel must be adjusted in
relation to the viscosity. For high-viscosity fuels the separation temperature must be increased,
and the flow rate must be decreased in relation to the nominal capacity of the separator. For the
recommended data to operate the separator, refer to the documentation of the manufacturer.
12.4.3.11 Ash and Trace Metals
Fuels with a low content of ash, vanadium, sodium, aluminum, silicon, calcium, phosphorous and
zinc are recommended. High quantities of these materials can increase mechanical wear, high-
temperature corrosion and particles in the turbocharger, exhaust system and boilers.
• Vanadium and Sodium
Sodium compounds decrease the melting point of vanadium oxide and sulphate salts,
especially when the vanadium to sodium ratio is 3:1 or higher. High sodium quantities (as
well as lithium and potassium) at the engine inlet can cause damage to the turbocharger,
exhaust system and boilers. Ash modifiers can correct the effect of high-temperature
corrosion and particles.
• Aluminum and Silicon
Aluminum (Al) and silicon (Si) in the fuel are an indication of catalytic fines. These are
particles of hard oxides (round particles of material almost the same as porcelain) which
cause high abrasive wear to pistons, piston rings and cylinder liners. Catalytic fines are used
as a catalyst in some processes in petroleum refining and can be found in diesel engine
fuels. The most dangerous catalytic fines are between 10 microns and 20 microns.

X92-B AA00-0000-00AAA-030A-A
• Catalytic fines
Catalytic fines cause cylinder liners to become worn. Catalytic fines are attached to water
droplets and are very difficult to remove from the fuel. With correct treatment in the fuel
separator, the aluminum and silicon content of 60 ppm (mg/kg) can be decreased to 15 ppm
(mg/kg), which is thought to be satisfactory. For satisfactory separation, a fuel temperature
as close as possible to 98°C is recommended. A decreased fuel flow rate through the
separator gives a better separation. This is because the fuel stays in the separator for a
longer period. Also obey the instructions of the equipment manufacturer.
Catalytic fines can collect in the sediment of the fuel tank from other bunkers. During bad
weather conditions, the movement of the ship mixes the sediment into the fuel. Thus, it is
better to think that all fuels contain catalytic fines, although it is possible that a fuel analysis
can show a different result. Thus do also regular procedures to remove sludge and catalytic
fines from the fuel that is in the settling tank and the service tanks.
12.4.3.12 Used Lubricating Oil and Chemical Waste
Used lubricating oils and chemical waste must not be mixed into the fuel. If you do so, the fuel
would not be stable because the base oil is very paraffinic and can cause too much sludge. Most
used lubricating oil is from the crankcase, thus large quantities of calcium, zinc, phosphorous and
other additives and wear metals can cause contamination. The limits in ISO 8217:2017 and the
WinGD specifications make sure that no used lubricating oil is in the fuel.
Chemical waste (eg polymers, styrene and other chemical substances) must not be added to the
fuel. These materials can cause the fuel to become too thick, to become almost solid and thus can
cause blocked filters. They can also cause corrosive attacks and damage to the fuel injection
system.
12.4.4 Distillate Fuel Specifications
Since 2015 more frequently distillate fuels are used in 2-stroke engines to obey the new ECA rules.
Distillate fuels are easier to operate than residual fuel, but caution is necessary for some problems.
In ISO 8217:2017 there are specified the DMX, DMA, DMZ and DMB grades and the new DFA,
DFZ and DFB grades with a maximum fatty acid methyl ester (FAME) content of 7.0 volume %.
The WinGD specifications use the DMB grade which is the highest viscosity grade, refer to Table
12-2 - Specifications for distillate fuels. The DMX grade is not applicable for use in 2-stroke engines
because of its low flash point and viscosity.
Tab 12-2 Specifications for distillate fuels
Kinematic viscosity Maximum 11.0 Minimum 2.0 (not re- mm2/s [cSt] 1 ISO 3104
at 40°C lated to temperature)
Minimum 2.0
Density at 15°C Maximum 900 Maximum 900 kg/m3 ISO 3675/12185
Cetane index Minimum 35 Minimum 35 - ISO 4264
Sulphur 2 Maximum 1.5 Maximum 1.5 mass % ISO 8754/14596
Flash point Minimum 60 Minimum 60 °C ISO 2719
Hydrogen sulphide 3 Maximum 2.0 Maximum 2.0 mg/kg [ppm] IP 570

