om-rt-flex96c_wecs-9520_pulse_2012-11

RT-flex96C

Operation ManualMarine WECS9520 / Dynex Servo Oil Pump

Pulse Lubrication

Vessel:

Type:

Engine No.:

Document ID: DBAC352038

Wrtsil Switzerland Ltd 24hrs Support: +41 52 262 80 10PO Box 414 [email protected] WinterthurSwitzerland

2012-11 Wrtsil Switzerland Ltd, Printed in Switzerland

Intentionally blank

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

Date No.

new exch.

0020-1/A2 12.08 Table of Contents x

0030-1/A2 Subject Index x

Index 2, 4, 7 x

0035-1/A2 (2) Guide for Symbols and

Abbreviations

Row with SIPWA-TP deleted x

0110-1/A2 (1) Preparation for Taking

into Service

3rd paragraph: Remark concerning tool 94844 added x

0130-1/A1 10th paragraph: Drain screws 24 & 24a with (4.82)

specified

15th paragraph: Stop valve 30 (4.30- 4) deleted

x

0140-1/A2 3rd paragraph: shut off valve 3 altered to ball valve 5

4th paragraph: measurement tube 4 (8.19) added

x

0250-2/A2 7-66.291 Operating Data Sheet TE2601-04A_SLD; TE3411A_ALM and TE3431-38A, 13)

adapted; Remarks 12 to 14 added

x

0410-1/A2

(1, 2)

Running-in of New

Cylinder Liners

Wording required feed rate replaced with guide feed rate x

0510-1/A2

(2, 3)

Operation under

Abnormal Condition

Fig. 'A': Stop valve deleted; drain screws 17 with (3.82)

specified

x

0515-1/A1

(3, 4)

7-41.758 Fig. 'C' modified, Fig. 'D': Stop valve deleted, lubricant for

screws 3 and 6 specified accoring to modification

x

0520-1/A2 (3) Fig. 'A': Stop valve deleted x

0525-1/A1 (3) Fig. 'A': Stop valve deleted x

0620-1/A2 Special Measures Measures to be taken before putting out of service revised x

0710-1/A1

(3, 4, 6)

Operating Media ISO standard adapted, table 'Fuel oil requirements' revised x

0750-1/A1

(3, 5)

Lubricating oils (sections 3 and 7) revised x

0850-1/A2 (20) Operating Troubles ME servo oil pump #5, #6 fail: Numbers of cylinders

corrected

x

2124-1/A2 Cylinder Liner Remark concerning SIPWATP deleted, new lubr. grooves

SN designed

x

2138-1/A1 Lubricating Quill on

Cylinder Liner

Lubri. quill newly adapted for 'Pulse Feed': former A1

(Pulse Jet) designated with A2

x

2138-1/A2 Lubricating Quill on

Cylinder Liner

Lubri. quill for 'Pulse Jet' x

4002-3/A2 (1) Engine Control Table, Lubrication (Feed rate): Adjusting required desired

feed rate (...)

x

4003-1/A2

(6, 7)

13th paragraph: Stop valve 4.30- 4 deleted

13th, 14th paragraphs and 3rd Remark: adapted to

pulse feed lubr.

x

4003-2/A0

(Pulse)

Engine Control

Descriptions

3.17, 3.82, 4.82 added; 3.51, 3.54, 4.30-4 deleted x

4003-2/A3, A4,

A5, A6

7-66.121 Engine Control System

WECS-9520

Control diagram adapted; execution with 'Pulse Jet'

integrated

4003-3/A2 7-51.751

7-51.855

7-66.121

Control and Auxiliary

Systems

Control diagrams revised; execution with 'Pulse Jet'

(pages 13 and 14) integrated

x

5551-1/A1 (2) 7-42.147 Servo Oil Pump Pinion 4.45 adapted according to modification x

5552-1/A1 (2) 7-42.147 Supply Unit Pinion 4.45 adapted according to modification x

5556-1/A1

(2, 3, 4, 5)

7-51.751

7-57.032

Fuel Pump Fuel pump revised x

5571-1/A1 (2) 7-53.297 Control Oil Pump Unit Control oil pump revised x

6420-1/A1 (2) 7-54.148

7-56.355

Scavenge Air Receiver Scavenge air receiver revised x

6606-1/A1 (4) Scavenge Air Cooler Additional drain with orifice adapted between scavenge air

receiver

and pipe 21; new vent pipe from venting unit 23 to plant

x

7218-1/A2 Cylinder Lubrication Cyl. Lubri. newly adapted for 'Pulse Feed'; and former A2

('Pulse Jet') designated with A3

x

7218-1/A3 Cylinder Lubrication Cyl. Lubri. adapted for 'Pulse Jet' x

Completed with new groups, i.e. 2124-1/A3, 2138-1/A2,

4003-2/A5, 4003-2/A6, 7218-1/A3 concerning execution

with Pulse Jet integrated

Manual

Page or

Modification ServiceEngine Documentation

Modification

RT-flex96C_WECS-9520_Dynex_Pulse

1/5 29.1.2014


Date No.

new exch.

