operation manual (om)

RT-flex50-D

Operation ManualMarine Pulse Lubrication

Vessel:

Type:

Engine No.:

Document ID: DBAC351330

Winterthur Gas & Diesel Ltd. 24hrs Support:Schtzenstrasse 13 Wrtsil Services Switzerland Ltd.CH-8400 Winterthur Zrcherstrasse 12Switzerland CH 8400 Winterthur

Switzerland+41 52 262 80 [email protected]

2015-03 Winterthur Gas & Diesel Ltd., Printed in Switzerland All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electron-ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems)without the prior written permission of the copyright holder.

Wrtsil Services Switzerland Ltd. makes no representation, warranty (express or implied) inthis publication and assumes no responsibility for the correctness, errors or omissions for infor-mation contained herein. Information in this publication is subject to change without notice.

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUEN-TIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THISPUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

RT-flex50-D

Operation ManualMarine Pulse Lubrication

Vessel:

Type:

Engine No.:

Document ID: DBAC351330

Winterthur Gas & Diesel Ltd. 24hrs Support:Schtzenstrasse 13 Wrtsil Services Switzerland Ltd.CH-8400 Winterthur Zrcherstrasse 12Switzerland CH 8400 Winterthur

Switzerland+41 52 262 80 [email protected]

2015-03 Winterthur Gas & Diesel Ltd., Printed in Switzerland All rights reserved

No part of this publication may be reproduced or copied in any form or by any means (electron-ic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems)without the prior written permission of the copyright holder.

Wrtsil Services Switzerland Ltd. makes no representation, warranty (express or implied) inthis publication and assumes no responsibility for the correctness, errors or omissions for infor-mation contained herein. Information in this publication is subject to change without notice.

NO LIABILITY WHETHER DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUEN-TIAL, IS ASSUMED WITH RESPECT TO THE INFORMATION CONTAINED HEREIN. THISPUBLICATION IS CONFIDENTIAL AND INTENDED FOR INFORMATION PURPOSES ONLY.

Summary for Operation Manual (OM)Page No. Title Subject

Date No.

new exch.

2010 Operation Manual, Issue 2010 x

Date of publication 2010-09-16

0515-1/A1 (3) 2011-01 Faults in High Pressure

Fuel System

Figure 'C': drawn for 5 & 6 cylinders and for Heinzmann

actuators specified

x

5801-1/A1 (3) Regulating Linkage Woodward ProAct II - Analog Actuator added x


7218-1/A2 (8) 2011-09 Cylinder Lubrication Remark concerning pre/post lubrication added to avoid

miss understanding of this function

x

7218-1/A3 (8) Cylinder Lubrication Remark concerning pre/post lubrication added to avoid

miss understanding of this function

x


0020-1/A2 2011-12 Table of Contents x

0030-1/A2 Subject Index x

Index Gr. 0, 6, 8 as well as 8135-1 added x

0040-1/A3 2011 Explanation on the Use of

the Operating Manual

Version with TurboCharger at Aft End x

0080-1/A2 Engine Numbering and

Designations

Version with TurboCharger at Aft End x

0120-1/A1 (1) 2011-12 Prepare the Fuel Oil

System for Operation

1st Remark altered: (see 0710-1 'Viscosity-Temperature

Diagram')

x

0130-1/A1 EAAD082895

EAAD083177

Prepare the Servo Oil

System

Drain screw (33) 4.82 introduced x

0240-1/A1 (2) Normal Running 2nd altered: (see 0710-1 'Viscosity-Temperature

Diagram')

x

0250-1/A1 Operating Data Sheet Min. press. servo oil inlet deleted; TC type A100-L added x

0250-2/A2

(1, 2)

Operating Data Sheet TE1121-28A_SLD data added; TC type A100-L added;

Remark for fuel oil (0270-2 altered to 0710-1)

x

0260-1/A1 (2) Manoeuvring 2nd sentence altered: (see 0710-1 'Viscosity-

Temperature Diagram').

x

0270-1/A1 (1) Changing Over from

DO to HFO

Section 2 1st sentence altered: (see 0710-1 'Viscosity-

Temperature Diagram')

x

0270-2/A1 Viscosity-Temperature

Diagram

deleted, its content however, newly added in 0710-1 (x)

0320-1/A2 (1) Measures to be Taken

after Stopping

5th altered: (see 0710-1 'Viscosity-Temperature

Diagram')

x

0510-1/A2 EAAD083177 Operation with Injection

Cut Out

Pressure relief and draining of servo oil and fuel rails

adapted

x

0515-1/A1

5, 6)

EAAD083177

DAAD007677

Faults in High Pressure

Fuel System


adapted

x

0520-1/A1 EAAD083177

DAAD082586

EAAD082206

Operation with EVControl

Unit Cut Out

Cost down solution of exhaust valve and EVCU introduced;

pressure relief and draining of servo oil and fuel rails

adapted

x

0525-1/A1

(2, 3)

EAAD083177

DAAD007677

Faults in Servo Oil

System


adapted

x

0540-1/A1

2, 3)

DAAD012317

EAAD082586

Operation with Running

Gear Partially or Totally

Removed

Cost down solution of exhaust valve introduced;

pressure relief and draining of servo oil and fuel rails

adapted

x

0590-1/A2 TC Out of Service Version with TurboCharger at Aft End x

0610-1/A1 EAAD082895

EAAD083177

Preparation before

Starting after a Prolo

Drain screw (33) 4.82 introduced x

0710-1/A1 Diesel Engine Fuels Heavy fuel oil requirements revised and former viscosity-

temperature diagram 0270-2 added

x

0750-1/A1 Lubricating Oils Lubricating oil requirements revised x

0760-1/A1 Cooling Water Cooling water and treatment requirements revised x

0800-1/A2 Operating Troubles Paragraph 1.2: The last two points added x

0270-2 deleted, its content however, newly added in 0710-

1;

new groups related to version with TurboCharger at Aft End

incorporated: 0040-1/A3, 0080-1/A2, 0590-1/A2, 6420-

1/A2,

Manual

Page or

Modification ServiceEngine Documentation

Modification

RT-flex50-D

1/7 16.3.2015


Date No.

new exch.

Manual

Page or


Modification

RT-flex50-D

0820-1/A2 (6) Irregularities During

Operation

Exhaust Waste Gate added with: Engine thermally

overloaded; and scavenge air pressure excessively high

x

0850-1/A2 (13,

15, 23, 25, 28)

2011-12 Failures and Defects of

WECS Components

Sensors ZT5441C48C deleted (acc. to new exhaust

valve);

New criteria added under 3.4: ME scavenge air pressure

high; ME exhaust waste gate not closed, ME engine waste

gate not open (engine with LLT only);

3.6 ME scavenge air pressure very high

x

1203-1/A1 EAAD082581 Thrust Bearing New arbor supports (9) introduced x2138-1/A1 EAAD082645 Lubricating Quill

(Pulse Feed)

LEE non-return valve removed from lubricating quill and

arranged in screwed union (9)

x

2751-1/A1 EAAD082586 Exhaust Valve Exhaust valve redesigned with simplified lower housing,

with only one valve stroke sensor and new blocking

procedure

x

4002-1/A2 (3, 7,

8,10, 11)

EAAD082586

EAAD082120

EAAD083048

Engine Control System

WECS-9520

Fig. 'B': Exhaust Waste Gate (optional) connected with

FCM-20 Cyl. 1 & 5; Fig. 'E', 'G' and emergency mode

adapted with only one position sensor removed

x

4003-2/A0 EAAD082895 Designations Sensors 4.70-2 and ZT5441-48 deleted x

CAS unit 1.01-1 & 2, drain screws 3.82 & 4.82, throttle

4.19,

sensors ST5131-33C, ST5134-36C, ZS5124C, ZS5225C,

ZS5372C, actuator ZV7076C added

x

4003-2/A2 EAAD082895

107.383.325

Control Diagram

(Pulse Feed)