X92-B AA00-0000-00AAA-030A-A
Acid number Maximum 0.5 Maximum 0.5 mg KOH/g ASTM D 664
Total sediment by Maximum 0.1 Maximum 0.1 4 mass % ISO 10307-1

hot filtration
Oxidation stability Maximum 25 Maximum 25 5 g/m3 ISO 12205
Fatty acid methyl es- - - volume % ASTM D7963 or

ter (FAME) IP 579
Carbon residue: mi- Maximum 0.3 - mass % ISO 10370

cro method on 10%
volume distillation
residue
Carbon residue: mi- Maximum 0.3 Maximum 0.3 mass % ISO 10370
cro method
Pour point (upper) Maximum 0 Maximum 0 °C ISO 3016

winter 6
Pour point (upper) Maximum 6 Maximum 6 °C ISO 3016

summer
Cloud point winter - - °C ISO 3015
Cloud point summer - - °C ISO 3015
Cold filter plugging - - °C IP 309 or IP 612

point winter
Cold filter plugging - - °C IP 309 or IP 612

point summer
Water Maximum 0.3 Maximum 0.2 volume % ISO 3733
Ash Maximum 0.01 Maximum 0.01 mass % ISO 6245
Lubricity, corrected Maximum 520 Maximum 520 μm -

wear scar diameter
(WSD) at 60°C 7
1 1 mm2/s = 1 cSt (Centistoke)

2 The purchaser must specify the maximum sulphur content in accordance with the usual
statutory specifications.
3 The hydrogen sulphide limit is applicable from 1 July 2012.
4 If the sample is not clear and bright, it is necessary to do the total sediment by hot filtration
and the water tests.
5 If the sample is not clear and bright, you cannot do this test. Thus it is not possible to see
the compliance with the limit.
6 Purchasers must make sure that the pour point is sufficient for the equipment on board,
specially for operation in cold climates.
7 This parameter is applicable to fuels with a sulphur content of less than 0.05 mass %.

X92-B AA00-0000-00AAA-030A-A
12.4.5 Data about distillate fuel specifications
The paragraphs that follow give more data about the specifications for distillate fuels.
12.4.5.1 Viscosity
For distillate fuel a minimum viscosity of 2.0 mm2/s (cSt) at the engine inlet is necessary. A lower
viscosity can cause too much leakage in the fuel system.
Operators must be careful during the change-over procedure from distillate to residual fuel and
back to make sure of problem free operation. Refer to the related fuel change-over procedures in
the Operation Manual.
In some conditions, it is possible that you cannot get the minimum viscosity of 2.0 mm2/s (cSt) at
the engine inlet. In such conditions, a fuel cooling system is necessary to make sure that the inlet
to the engine has the minimum viscosity.
12.4.5.2 Lubricity
ISO 8217:2017 specifies a maximum lubricity wear scar diameter (WSD) of 520 μm to make sure
that the fuel has sufficient lubricity. This prevents quick wear of the fuel system components.
12.4.5.3 Density
The distillate density is related to the composition of the fuel. A high density indicates a high
aromatic quantity.
12.4.5.4 Cetane index
The ignition and combustion properties of a distillate fuel in a diesel engine is related to the specific
engine design, load profile and fuel properties. The Cetane Index is a calculated value of the
ignition quality of the fuel related to the distillation and density. The density and the temperature
when 10%, 50% and 90% of the fuel is distilled, gives the Cetane Index. This has no effect on the
fuel combustion properties.
12.4.5.5 Sulphur
Sulphur limits are specified in ISO 8217:2017 for distillate fuels, but statutory specifications must
be obeyed. The alkalinity (BN) of the cylinder oil must be selected in relation to the sulphur content
of the fuel in use.
Indications for the selection of the BN of the cylinder oil in relation to the sulphur content of the
fuel are found in the related specifications.
12.4.5.6 Acid number
Fuels with high acid numbers can cause damage to fuel injection systems. Most fuels have a low
acid number, which is not dangerous, but an acid number above 2.5 mg KOH/g can cause damage.