Manual

Page or


Modification


7218-2/A2 12.08 Lubricating Oil System Instructions Concerning Measurement (...) adapted for

pulse

x

8016-1/A5, A6,

A7, A8

7-54.266 Fuel Oil System Fig 'C' adapted acc. to Modification; stop valve 30 (4.30- 4)

deleted; drain screws 24 & 24a with (4.82) specified; Fig.

'H': Stop

valve deleted

x

8019-1/A1 7-51.751

7-53.297

Fuel oil system revised, and adapted according to

modifications

x

8345-1/A1 (2) Drainage System and

Wash-water Piping

System

Additional drain with orifice adapted between scavenge air

receiver

and pipe 12; new vent pipe from venting unit 20 to plant

x

Date of publication 2009-02-04

0525-1/A1 (4) 4.09 Operation under

Abnormal Condition

Last sentence deleted, as engine operation is also possible

without control oil pumps

x

4003-1/A2

(1, 5, 6)

7-58.635 Engine Control Test of auxiliary blowers in ECR manual control panel

added,

therefore part of paragraph 4.6 placed on page 5

x


0250-1/A1 11.09 7-76.002 Operating Data Sheet Servo oil pump inlet: Max. pressure deleted x

0250-2/A1 7-76.002

7-72.407

7-72.789

Operating Data Sheet Signal No. PT2051A_ALM_H deleted, piston cooling oil:

outlet each Cyl._ALM and _SLD deleted;

PS3121A_ALM_H altered to 0.5 bar, fuel oil

viscosity_ALM_L altered to 13 cSt; TE3731-34A_SLD_H,

Remark 15) added

x


Index 8 12.09 8135-1: Exhaust Waste Gate added x

0020-1/A2 Table of Contents x


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

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 Failures and Defects of

WECS Components

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

4002-1/A2 (3) Engine Control System

WECS-9520

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

FCM-20 Cyl. 1 & 5

x

4003-2/A0 (3) Designation Description Sensor ZS5372C and actuator ZV7076C added x

8135-1/A1 2009 Exhaust Waste Gate Low-Load Tuning x


Index 0 2010-07 0130-1/A2 Prepare the Servo and Control Oil System

added

x


0030-1/A2 Subject Index _ vapor trap 8019-1/A1 added x

0010-1/A1

(2, 3)

Preface Modification date written incl. year and month (2010-07);

penultimate deleted (manuals in English available only)

x

0120-1/A1 (2) 7-75.972

7-78.592

Prepare the Fuel System Former 2nd and 7th paragraphs deleted because tool

94585 has been omitted

x

0130-1/A2 Preparation before

Taking into Service

Former group 0130-1/A1 changed to A2 related to Pulse

version

x

0240-1/A1 (3) 7-71.837 Normal Running 6th paragraph concerning vapor trap added x

0320-1/A2 7-71.837 Shutting Down Vapor trap integrated in fuel leakage system, therefore 1.1

and 1.2 adapted correspondingly

x

0410-1/A2 Special Measures in

Operation

Running-in of new cylinder liners and piston rings revised x

0510-1/A2 7-75.972

7-78.592

Operation under

Abnormal Conditions

Tool 94585 has been omitted, therefore section 2

Restarting of injection adapted correspondingly

x

0515-1/A1

(3, 4, 5)

Faults in HP Fuel System Fig. 'C' and 'F' modified x

0520-2/A1 (3) Operation with Exhaust

Vale Drive Cut Out

Fig. 'C' modified x

0525-1/A1 (3) Faults in Servo and

Control Oil System

Fig. 'C' modified x

0620-1/A2 (2) 7-71.837 Special Measures 3rd, 5th and 6th paragraphs added x

0710-1/A1 Diesel Engine Fuels Complete group revised x

2/5 29.1.2014


Date No.

new exch.

Manual

Page or


Modification


0820-1/A2 (2) 2010-07 7-75.972

7-78.592

Irregularities During

Operation

Engine speed drops: 4th remedial point: Shut off altered to

Cut out or replace

x

2138-1/A1 7-73.638 Lubricating Quill on

Cylinder Liner

Multi-part quill replaced with one-part quill x

3146-1/A1 (1) Axial Damper 4th sentence adapted: The damping effect can be adjusted

. . .

x

4003-1/A2

(6, 8)

7-75.972

7-78.592

Engine Control 1st paragraph: pressures specified for Tier I or Tier II and

corr. table added; 4.11: former 5th paragraph deleted

x

4003-2/A0 Descriptions Plugs 3.37 and 3.38 deleted x

4003-2/A3,

A4, A5, A6

7-75.972

7-78.592

7-71.837

Control Diagram Plugs 3.37 and 3.38 deleted; vapor trap designed before

overflow tank

x

4003-3/A2

(4, 7, 8, 10, 11,

12, 16, 17)


Systems

Path-No. 48: under carrying number 48 path-No. 150

added; Plugs 3.37 and 3.38 deleted; vapor trap designed

before overflow tank

x

4325-1/A1 (2) 7-72.925 Shut-off Valve for Starting

Air

Control valve modified x

5556-2/A1

(1, 3)