Redesigned with exhaust waste gate, FPCV 3.06, exhaust

valve drive 4.03, EVCU 4.10 and servo oil rail 4.11

x

4003-2/A3 EAAD082895

107.383.325

Control Diagram

(Pulse Jet)

Redesigned with exhaust waste gate, FPCV 3.06, exhaust

valve drive 4.03, EVCU 4.10 and servo oil rail 4.11

x

4003-3/A2 Control and Auxiliary

Systems

Hydraulic and servo oil supply with TC at AE, speed control

(CAS Hengstler), TC type A100-L added; diagrams

redesigned with exhaust waste gate, new FPCV 3.06,

exhaust valve drive 4.03, EVCU 4.10 and servo oil rail

4.11

x

6420-1/A2 2011 Scavenge Air Receiver Version with TurboCharger at Aft End x

6500-1/A2 Turbocharging Version with TC type A100-L added x

6510-1/A3 Cleaning Turbocharger in

Operation

Version with TC type A100-L added x

6545-1/A2 Auxiliary Blower Version with TurboCharger at Aft End x

6606-1/A1 2011-12 EAAD082246

DAAD008840

Scavenge Air Cooler SAC cleaning system redesigned with one and two

turbocharger(s)

x

6606-1/A2 2011 Scavenge Air Cooler Version with TurboCharger at Aft End x

7218-1/A2

(2, 3, 5, 8)

2011-12 EDDA083089

EAAD082120

EAAD083048

Lubricating Pump with

Pulse Feed

Pressure regulating valve 8.11-1 integrated in servo oil rail,

PT2046A adapted to last CLP, double filter 8.17

introduced, servo oil connections for PLS altered, remarks

to MM_7218-1

x

7218-1/A3

(2, 3, 5, 8)

2011-12 EDDA083089

EAAD082120

EAAD083048

Lubricating Pump with

Pulse Jet

Pressure regulating valve 8.11-1 integrated in servo oil rail,

PT2046A adapted to last CLP, double filter 8.17

introduced, servo oil connections for PLS altered, remarks

to MM_7218-1

x

8016-1/A3 EAAD082921 Lubricating Oil System Specified and adapted for TPL & A100-L turbochargers,

drain screw 4.82 added

x

8016-1/A4 EAAD083177

EAAD082895

Lubricating Oil System Redesigned for MET turbocharger, drain screw 4.82 added x

8019-1/A1

(2-7)

EAAD082510

EAAD082895

Fuel Oil System Drain screw (35) 3.82 introduced in fuel rail (12) 3.05,

therefore former items 35-39 renumbered with 36-40

x

8135-1/A1 2011 EAAD082110 Exhaust Waste Gate for Low-Load Tuning introduced x

8345-1/A1 2011-12 7-78.437 Drainage System and

Wash-water Piping

System

Drainage system redesigned with one and two

turbocharger(s)

x

8345-1/A2 2011 Drainage System Version with TurboCharger at Aft End x


0020-1/A2 2012-07 Table of Contents x

0030-1/A2 (4) Subject Index x

Index Gr. 0, 8 x

0120-1/A1 Prepare the Fuel Oil

System for Operation

Electrical trace heating system data added x

new groups 0546-1/A1 and 8825-1/A1 added

2/7 16.3.2015


Date No.

new exch.

Manual

Page or


Modification

RT-flex50-D

0140-1/A2 Prepare the Cylinder

Lubrication System

Annotation correction: 'stop valve 5 (4.30-5)' to 'stop valve

4 (4.30-5)'

x

0250-2/A2 (2) 2012-07 Alarms and Safeguards

at Continuous Service

Power

Data row added to bottom of page 2 x

0546-1/A1 2012 Overpressure in the

Combustion Chamber

New group added x

2722-1/A1 (1) 2012-07 Injection Vavle Word "atomized" removed and sentences restructured x

4003-1/A2 (4) EAAD083016 Engine Control NABTESCO resistor changed to 5.6 kOhms x

5562-11A1 (3) Fuel Pressure Control

Valve

Fig. B changed to show different oil filter x

8825-1/A1 2012 Electrical Trace Heating

System

New group added x


Group 0 2014-04 TOC Group Updated x

0020-1/A2 TOC Updated x

0030-1/A2 Alphabetical TOC Updated x

0035-1/A1 (1) Abbreviations Abbreviations added x

0040-1/A2 (3) Explanation on the Use of

the Operating Manual

Note added x

0070-1/A1 The Relation between

Engine and Propeller

Chapter updated: Controlled English;

Load range diagram changed

x

0080-1/A1, A2 Engine Numbering and

Designations

Illustration CAS Gear Wheel added x

0210-1/A1 (1, 3) Safety Precautions and

Warnings

paragraph 3: Clean areas added

paragraph 14: Hydrogen Sulphide added

x

0250-1/A1 (1) EAAD085050

E-Mail Beat

Schumacher

vom 21.April

2014

Operating Data Sheet Fresh water: max. temperature 80C added

Lubricating oil (TC bearing with external oil supply): max.

temperature inlet 85C added; max. temperature housing

outlet changed from 120C to 130C

Scavenge air: min. and max. temperature removed

Lubricating oil (Servo oil pump inlet): min. pressure 4.0bar

added; max. pressure 6.5bar added

Sea-water: data removed

PT2711A: Alarm value changed from 1.0bar to 1.5bar

x

0250-2/A1 (1, 3) E-Mail Beat

Schumacher

vom 21.April

2014

Operating Data Sheet Sea-water: data removed

Notes: new text

Minimum value for vibration damper changed from 1.0bar

to 1.5bar

x

0270-2/A1 Viscosity-Temperature

Diagram

Chapter removed x

0320-1/A2 (2, 3) Engine Shutdown Chapter updated: Controlled English

paragraph 1.3: Data about pressure release starting air

manifold added

x

0510-1/A2 (2) EAAD084722 Operation with Injection

Cut Out

Illustration ICU MK3 added x

0515-1/A1 (2) Faults in the HP Fuel

System

paragraph 2.3: the check of the control signals and free

movement of the regulating linkage moved to the start of

the procedure

x

0515-1/A2 2014 EAAD084722 Faults in the HP Fuel

System

Paragraph 4 with additional data about ICU MK-3 added x

0520-1/A1 (2, 3) 2014-04 Operation with Exhaust

Valve Control Unit Cut

Out

New illustations ICU MK-3 x

0525-1/A1 (3) 2014-04 Faults in the Servo Oil

System

Note added x

0535-1/A1 2014 Operation without

Crosshead Lubricating

Oil Pump

Chapter added x

0710-1/A1 2014-04 Diesel Engine Fuels Chapter updated: latest data, Controlled English x

3/7 16.3.2015


Date No.

new exch.