X92-B AA00-0000-00AAA-030A-A
12.4.5.7 Flash Point
The flash point is an important safety and fire hazard parameter for diesel fuels. Fuel is always a
fire hazard because there can be flammable vapors in the air space above the remaining fuel in
the tanks.
12.4.5.8 Hydrogen sulphide (H2S)
Hydrogen Sulphide (H2S) is a very toxic gas and exposure to high concentrations is dangerous
and can kill you. Be careful when tanks or fuel lines are opened because there can be H2S vapor.
At low concentrations H2S smells almost the same as bad eggs. You cannot sense H2S at
moderate concentrations. H2S causes nausea and dizziness.
12.4.5.9 Sediment
High quantities of sediment, carbon and asphaltenes decrease the ignition and combustion quality
of the fuel and increase wear and damage to engine components. High sediment quantities can
cause filters to block, or frequent discharge from filter systems that have automatic cleaning. For
more data about mixtures, refer to Para 12.4.3.8.
12.4.5.10 Pour point
The operation temperature of the fuel must be kept between approximately 5°C and 10°C above
the pour point to make sure that the fuel flows easily. It is possible that in very cold conditions,
there could be problems for distillate fuel.
12.4.5.11 Water
The quantity of water in distillate fuel can be decreased as follows:

• Let the fuel settle in the service tanks.
• Use a separator to remove water from the fuel.
12.4.5.12 Ash and trace metals
Distillate fuels must have low quantities of ash, vanadium, sodium, aluminum, silicon, calcium,
phosphorous and zinc related to residual fuels. High quantities of these materials increase
mechanical wear, high-temperature corrosion and particles in the turbocharger, exhaust system
and the boilers.
12.4.5.13 Used lubricating oil and other contamination
Lubricating oils and chemical waste must not be mixed into the distillate fuel. Lubricating oil can
cause water to stay because of the large quantity of detergent. Additive materials such as calcium,
magnesium, zinc and phosphorous could increase the ash content to more than that given in the
specification.

X92-B AA00-0000-00AAA-030A-A
Chemical waste must not be added to distillate fuel. These materials can have the effects that
follow:
• Can cause the fuel to become too thick and thus can cause a blockage of the filters
• Can cause damage to fuel injection systems
• Can cause a blockage of the fuel pump plungers or injectors.
12.4.5.14 Cloud point and cold filter plugging point
Before you bunker fuel, make sure that the pour point, the cloud point and the cold filter plugging
point (also known as cold flow characteristics) are correct for your ship’s design and voyage. There
could be problems with wax deposits in the storage tanks and in the separators, or with clogged
filters.
12.4.6 Bio-derived products and fatty acid methyl esters
Such components can be found in diesel engine fuels and can cause a decrease of greenhouse
gases and SOx emissions. Most bio-fuel components in the diesel fuel are Fatty Acid Methyl Esters
(FAME), which come from a special chemical treatment of natural plant oils. These components
are mandatory in automotive and agricultural diesel in some countries. FAME is specified in
ISO 14214 and ASTM D 6751.
FAME has good ignition properties and very good lubrication and environmental properties, but
FAME has also known negative properties as follows:
• Possible oxidation and thus long term storage problems
• A chemical attraction to water and nutrient for microbial growth
• Unsatisfactory low temperature properties
• FAME material particles can appear on exposed surfaces and filter elements.
If you use FAME as a fuel, make sure that the on-board storage, handling, treatment, service and
machinery systems can be used with such a product.
12.4.7 Ultra low sulphur fuel oils
Some fuel suppliers are selling ultra low sulphur fuel oils (ULSFO, sometimes also referred to as
hybrid fuels) as an alternative to distillate fuels to obey the ECA rules.
Many of these products obey the specifications for residual fuel related to ISO 8217:2017, but they
are different to heavy fuel oil (HFO) in properties like sulphur content, compatibility, stability
viscosity, density and pour point. Do the same procedures for ULSFO as for HFO related to
storage, heating and separation.
The use of ULSFO is under the full responsibility of the operating company. WinGD recommends
to speak to the fuel supplier.