Manual

Page or


Modification

RT-flex50-D

0720-1/A1 EAAD083822 Fuel Treatment, Fuel Oil

System

Chapter updated: new style, Controlled English

New schematic added, new fuel oil filter, new tank design,

fuel change-over unit added, overflow line changed, fresh

water fuel oil cooler added, new non-return valves drain

pipes

x

0750-1/A1 Service

Bulletins

RT-138

RT-138_1

Operating Media -

Lubricating Oils

paragraph 2.1: additional data added

Table 1: data FZG gear machine test added

Table 2: data FZG gear machine test added

paragraph 2.4: Sample point added

paragraph 3.1: updated

Fig. 1: illustration updated

paragraph 3.2: new data and Fig. 2 added

paragraph 3.3: new paragraph added


paragraph 7: new paragraph added


paragraph 8.2: list of approved lubricating oils updated

paragraph 8.3: new table added added

x

0760-1/A1 Operating Media -

Cooling Water

Chapter updated: latest data, Controlled English x

0810-1/A1 Troubles during Starting

and Stopping

Links added, new structure x

0820-1/A2 (3) Irregularities During

Operation

Data about crosshead bearing oil pressure decrease added x

0850-1/A2 EAAD084143 Failures and Defects of

WECS Components

Chapter updated: latest data, Controlled English, new FCM-

20 with Two-digit display; paragraph 4.4 Failure ID added;

Failure ID 109 ME fuel pump actuator fail. added;

Failure ID 26 ME servo oil pump #3 removed;

x

1903-1/A1 Tie Rod Chapter updated: New illustations assembly, Controlled

English

x

Group 2 TOC Group 2 Injection valve with FAST added x

2722-1/A2 2014 EAAD084502

EAAD085046

Injection Valve Injection valve with FAST x

Group 4 2014-04 TOC Group 4 4002-1/A3; 4003-2/A4 and 4628-1/A3 added x

4002-1/A3 2014 Engine Control System

WECS-9520

New chapter added: CAS Gear Wheel; Schematic CAS

gear wheel

x

4002-4/A1 2014-04 Regular Checks and

Recommended

Procedures for WECS-

9520

Chapter updated: Additional data for the procedure to

replace FCM-20; Controlled English

x

4003-2/A0 (3) Control Diagram -

Designations

ST5101-04C; ST5111-12S, ZS5123C added x

4003-2/A4 2014 EAAD084534 Control Diagram New diagram added for engines with CLU-4, CAS gear

wheel, ICU MK-3

x

4003-3/A2 2014-04 Control and Auxiliary

Systems

Schematic exhaust valve drive / air spring air CLU-4

added; Fuel injection FAST added;

x

4628-1/A2 2014 Pick-up for Speed

Measurement

new schematic added; CAS Gear Wheel x

5551-1/A1 2014-04 EAAD084362 Servo Oil Pump New illustation Fig. A; Position 8 and 11 removed x

Group 6 TOC Group 6 New chapter 6510-1/A1

6510-1/A1 2014-04 Cleaning Turbocharger in

Operation

6510-1/A1 updated: data about cleaning the turbocharger

in operation removed (reference to the manual of the

turbocharger manufacturer);

6510-1/A2 and 6510-1/A3 removed

x

7218-1/A2 (12) Cylinder Lubrication with

Pulse Feed

Illustration Fig. H changed: CAS units x

4/7 16.3.2015


Date No.

new exch.

Manual

Page or


Modification

RT-flex50-D

7218-1/A3 (12) Cylinder Lubrication with

Pulse Jet

Illustration Fig. H changed: CAS units x

Group 8 TOC Group 8 New chapters added x

8016-1/A5 2014 EAAD084041 Lubricating Oil System New data for CAS gear wheel - TC all types; procedure for

taking an oil samples changed (related to the data in the

Service Bulletin RT-138)

x

8019-1/A2 Fuel Oil System New chapter for ICU MK3 added x

8135-1/A2 Exhaust Waste Gate New chapter exhaust waste gate with TC at exhaust side x

Group 9 2014-04 TOC Group 9 New chapter added x

9223-1/A2 2014 EAAD084019 Crank Angle Sensor Unit New data for CAS gear wheel x

9258-1/A1 2014-04 EAAD083907 Pressure Switches and

Pressure Transmitters

Terminal Box E150 removed, new illustration x

9308-1/A1 2014 EAAD084911 Intelligent Combustion

Control

New chapter added x

9314-1/A1 2014-04 EAAD084983 Oil Mist Detector New data, controlled english x

9362-1/A2 Location of flex Electronic

Componets

New illustration, controlled english x


0020-1/A2 2014-07 Table of Contents New chapter 7218-3/A1 added x

0030-1/A2 Subject Index New chapter 7218-3/A1 added x

0410-1/A2 Service

Bulletins

RT-161

Running-in New Cylinder

Liners and Piston Rings

Paragraph 1: latest data related to the Service Bulletin RT-

161 added;

Paragraph 5: Note changed; Running-in sequence diagram

x

0710-1/A1 Operating Media - Diesel

Engine Fuels

Chapter updated (style, Simplified Technical English),

latest data added

x

0750-1/A1 Service

Bulletins

RT-138

Operating Media -

Lubricating Oils

Chapter updated (style, Simplified Technical English);

Paragraph 2.1.2 Servo Oil System added;

Table 4: List of Validated Lubricating Oils updated (latest

data);

Table 5: List of Validated System Oils updated (latest

data);

x

Group 7 Group TOC New chapter 7218-3/A1 added x

7218-3/A1 Service

Bulletins

RT-161

Feed Rate - Adjustment New chapter added, related to the Service Bulletin x

8016-1/A1 Service

Bulletins

RT-138

Lubricating Oil System -

CAS Gear Wheel

paragraph 2.3: New data about taking dirty oil samples

related to the Service Bulletin RT-138

x

8016-1/A2 Service

Bulletins

RT-138


CAS Gear Wheel



x

8016-1/A3 Service

Bulletins

RT-138


CAS Gear Wheel



x


OM_2015-01 2015-01 New Disclaimer; x

0000-1/A1 2015-01 For Your Attention Document updated x

0020-1/A2 2015-01 Table of Contents New chapters added: 4003-3/A5, 8016-1/A6; x

0030-1/A2 2015-01 Subject Index New chapters added x

0035-1/A2 2015-01 Service

Bulletin

RT-138

(Version 4)

Abbreviations Abbreviations added x

5/7 16.3.2015


Date No.

new exch.

Manual

Page or


Modification

RT-flex50-D

0070-1/A1 2015-01 Marine

Installation

Manual

(Version 17.

Dez 2014)

The Relation between

Engine and Propeller

Chapter updated: Content latest data, Fig. A Load range

limits diagram, Fig. B Schematic Diagram of Speed /

Power Relation (CPP), Controlled English;

x

0210-1/A1 2015-01 Safety Precautions and

Warnings

Chapter updated x

0250-1/A1 2015-01 EAAD085573

Technical

Circular to

Licensees

7412-2;

E-Mail from

Licensee 23.

Dec 2014

Operating Data Sheet -

Pressure and

Temperature Ranges

Document updated with latest data from the MIM;

Additional data crosshead lubrication oil added;

Additional data for engines with a CMCR less than 106 rpm

added;

x

0250-2/A2 2015-01 EAAD085573

Technical

Circular to

Licensees

7412-2;

E-Mail from

Licensee 23.

Dec 2014

Operating Data Sheet -

Alarms and Safeguards

Document updated with latest data;

Changed values:

PT1101A ALM from 2.0 bar to 3.0 bar;

PT1101A SLD from 1.8 bar to 2.8 bar;

PT1101S SHD from 1.5 bar to 2.5 bar;

TE1121-28A ALM from 90C to 95C;

TE1121-28A SLD from 95C to 98C;

PT2001 ALM from 5.0 bar to 4.0 bar;

PT2001 SLD from 4.8 bar to 3.8 bar;

PS2001S SHD from 4.3 bar to 3.3 bar;

PT2711A from 1.0 bar to 1.5 bar;

TE1381-82A ALM Note (11) added;

TE2102-10A added;

PT2041A added;

PT2046A added;

TE2101A added;

TE2201-08A added;

TE2301-08A added;

PT2021A added;

PT2023A added;

PS3121A added;

LS3426A added;

LS3444A added;

LS2446A added;

TE2501-08A Temperature difference added;

LS2055C to LS2055A changed;

Note (12) to Note (16) added;

x

0270-1/A1 2015-01 Service

Bulletin

RT-82

Change-over from Diesel

Oil to Heavy Fuel Oil and

Back

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

related to the Service Bulletin;

x

0535-1/A1 2015-01 Technical

Circular to

Licensees

7412-2;

Operation without

Crosshead Lubricating

Oil Pump

References added;

Note about operation without crosshead lubricating oil

pump added;

The maximum value for engine operation with crosshead

lubricating oil pump changed from 40% to 25-30%;

x

6/7 16.3.2015


Date No.

new exch.

Manual

Page or


Modification

RT-flex50-D

0750-1/A1 2015-01 Service

Bulletins

RT-138

(Version 4)

RT-138_1

(Version 4)

Operating Media -

Lubricating Oils

Chapter updated (style, Simplified Technical English);

Paragraph 2.1: additional data added

Paragraph 2.1.1: recommended oil temperature changed;

Paragraph 2.1.2 Servo Oil System added;

Paragraph 2.4: Sample point added

Paragraph 3: updated content with latest data;

Paragraph 3.1: updated

Paragraph 3.2: new data and Fig. 2 added

Paragraph 3.3: new paragraph added


Paragraph 7: new paragraph added


Paragraph 8.2: list of approved lubricating oils updated

Paragraph 8.3: new table added added

Fig. 1: new illustration with latest data;

Table 1 and table 2: data FZG gear machine test added,

test methods updated;

Table 4: List of Validated Lubricating Oils updated (latest

data);

Table 5: List of Validated System Oils updated (latest

data);

x

3326-1/A1 2015-01 EAAD085502 Crosshead and Guide

Shoe

Page 1: Remark about engines with a CMCR less than 106

rpm added;

Illustrations: Remark added;

x

Group 4 2015-01 Group TOC New chapter 4003-2/A5 added x

4003-2/A5 2015-01 EAAD085450 Engine Control Diagram Latest data about crosshead bearing oil system added;

Note added;

x

4003-3/A2 2015-01 EAAD085450 Control and Auxiliary

System

Page 5: new page added; Bearing and Cooling Oil Supply

with high pressure crosshead bearing lubrication

Page 21: new page added; Main Bearing and Crosshead

Lubrication with high pressure crosshead bearing

lubrication

x

Group 8 2015-01 Group TOC New chapter 8016-1/A6 added; x

8016-1/A6 2015-01 EAAD085578

Service

Bulletin

RT-138

(Version 4)

Lubricating Oil System Page 1: paragraph about booster pump for crosshead

lubrication added;

Page 2: new schematic with booster pump for crosshead

lubrication added;

x

9258-1/A1 2015-01 EAAD083907 Pressure Switches and

Pressure Transmitters

Terminal Box E150 removed, new illustration; Note added; x


0250-2/A1 2015-03 Operating Data Sheet,

Alarms and Safeguards

For engines with CMCR 106rpm (without booster pump):

PT2001A: ALM changed from 4.0 bar to 5.0 bar; SLD

changed from 3.8 bar to 4.8 bar;

PS2002S: SHD changed from 3.3 bar to 4.3 bar;

x


7/7 16.3.2015

Intentionally blank

0

1

2

3

4

5

6

7

8

9

OM

/ R

T

flex

/ Reg

iste

r

Engine Control and Control Elements

Crankshaft, Connecting Rod and Piston

Cylinder Liner and Cylinder Cover

Bedplate and Tie Rod

Operating Descriptions

Supply Unit, Servo Oil Pump and Fuel Pump

Scavenge Air System

Cylinder Lubrication

Piping Systems

Engine Monitoring

Intentionally blank

Operation Group0RT-flex50-D

Winterthur Gas & Diesel Ltd. 1/ 1

For Particular Attention 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General

Preface 00101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents 00201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subject Index 00301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guide for Symbols and Abbreviations 00351/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanations on the Use of the Operating Manual 00401/A2. . . . . . . . . . . . . . . . . . . . . . . .

Explanations on the Use of the Operating Manual (TC at AFT END) 00401/A3. . . . . . . .

Brief Description of the Engine 00501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Principle of the Two-stroke Diesel Engine 00601/A1. . . . . . . . . . . . . . . . . . . . . . .

Interrelationship between Engine and Propeller 00701/A1. . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Numbering and Designations 00801/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Numbering and Designations (Turbocharger at AFT END) 00801/A2. . . . . . . . . .

Preparation before Taking into Service

Preparations before Starting after a Short Shut-down (One or More Days) 01101/A2. . .

Prepare the Fuel Oil System for Operation 01201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Servo Oil System 01301/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Cylinder Lubricating System 01401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation under Normal Conditions

Summary 02001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Warnings (General Information) 02101/A1. . . . . . . . . . . . . . . . . .

Slow Turning 02201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 02301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Running 02401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Data Sheet

Pressure and Temperature Ranges at Continuous Service Power MCR 02501/A1. . . . .

Alarms and Safeguards at Continuous Service Power 02502/A2. . . . . . . . . . . . . . . . . . . .

Operation

Manoeuvring 02601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Over from Diesel Oil to Heavy Fuel Oil and Vice Versa 02701/A1. . . . . . . . . . .

Operation at Low Load 02801/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation at Overload 02901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down

General 03101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures to be Taken after Stopping 03201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Descriptions Group 0

Winterthur Gas & Diesel Ltd. RT-flex50-D / OM / 2014-04

OperationGroup0 RT-flex50-D

2/ 1 Winterthur Gas & Diesel Ltd.

Special Operational Measures

Running-in of New Cylinder Liners and Piston Rings 04101/A2. . . . . . . . . . . . . . . . . . . . .

Indicator Diagrams 04201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures against Fouling and Fires in the Scavenge Air Spaces 04501/A2. . . . . . . . . . .

Instructions Concerning the Prevention of Crankcase Explosions 04601/A1. . . . . . . . . .

Operation under Abnormal Conditions

General Information 05001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation with Injection Cut Out (One or More Cylinders) 05101/A2. . . . . . . . . . . . . . . . .

Faults in HP Fuel System 05151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Faults in HP Fuel System ICU Version MK-3 05151/A2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation with Exhaust Valve Control Unit Cut Out 05201/A1. . . . . . . . . . . . . . . . . . . . . . .

Faults in Servo Oil System 05251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation without Crosshead Lubricating Oil Pump 05351/A1. . . . . . . . . . . . . . . . . . . . . .

Operation with Running Gear Partially or Totally Removed 05401/A1. . . . . . . . . . . . . . . .

Operation with Water Leakage into the Combustion Chamber 05451/A1. . . . . . . . . . . . .

Overpressure in the Combustion Chamber 05461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air Cooler Out of Service / Failure of Auxiliary Blowers 05501/A1. . . . . . . . . .

Defective Remote Control 05601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defect in Speed Control System 05701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger Out of Service 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger Out of Service (Turbocharger at AFT END) 05901/A2. . . . . . . . . . . . . . . . .

Special Measures before and after Operation

Preparations before Starting after a Prolonged Shut-down Periodor an Overhaul 06101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures to be taken before Putting Out of Service for Extended Period 06201/A2. . . .

Operating Media

Diesel Engine Fuels 07101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Treatment and Fuel Oil System 07201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air and Compressed Air 07401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oils 07501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Water / Cooling Water Treatment 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Troubles

General 08001/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubles During Starting and Stopping 08101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Irregularities During Operation 08201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubles and Damages with Engine Parts 08401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Failures and Defects of WECS Components 08501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RT-flex50-D / OM / 2014-04 Winterthur Gas & Diesel Ltd.

Operation 00001/A1RT-flex50-D


1. General

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

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

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

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

2. Spare Parts

Use only original spare parts and components to make sure that the engine willcontinue to operate satisfactorily. All equipment and tools for maintenance and op-eration must be serviceable and in good condition.

The extent of all supplies and services is set exclusively to the related supply con-tract.

3. Data

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

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

4. Personnel

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

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

For Your Attention

2015-01

Intentionally blank



1. Summary

The documentation for this diesel engine type comprises the following books andpublications:

1.1 Operating Manual

This contains information covering engine operation, the required operating media(oil, water and fuel), as well as a description of the function of specific systems.