X92-B AA00-0000-00AAA-030A-A
12.4.8 Fuel Additives
WinGD does not recommend the use of fuel additives. Additives are not necessary for fuels that
obey the ISO 8217:2017 standard or for fuels that WinGD has recommended.
If you think that it is necessary to use additives, WinGD recommends to speak to the fuel supplier
and to the additive supplier. They can give you the related results of the use of additives. If you
use additives for some causes, you assume full responsibility. Existing No Objection Letters done
by Wärtsilä Switzerland Ltd. are no longer applicable and have no more support by WinGD.
NOTE: WinGD does not accept liability or responsibility for the performance or potential damage
caused by the use of such additives.
12.4.9 Non-standard fuels
If it is necessary to use non-standard fuels (fuels that are not in the related list from WinGD), speak
to or send a message to WinGD before use.
NOTE: WinGD does not accept liability or responsibility for the performance or potential damage
caused by the use of non-standard fuels.

X92-B
Operation Manual
13 Attachments
13.1 Schematic diagrams - general.................................................................................456

X92-B AA00-0000-00AAA-043I-A
Operation Manual Schematic diagrams - general
13.1 Schematic diagrams - general

NOTE: The diagrams below are part of the Engine-Builder Drawing-Set and are not included in
this operation manual. The diagrams below can be referenced directly in the specific
Engine-Builder Drawing-Set. Please contact your Engine-Builder, if you need the specific
diagrams.
13.1.1 Engine control diagram
The engine control diagram shows data about the control items of the engine and its systems.
In the sub-sections that follow you find general data about the engine control diagram.
13.1.1.1 Area codes in the engine control diagram
The area codes in the engine control diagram are as follows:

• A - Control air supply unit
• B - Fuel supply
• D - Servo oil supply
• E - Valve unit for start
• K - Local control panel.
13.1.1.2 Line codes in the engine control diagram
The line codes in the engine control diagram are shown in Figure 13-1.
Fig 13-1 Line codes
001
002
003
004
005
006
007
00208
Legend
001 Low pressure oil circuits 005 Heating

002 High pressure oil circuits 006 Control air circuits
003 Low pressure fuel circuits 007 Starting air circuits
004 High pressure fuel circuits

X92-B AA00-0000-00AAA-043I-A
13.1.1.3 System codes in the engine control diagram
The system codes in the engine control diagram are as follows:

• Code 10 - Fuel system
• Code 20 - Oil system
• Code 25 - Cylinder oil system
• Code 30 - Starting air system
• Code 35 - Control air system
• Code 40 - HT Cooling water system
• Code 48 - Cylinder cooling water system
• Code 50 - Exhaust gas system
• Code 70 - Miscellaneous systems
• Code 80 - Automation system
• Code 99 - Pipe diagram
• Code 900 - Engine room.
13.1.1.4 Component codes in the engine control diagram
The component codes in the engine control diagram are shown as example in Figure 13-2.
Fig 13-2 Process codes
10-5553_E0_1
001 002 003 004 005
00206
Legend
001 System code 004 CX - Cylinder, eg C5 = for cylinder 5

002 Design group 005 Running number
003 E0 = for engine
13.1.1.5 Signal codes - identification
The signal codes in the engine control diagram are shown as example in Figure 13-3.