1.2 Maintenance Manual

This contains, in addition to the maintenance diagrams, information covering spe-cific dismantling and assembly work necessary for engine maintenance.It contains furthermore a masses (weight) table of certain individual parts, a clear-ance table, a list of rubber / O-rings, tightening values for important screwed con-nections and a tools list.

1.3 Code Book (spare parts catalogue)

In this book all parts are marked with a code number by which they can be orderedfrom Wrtsil Switzerland Ltd or the engine supplier. Such spare parts are to beordered exclusively from this book.

1.4 Documentation for bought-out items

Separate publications are provided for those items on the engine supplied by out-side manufacturers, such as turbocharger, automatic filter, torsional vibrationdamper, etc. In most cases these can also be used as a spare parts catalogue.

1.5 Records and drawings

With the first delivery of the documentation, the setting tables, shop trial docu-ments and surveyors certificates of the engine concerned as well as schematicdiagrams are also supplied.

2. Structure of manuals

Generally the manuals have to be regarded as Basic Manuals. They describeparticularly the standard engine with all cylinder numbers, alternative designexecutions and special equipment.

As a rule, in the case of alternative design executions the descriptions have beendivided in separate groups and clearly designated by the respective alternativenames. This allows on one hand to quickly find with certainty the respective pas-sages, on the other hand it allows the later removal of sheets of not supplied alter-natives and special executions.

Further indications can be found under Explanation on the Use of the OperatingManual 00401.

GeneralPreface

2008

Operation00101/A1 RT-flex50-D


2.1 Structure and page designations

The individual groups with their illustrations are divided according to the designgroups whenever possible.

0peration 11321/A1

TitleSubtitle

Wrtsil Switzerland Ltd 1 / 42010

XXX / 2010-02Year of issue(or)

Modification dateInternal identification

Page numberTotal pages of group

Engine typeManual type

Group No.Design variant

Variantdescription

(Version)

RT-flex50-D

2.2 Symbols

Remark: Refers to important details and recommendations concerning operationand maintenance of the engine.

Refers to checks which must be carried out for trouble-free operation and duringmaintenance.

2010

Preface

CHECK



Attention! Risk of injury! or Risk of accident! Refers to instructions for opera-tion and maintenance of the engine which absolutely must be complied with.In case of non-observance high risk of injury as well as damage to componentsmust be expected.

Refers to activities which must not be carried out during operation and mainte-nance of the engine. In case of non-observance damage to components must beexpected.

Sign for order of actions, activities to be carried out

Sign for observance of regulations

Sign for enumerations

3. Repeat-order of technical documentation

Remark: Corresponding to the continuing development of the engines the docu-mentation is continually being updated.This means that in a later ordered manual for the same engine, text and designa-tions may no longer coincide in every way with the previous version (see modifica-tion date on the relevant pages).

Not withstanding the foregoing, important information and improvements arebrought to the customers notice by Service Bulletins so that the relevant part ofany development should already be known.

When ordering documentation at a later stage for engines which have alreadybeen in operation since several years, the following details are basically required:

Engine type, year of manufacture and engine manufacturer

Name of vessel or site of installation

Cylinder or engine number

Special equipment

Form of documentation (printed Manuals or CD-ROM)

2010

Preface

Intentionally blank

Operation 00201/A2

Table of Contents

RT-flex50-D

Winterthur Gas & Diesel Ltd. 1/ 5 Pulse / 2015-01

Operating Descriptions Group 0For Particular Attention 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General

Preface 00101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Subject Index 00301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Guide for Symbols and Abbreviations 00351/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanations on the Use of the Operating Manual 00401/A2. . . . . . . . . . . . . . . . . . . . . . . .

Explanations on the Use of the Operating Manual (TC at AFT END) 00401/A3. . . . . . . .

Brief Description of the Engine 00501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working Principle of the Two-stroke Diesel Engine 00601/A1. . . . . . . . . . . . . . . . . . . . . . .

Interrelationship between Engine and Propeller 00701/A1. . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Numbering and Designations 00801/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Numbering and Designations (Turbocharger at AFT END) 00801/A2. . . . . . . . . .

Preparation before Taking into Service

Preparations before Starting after a Short Shut-down (One or More Days) 01101/A2. . .

Prepare the Fuel Oil System for Operation 01201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Servo Oil System 01301/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prepare the Cylinder Lubricating System 01401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation under Normal Conditions

Summary 02001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Precautions and Warnings (General Information) 02101/A1. . . . . . . . . . . . . . . . . .

Slow Turning 02201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 02301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Normal Running 02401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Data Sheet

Pressure and Temperature Ranges at Continuous Service Power MCR 02501/A1. . . . .

Alarms and Safeguards at Continuous Service Power 02502/A2. . . . . . . . . . . . . . . . . . . .

Operation

Manoeuvring 02601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Over from Diesel Oil to Heavy Fuel Oil and Vice Versa 02701/A1. . . . . . . . . . .

Operation at Low Load 02801/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation at Overload 02901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutting Down

General 03101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures to be Taken after Stopping 03201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents

Operation00201/A2

Table of Contents

RT-flex50-D

Winterthur Gas & Diesel Ltd. 2/ 52015-01 / Pulse

Special Operational Measures

Running-in of New Cylinder Liners and Piston Rings 04101/A2. . . . . . . . . . . . . . . . . . . . .

Indicator Diagrams 04201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures against Fouling and Fires in the Scavenge Air Spaces 04501/A2. . . . . . . . . . .

Instructions Concerning the Prevention of Crankcase Explosions 04601/A1. . . . . . . . . .

Operation under Abnormal Conditions

General Information 05001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation with Injection Cut Out (One or More Cylinders) 05101/A2. . . . . . . . . . . . . . . . .

Faults in HP Fuel System 05151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Faults in HP Fuel System ICU Version MK-3 05151/A2. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation with Exhaust Valve Control Unit Cut Out 05201/A1. . . . . . . . . . . . . . . . . . . . . . .

Faults in Servo Oil System 05251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation without Crosshead Lubricating Oil Pump 05351/A1. . . . . . . . . . . . . . . . . . . . . .

Operation with Running Gear Partially or Totally Removed 05401/A1. . . . . . . . . . . . . . . .

Operation with Water Leakage into the Combustion Chamber 05451/A1. . . . . . . . . . . . .

Overpressure in the Combustion Chamber 05461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air Cooler Out of Service / Failure of Auxiliary Blowers 05501/A1. . . . . . . . . .

Defective Remote Control 05601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Defect in Speed Control System 05701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger Out of Service 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharger Out of Service (Turbocharger at AFT END) 05901/A2. . . . . . . . . . . . . . . . .

Special Measures before and after Operation

Preparations before Starting after a Prolonged Shut-down Periodor an Overhaul 06101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Measures to be taken before Putting Out of Service for Extended Period 06201/A2. . . .

Operating Media

Diesel Engine Fuels 07101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Treatment and Fuel Oil System 07201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air and Compressed Air 07401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oils 07501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Water / Cooling Water Treatment 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Troubles

General 08001/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubles During Starting and Stopping 08101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Irregularities During Operation 08201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubles and Damages with Engine Parts 08401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Failures and Defects of WECS Components 08501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 00201/A2

Table of Contents

RT-flex50-D


Bedplate and Tie Rod Group 1Main Bearing 11321/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thrust Bearing 12031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tie Rod 19031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Liner and Cylinder Cover Group 2

Cylinder Liner

with Pulse Feed Lubrication 21241/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with Pulse Jet Lubrication 21241/A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Quills on Cylinder Liner

with Pulse Feed Lubrication 21381/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with Pulse Jet Lubrication 21381/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Rod Gland 23031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Valve 27221/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Valve FAST 27221/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Valve 27281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Valve 27511/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Connecting Rod and Piston Group 3Axial Damper 31461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting Rod and Connecting Rod Bearing 33031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crosshead and Guide Shoe 33261/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston 34031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston Cooling and Crosshead Lubrication 36031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Control and Control Elements Group 4

Engine Control

Engine Control System WECS9520 40021/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Control System WECS9520 CAS Gear Wheel 40021/A3. . . . . . . . . . . . . . . . .

User Parameters and Maintenance Settings 40023/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regular Checks and Recommendations for WECS9520 40024/A2. . . . . . . . . . . . . . . . .

Engine Control 40031/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Diagram

Designations (Description to 40031, 40032 and 40033) 40032/A0. . . . . . . . . . . . . . . .

Control Diagram (with Pulse Feed Lubrication) 40032/A2. . . . . . . . . . . . . . . . . . . . . . . . . .

Control Diagram (with Pulse Jet Lubrication) 40032/A3. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Diagram (with Pulse Jet Lubrication and CAS Gear Wheel) 40032/A4. . . . . . . . .

Control Diagram (Pulse Jet, CAS Gear Wheel, Crosshead Booster Pump) 40032/A5. .

Operation00201/A2

Table of Contents

RT-flex50-D

Winterthur Gas & Diesel Ltd. 4/ 52015-01 / Pulse

Control and Auxiliary Systems

Detailed Control Diagrams with Interfaces to the Plant 40033/A2. . . . . . . . . . . . . . . . . . . .

Drive Supply Unit 41041/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shut-off Valve for Starting Air 43251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Air Supply 46051/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Control Panel 46181/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick-up for Speed Measurement 46281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pick-up for Speed Measurement CAS Gear Wheel 46281/A2. . . . . . . . . . . . . . . . . . . . . . . .

Supply Unit, Servo Oil Pump and Fuel Pump Group 5Servo Oil Pump 55511/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply Unit 55521/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump 55561/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cutting Out and Cutting In of the Fuel Pump 55562/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pressure Control Valve 3.06 55621/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulating Linkage 58011/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air System Group 6Scavenge Air Receiver 64201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air Receiver (Turbocharger at AFT END) 64201/A2. . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharging 65001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharging (Turbocharger at AFT END) 65001/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Turbocharger in Operation Turbocharger All Types 65101/A1. . . . . . . . . . . .

Auxiliary Blower and Switch Box 65451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Blower and Switch Box (Turbocharger at AFT END) 65451/A2. . . . . . . . . . . . . . . . .

Scavenge Air Cooler: Operating Instructions and Cleaning 66061/A1. . . . . . . . . . . . . . . . . . .

Scavenge Air Cooler: Operating Instructions and Cleaning (TC at AFT END) 66061/A2. . .

Scavenge Air Waste Gate (Blow off Valve for Low Suction Temperatures) 67351/A1. . . . . .

Cylinder Lubrication Group 7

Cylinder Lubrication

with Pulse Feed 72181/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with Pulse Jet 72181/A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instructions Concerning Measurement ofCylinder Lubricating Oil Consumption 72182/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Feed Rate Adjustment 72183/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 00201/A2

Table of Contents

RT-flex50-D


Piping Systems Group 8Lubricating Oil System Turbocharger TPL and A100-L Type 80161/A3. . . . . . . . . . . . . . . .

Lubricating Oil System Turbocharger MET Type 80161/A4. . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil System Turbocharger All Types CAS Gear Wheel 80161/A5. . . . . . . . . . . .

Lubricating Oil System Turbocharger All Types, CMCR < 106 rpm 80161/A6. . . . . . . . . . .

Cooling Water System 80171/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting Air Diagram 80181/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Oil System 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Oil System ICU Version MK-3 80191/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Waste Gate (Low-Load Tuning) TC Aft End 81351/A1. . . . . . . . . . . . . . . . . . . . . . .

Exhaust Waste Gate (Low-Load Tuning) TC Exhaust Side 81351/A2. . . . . . . . . . . . . . . . . .

Drainage System and Wash-water Piping System 83451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Drainage System and Wash-water Piping System (TC at Aft End) 83451/A2. . . . . . . . . . . . .

Electrical Trace Heating System System (TC at AFT END) 88251/A1. . . . . . . . . . . . . . . . . . .

Engine Monitoring Group 9Instrument Panel 92151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crank Angle Sensor Unit Free End 92231/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crank Angle Sensor Unit Gear Wheel 92231/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Switches and Pressure Transmitters 92581/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intelligent Combustion Control 93081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Mist Detector 93141/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location of flex Electronic Components 93621/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intentionally blank



AAbbreviations 00351/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abnormal operating condition 05001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Adjustment, Feed rate 72183/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air flaps in the scavenge air receiver 64201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . .Air flaps in the scavenge air receiver (Turbocharger at AFT END) 64201/A2. .Alarms and safeguards at continuous service power 02502/A2. . . . . . . . . . . . . .Auxiliary blower and switch box 65451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary blower and switch box (Turbocharger at AFT END) 65451/A2. . . . . . .Auxiliary blower, failure of... 05501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Axial damper 31461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Auxiliary systems 40033/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BBrief description of the engine 00501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CChangeover, diesel oil heavy fuel oil operation 02701/A1. . . . . . . . . . . . . . . . .Checking engine controls 40031/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the cooling system 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cleaning the scavenge air cooler in operation 66061/A1. . . . . . . . . . . . . . . . . . .Cleaning the scavenge air cooler in operation (TC at AFT END) 66061/A2. . . .Cleaning exhaust gas turbocharger (all type) in operation 65101/A1. . . . . . . . .Compressed air, starting air, control air 07401/A1. . . . . . . . . . . . . . . . . . . . . . . . .Control air supply 46051/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control diagram, designations 40032/A0. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control diagram (with pulse feed lubrication) 40032/A2. . . . . . . . . . . . . . . . . . . .Control diagram (with pulse jet lubrication) 40032/A3. . . . . . . . . . . . . . . . . . . . . .Control diagram (with pulse jet lubrication and CAS Gear Wheel) 40032/A4. .Connecting rod, connecting rod bearing 33031/A1. . . . . . . . . . . . . . . . . . . . . . . . .Cooling water system 80171/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling water treatment 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crank angle sensor unit Free End 92231/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Crank angle sensor unit Gear Wheel 92231/A2. . . . . . . . . . . . . . . . . . . . . . . . . .Crankcase explosions, prevention of... 04601/A1. . . . . . . . . . . . . . . . . . . . . . . . . .Crosshead and guide shoe 33261/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crosshead Lubricating Oil Pump, Operation without 05351/A1. . . . . . . . . . . . .Cutting out and cutting in of the fuel pump 55562/A1. . . . . . . . . . . . . . . . . . . . . . .Cut out an exhaust valve control unit 05201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder liner (with pulse feed lubrication) 21241/A2. . . . . . . . . . . . . . . . . . . . . . .Cylinder liner (with pulse jet lubrication) 21241/A3. . . . . . . . . . . . . . . . . . . . . . . . .Cylinder liner, running-in of new... 04101/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder lubrication (with pulse feed lubrication) 72181/A2. . . . . . . . . . . . . . . . . .Cylinder lubrication (with pulse jet lubrication) 72181/A3. . . . . . . . . . . . . . . . . . .Cylinder lubricating oil consumption, Instructions ... 72182/A2. . . . . . . . . . . . . . .Cylinder lubricating system, control (with pulse feed lubrication) 72181/A2. . . .Cylinder lubricating system, control (with pulse jet lubrication) 72181/A3. . . . .Cylinder lubricating system, preparation before taking into service 01401/A2. .