X92-B AA00-0000-00AAA-043I-A
Fig 13-3 Signal codes
PT 1012 C
001 002 003 004
00207
Legend
001 Function code 003 Running number

002 Function group 004 Applied system
Tab 13-1 Function code
Code First position Second position
A Analysis n/a
C Control Control
E n/a Element
F Flow n/a
G Gauge n/a
H Hand n/a
I n/a Indication
J Power n/a
L Level n/a
P Pressure n/a
S Speed Switch
T Temperature Transmitter
V n/a Valve
X Unclassified Unclassified
Y Vibration Relay
Z Position (binary) n/a

X92-B AA00-0000-00AAA-043I-A
Tab 13-2 Function group
Code Signal type System
10 to 19 Signals from the engine Cooling water
20 to 29 Signals from the engine System oil, cooling oil
31 Signals from the engine Cylinder lubrication
34 Signals from the engine Fuel oil
37 Signals from the engine Exhaust gas
40 to 49 Signals from the engine Air systems
50 to 59 Signals from the engine Miscellaneous
60 to 69 Signals from the engine Spare
Tab 13-3 Applied system
Code Description
A Alarm and monitoring system
C Control system
L Local
M Measured indication, Local control panel
S Safety system
W Wrong way alarm
X Miscellaneous

X92-B AA00-0000-00AAA-043I-A
13.1.2 Electric connection diagram
The electric connection diagram shows data about the bus routing connections (without cylinder
related signals).
You can find an overview of the used color codes and symbols in Figure 13-4.
Fig 13-4 Color codes and symbols - electric connection diagram
Color codes:
CCM-20 A1
Power
Cylinder #1
Bus
Speed
Diesel
Option ECR component
00221
13.1.3 Piping and instrumentation diagram
The piping and instrumentation diagrams show data about the piping and instrumentation of the
auxiliary systems of the engine.

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Operation Manual

3 Design and function of the engine

4 Design and function of systems

5 Design and function of components

Winterthur Gas & Diesel Ltd. -3- Issue 002 2021-11

5.1 Group 1 - Engine frame and bearings

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5.7.1 Cylinder lubrication..........................................................................................188

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8.16 Emergency stop the engine - general......................................................................286

9 Service during operation

10 Troubleshooting and Special running condition

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11.1 Engine data.............................................................................................................416

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4 Design and function of systems

5 Design and function of components

10 Troubleshooting and Special running condition

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10-58 Cylinder liner wall temperature is too high .................................................. 335

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3 Design and function of the engine

4 Design and function of systems

5 Design and function of components

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5-4 Monoblock column (generic) ....................................................................... 120

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6-3 iGPR - schematic diagram .......................................................................... 214

9 Service during operation

10 Troubleshooting and Special running condition

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10-23 Turbocharger cut out procedure: Illustration 5 ........................................... 408

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Winterthur Gas & Diesel Ltd. - 17 - Issue 002 2021-11

Operation Manual Operation Manual - change record

1.1 Operation Manual - change record

New issue 002, 2021-11

- Rewritten introductory pages with additional explanations.

- Updated safety precautions and safety guidelines.

- Updated description of access to engine spaces.

- Updated descriptions of the design and function of the engine.

- Updated descriptions of the design and function of the systems.

- Updated descriptions of the design and function of the components.

- Updated the control system section.

- Updated the operation section.

- Updated the service during operation section.

- Added new chapters in troubleshooting and special running condition section.

- Updated the technical data section.

- Updated the copyright information.

New issue 001, 2020-06

Initial issue of the Operation Manual.

Winterthur Gas & Diesel Ltd. - 18 - Issue 002 2021-11

Operation Manual Operation Manual - change record

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