Subject IndexAlphabetical Table of Contents

2015-01



DDamage to engine parts 08401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defective remote control system 05601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Detailed control diagrams with interfaces to the plant 40033/A2. . . . . . . . . . . . .Determination of cylinder lubricating oil consumption 72182/A2. . . . . . . . . . . . .Drainage system and wash-water piping system 83451/A1. . . . . . . . . . . . . . . . .Drainage system and wash-water piping system (TC at AFT END) 83451/A2.Draining cooling water 80171/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive supply unit 41041/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EEmergency operation with exhaust valve closed / opened 05201/A1. . . . . . . . .Engine, brief description of... 00501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine control 40031/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine control system WECS9520 40021/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine control system WECS9520 CAS Gear Wheel 40021/A3. . . . . . . . . .Engine numbering and designations 00801/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine numbering and designations (Turbocharger at AFT END) 00801/A2. .Exchange of defective exhaust valve control unit 05201/A1. . . . . . . . . . . . . . . . .Exchange of filter element (pulse feed cylinder lubrication) 72181/A2. . . . . . . .Exchange of filter element (pulse jet cylinder lubrication) 72181/A3. . . . . . . . . .Exchange of defective hydraulic piping 05201/A1. . . . . . . . . . . . . . . . . . . . . . . . .Exhaust valve 27511/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust waste gate (Low-Load Tuning) TC Aft End 81351/A1. . . . . . . . . . . . .Exhaust waste gate (Low-Load Tuning) TC Exhaust Side 81351/A2. . . . . . . .Explanations on the use of the Operating Manual 00401/A2. . . . . . . . . . . . . . . .Explanations on the use of the Operating Manual (TC at AFT END) 00401/A3

FFailure of auxiliary blower 05501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Failures and defects of WECS components 08501/A2. . . . . . . . . . . . . . . . . . . . .FAST, Injection Valve 27221/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Faults in HP fuel system 05151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Faults in HP fuel system ICU Version MK-3 05151/A2. . . . . . . . . . . . . . . . . . . .Faults in servo oil system 05251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Feed rate Adjustment 72183/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling and pressure relief of servo oil system 80161/A3, A4, A5. . . . . . . . . . . . .Finding group and page numbers 00401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Finding group and page numbers (Turbocharger at AFT END) 00401/A3. . . . .Fires in scavenge air spaces, prevention of... 04501/A2. . . . . . . . . . . . . . . . . . . .For particular attention 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuels for diesel engines 07101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel leakage system 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel leakage system ICU Version MK-3 80191/A2. . . . . . . . . . . . . . . . . . . . . . .Fuel oil system 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel oil system ICU Version MK-3 80191/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel oil system, prepare for... 01201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pressure control valve 3.06 55621/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump, cutting out and in 55562/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump 55561/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel treatment 07201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2015-01

Alphabetical Table of Contents



GGeneral indications for operation 02101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Guide shoe on crosshead 33261/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HHeavy fuel oil, quality requirements 07101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Heavy fuel oil, treatment 07201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IIndicator diagrams 04201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Injection valve 27221/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Injection valve with FAST 27221/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intelligent Combustion Control 93081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interfaces to the plant, ... control diagrams 40033/A2. . . . . . . . . . . . . . . . . . . . . .Instructions concerning measurement of thecylinder lubricating oil consumption 72182/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrument panel 92151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Integrated axial damper 31461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intelligent Combustion Control 93081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Interrelationship between engine and propeller 00701/A1. . . . . . . . . . . . . . . . . .Irregularities during operation 08201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LLeakage and wash-water piping system 83451/A1. . . . . . . . . . . . . . . . . . . . . . . .Leakage and wash-water piping system (TC at AFT END) 83451/A2. . . . . . . . .Leakage localization (servo oil) 80161/A3, A4, A5. . . . . . . . . . . . . . . . . . . . . . . . .LED indications on ALM20 module (pulse feed) 72181/A2. . . . . . . . . . . . . . . . .LED indications on ALM20 module (pulse jet) 72181/A3. . . . . . . . . . . . . . . . . .LED indications on FCM20 module 08501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Local control panel 46181/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Location of flex electronic components 93621/A2. . . . . . . . . . . . . . . . . . . . . . . . . .Lubricating oils 07501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricating oil system (turbocharger TPL and A100-L type) 80161/A3. . . . . . . .Lubricating oil system (turbocharger MET type) 80161/A4. . . . . . . . . . . . . . . . . .Lubricating oil system (turbocharger all types CAS Gear Wheel) 80161/A5. .Lubricating quills (with pulse feed lubrication) 21381/A1. . . . . . . . . . . . . . . . . . . .Lubricating quills (with pulse jet lubrication) 21381/A2. . . . . . . . . . . . . . . . . . . . . .Lubrication of cylinder liner (pulse feed) 72181/A2. . . . . . . . . . . . . . . . . . . . . . . . .Lubrication of cylinder liner (pulse jet) 72181/A3. . . . . . . . . . . . . . . . . . . . . . . . . .

MMain bearing 11321/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manoeuvring 02601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measures to be taken before putting out of servicefor extended period 06201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Measures against fouling and fires in the scavenge air spaces 04501/A2. . . . .Measure to be taken after shutting down 03201/A2. . . . . . . . . . . . . . . . . . . . . . . .Measures to be taken before starting 01101/A2. . . . . . . . . . . . . . . . . . . . . . . . . . .

2014-04




NNormal running 02401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OOil mist detector 93141/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating data sheet, alarms and safeguards 02502/A2. . . . . . . . . . . . . . . . . . .Operating data sheet, pressure and temperature ranges 02501/A1. . . . . . . . . .Operating medium, air 07401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating medium, oil 07501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating medium, water 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating troubles, general 08001/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operating with defective turbocharger 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . .Operating with defective turbocharger (Turbocharger at AFT END) 05901/A2.Operation at low load 02801/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation at overload 02901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation under normal conditions, general information 02101/A1. . . . . . . . . . .Operation under normal conditions, summary 02001/A1. . . . . . . . . . . . . . . . . . . .Operation interruption, measures before extended standstill 06201/A2. . . . . . .Operation under abnormal conditions, general information 05001/A1. . . . . . . .Operation under breakdown conditions 05001/A1. . . . . . . . . . . . . . . . . . . . . . . . .

to 05901/A2Operation with injection cut out (one or more cylinders) 05101/A2. . . . . . . . . . .Operation with a running gear removed 05401/A1. . . . . . . . . . . . . . . . . . . . . . . . .Operation with cut out exhaust valve control unit 05201/A1. . . . . . . . . . . . . . . . .Operation with scavenge air cooler out of service 05501/A1. . . . . . . . . . . . . . . .Operation with water leakage into the combustion chamber 05451/A1. . . . . . .Operation without Crosshead Lubricating Oil Pump 05351/A1. . . . . . . . . . . . . . .Overpressure in combustion chamber 05461/A1. . . . . . . . . . . . . . . . . . . . . . . . . .

PParticular attention, for your... 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pick-up for speed measurement 46281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pick-up for speed measurement CAS Gear Wheel 46281/A2. . . . . . . . . . . . . .Piping systems Group 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston 34031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston cooling and crosshead lubrication 36031/A1. . . . . . . . . . . . . . . . . . . . . . . .Piston and piston rings, running-in of cylinder liner 04101/A2. . . . . . . . . . . . . . .Piston rod gland 23031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Precautionary measures for operation 02101/A1. . . . . . . . . . . . . . . . . . . . . . . . . .Preface 00101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Prepare the fuel oil system for operation 01201/A1. . . . . . . . . . . . . . . . . . . . . . . .Prepare the servo oil system 01301/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preparation before taking into service 01101/A2. . . . . . . . . . . . . . . . . . . . . . . . . .Preparations before starting after a prolonged shut-down periodor an overhaul 06101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure and temperature ranges 02501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure switch and pressure transmitter 92581/A1. . . . . . . . . . . . . . . . . . . . . . .Prevention of crankcase explosions 04601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Propeller curve 00701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

QQuality requirements for heavy fuel oil 07101/A1. . . . . . . . . . . . . . . . . . . . . . . . . .

2014-04




R

Regular checks and recommendations for WECS9520 40024/A2. . . . . . . . . .Regulating linkage 58011/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Remote control system defective 05601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Running gear, operation with removed... 05401/A1. . . . . . . . . . . . . . . . . . . . . . . .Running-in of new cylinder liner, piston and piston rings 04101/A2. . . . . . . . . . .

S

Safety measures and warnings (general information) 02101/A1. . . . . . . . . . . . .Scavenge air 07401/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scavenge air cooler, operating instructions and cleaning 66061/A1. . . . . . . . . .Scavenge air cooler, operating instructions and cleaning (TC at AE) 66061/A2Scavenge air cooler out of service, failure of auxiliary blower 05501/A1. . . . . .Scavenge air receiver 64201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scavenge air receiver (Turbocharger at AFT END) 64201/A2. . . . . . . . . . . . . . .Servo oil leakage system 80161/A3, A4, A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servo oil pump 55511/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Servo oil service pump 80161/A3, A4, A5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutting down, general 03101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shutting down, measures to be taken after the ... 03201/A2. . . . . . . . . . . . . . . .Shut off the injection control unit 05101/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Shut-off valve for starting air 43251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Slow turning 02201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speed control system defective 05701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speed measurement, pick-up for... 46281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Speed measurement, pick-up for CAS Gear Wheel 46281/A2. . . . . . . . . . . . .Starting 02301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting air system, schematic diagram 80181/A1. . . . . . . . . . . . . . . . . . . . . . . . .Starting valve 27281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Structure of the manuals 00101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Supply unit 55521/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Symbols 00101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T

Table of contents 00201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thrust bearing 12031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tie rod 19031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubles, during operation 08201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubles when starting and shutting down 08101/A1. . . . . . . . . . . . . . . . . . . . . . .Troubles with engine parts (damage) 08401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger (all type), cleaning in service 65101/A1. . . . . . . . . . . . . . . . . . . . . .Turbocharger out of service 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger out of service (Turbocharger at AFT END) 05901/A2. . . . . . . . . .Turbocharger surging 08201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharging 65001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharging (Turbocharger at AFT END) 65001/A2. . . . . . . . . . . . . . . . . . . . . .

2014-04




U

User parameters and maintenance settings 40023/A2. . . . . . . . . . . . . . . . . . . . .

V

Venting and leak test of fuel oil system on engine 01201/A1. . . . . . . . . . . . . . . .Venting the lubricating pump (pulse feed cylinder lubrication) 72181/A2. . . . . .Venting the lubricating pump (pulse jet cylinder lubrication) 72181/A3. . . . . . . .

W

Warnings and safety measures (general) 02101/A1. . . . . . . . . . . . . . . . . . . . . . .Wash-water piping system 83451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wash-water piping system (Turbocharger at AFT END) 83451/A2. . . . . . . . . . .Water, operating medium... 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WECS9520 components, failures and defects of... 08501/A2. . . . . . . . . . . . . .WECS9520 engine control system 40021/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . .WECS9520 engine control system CAS Gear Wheel 40021/A3. . . . . . . . . .WECS9520 manual control panel 46181/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Working principle of two-stroke diesel engine 00601/A1. . . . . . . . . . . . . . . . . . . .

2014-04




1. Symbols

These stand for control components (valve units etc.) used for engine control.

Symbols Explanations

A Control air supply unit

B Fuel supply

C Fuel injection

D Servo oil supply

E Valve unit for start

F Exhaust valve drive

H Instrument panel

I Pressure switches and pressure transmitters

K Local control panel

2. Abbreviations

2.1 General

The abbreviations used in the manuals are arranged alphabetically in this guide,however, unit of measures are not listed.

Remark: Identical abbreviations e.g. MCR can be distinguished in thecorresponding context.

Abbreviations Explanations

AHD Ahead

ALM Alarm

AST Astern

ASTM American Society for Testing and Materials

BDC Bottom Dead Center

BFO Bunker Fuel Oil

BN Base Number

BSFC Brake Specific Fuel Consumption

CA Crank Angle

CCAI Calculated Carbon Aromaticity Index

CMCR Contract Maximum Continuous Rating

COC Cleveland Open Cup

CSR Continuous Service Rate

DO Diesel Oil

EAL Environmentally Acceptable Lubricants

ECA Emission Control Area

EM Engine Margin

2015-01

Guide for Symbols and Abbreviations




FZG Gas Research Center

HFO Heavy Fuel Oil

ICC Intelligent Combustion Control

IMO International Maritime Organisation

ISO International Standard Organisation

JIS Japanese Industrial Standards

LED Light Emitting Diode

LLT Low Load Tuning

LSHFO Low Sulphur Heavy Fuel Oil

MARPOL International Convention for the Prevention of Pollutionfrom Ships

MCR Maximum Continuous Rating

MCR Micro Carbon Residue

MDO Marine Diesel Oil

mep mean effective pressure

MGO Marine Gas Oil

OM Operational Margin

OMD Oil Mist Detector

PLM Pulse Lubrication Module

PLS Pulse Lubrication System

PMCC Pensky Martens Closed Cup method

RCS Remote Control System

SAC Scavenge Air Cooler

SAE Society of Automotive Engineers

SCR Selective Catalytic Reduction

SHD SHut Down

SHF Sediment by Hot Filtration

SLD SLow Down

TC Turbocharger

TDC Top Dead Center

2015-01




2.2 Concerning engine control system WECS9520


ACM-20 Angle Calculation Module-20

ALM-20 Advanced Lubricating Module-20

AMS Alarm and Monitoring System

CANBus Controller Area Network

CAN M CAN Modul bus

CAN S CAN System bus

COMFN COMon FuNction (engine-related control functions)

CYLFN CYLinder FuNction (cylinder-related control functions)

DENIS9520 Diesel Engine CoNtrol and OptImizing Specification forWECS9520

ECR Engine Control Room

FCM-20 Flex Control Module-20

FQS Fuel Quality Setting

LED Light Emitting Diode

SCS Speed Control System

Modbus GouldModicon Fieldbus

OPI OPerator Interface (user interface in control room)

PCS Propulsion Control System

RCS Remote Control System

SIB Shipyard Interface Box (engine / remote control interface)

SS Safety System

SSI Synchron Serial Interface

VEC Variable Exhaust valve Closing

VEO Variable Exhaust valve Opening

VIT Variable Injection Timing

WECS Wrtsil Engine Control System

WECS9520 Computerized control system for all flex-specific functions

2015-01


Intentionally blank



1. Contents

The Operating Manual, called Operation for short, mainly contains descriptionsand indications on:

Servicing of the engine in operation.

Required operating media (oil, water, air, fuel).

Explanations of the function of specific components and systems.

Remark: The instructions on maintenance and overhauls are found in a separatebook, the Maintenance Manual.

2. Where to find what

When looking for group descriptions consult first of all the Table of Contents00201. The Subject Index 00301 is also very useful.In the cross section and longitudinal section illustrations, important componentshave been marked with the group number where they can quickly be found withtheir description. The sections further provide a general view of the design of theengine, which, depending on specific executions, may differ slightly.

Cross section and longitudinal section see pages 2 and 3.

3. Guide for symbols and abbreviations

The symbols and abbreviations used in the Operating Manual are explained in theguide 00351. Abbreviations used in the illustrations are listed in the correspond-ing keys.

2010

GeneralExplanations on the Use of the Operating Manual



Cross Section:

65001

operation manual (om)

Documents