Cutting Out and Cutting

In of the Fuel Pump

Sec. 1: 4th sentence concerning complete FP removed

added; Remark on page 3 deleted

x

6510-1/A1

(2, 4, 6-8)

Cleaning Turbocharger in

Operation

Modifications introduced according to ABB instructions: 2.1

5th sentence deleted; 3.1 water injection changed to ten

minutes, closing shut-off valves 3 & 5 after about one

changed to three to four minutes

x

6510-1/A2

(1, 3)

Cleaning Turbocharger in

Operation

MET 83MA turbocharger added x

6545-1/A1 (2) Auxiliary Blower Relief valve deleted on front face; Operating function:

specified pressure deleted as pressures are different for

Tier I or Tier II

x

8016-1/A5,

A6, A7, A8

(7, 12)

7-75.972

7-78.592

Lubricating Oil System ICU can not be blocked, therefore 2nd part of Remark

adapted correspondingly; former item 64 changed to 66

x

8019-1/A1

(2, 3, 6-8)

7-75.972

7-78.592

7-71.837

Fuel Oil System Former item 18 (plug 3.35) and Remark concerned

deleted; vapor trap (18) designed before overflow tank;

paragraph 4.2 Vapor trap added; figure 'C', relevant key to

illustration adapted and ball valve 66 & 67 added

x

8345-1/A1

(2, 3)

Drainage System and

Wash-water Piping

System

Sludge oil tank (24): 'ZS' (to sludge tank) deleted and 'ES'

(to venting collector) added

x

9215-1/A1 Instrument Panel Manometer CHARGING AIR (6) newly specified for Tier II

(2)

x

9258-1/A1 (2) Pressure Switches and

Pressure Transmitters

Pressure transmitter for CHARGING AIR (5) newly

specified for Tier II (2)

x

9314-1/A1 (1) Oil Mist Detector Fig. 'A': Supply unit (9) with its sensors added x


0140-1/A2 2010-10 TB_RT-96 Preparation for Taking

into Service

Position of stop valve (7) altered from closed to open ;

Remark deleted

x

2751-1/A2 (2) Exhaust Valve Remark deleted and sentence concerning valve spindle

lubrication added instead

x

4003-1/A2 (7) Engine Control 4.9_6th paragraph: Position of stop valve (7) altered from

closed to open; Remark deleted

x

7218-1/A2, A3

(12)

Cylinder Lubrication 7. Additional lubrication of exhaust valve spindle:

Description and position of stop valve (7) altered according

to TB

x


0120-1/A1 2011-03 EAAD082459 Prepare the Fuel System

System

1st sentence concerning checking drain valve 46 (3.65)

added

x

0250-1/A1 Operating Data Sheet Single-stage SAC: inlet pressure adapted to 2 bar x

2722-1/A1 (1) 7-77.630 Injection Valve Attention concerning fuel leakage pipe added; Fig. 'A':

detail with spherical insert bush added

x

4002-1/A1 (4) EAAD082328 Engine Control System

WECS-9520

Non-return valve at inlet flanges of intermediate fuel

accumulator removed

x

4003-2/A0 EAAD082459 Control Diagram Drain valve 3.65 and condensation water trap added x

3/5 29.1.2014


Date No.

new exch.

Manual

Page or


Modification


4003-2/A3, A4,

A5, A6

2011-03 EAAD082110

EAAD082459

Control Diagram x

4003-3/A2

(3, 15, 16, 19,

20)

Engine Control x

4003-3/A2

(7, 8)

EAAD082328 Engine Control Non-return valve (3.22) at inlet flanges of intermediate fuel

accumulator removed

x

5556-1/A1

(3, 4)

EAAD082459 Fuel Pump Non-return valve at inlet flanges of intermediate fuel

accumulator removed

x

5571-1/A1 (1) Control Oil Pump Unit Function: 2nd sentence related to start/stop of control oil

pump corrected

x

8019-1/A1

(2, 3-8)

EAAD082328

EAAD082459

Fuel Oil System Non-return valve at inlet flanges of intermediate fuel

accumulator removed; drain valve 3.65 (46) added and

therefore following items renumbered

x

8135-1/A1 EAAD082110 Exhaust Waste Gate

(Low-Load Tuning)

Air supply to LLT valve altered from control air to air spring

air

x


Index 6, 8 2011-05 6510-1/A3; 8016-1/A5, A6: Turbocharger A100-L type

added

x



0250-1/A1

0250-2/A2

EAAD079729

EAAD082213

Operating Data Sheet Lube oil, turbocharger bearing: data upgraded for A100-L

type

x

0515-1/A1 EAAD082328 Faults in HP Fuel System Paragraph 1.4 added: Localization of defective non-return

valve in fuel pump and emergency operation

x

2138-1/A1 EAAD082645 Lubricating Quill Arrangement of LEE non-return valve redesigned, i.e.

placed into screw-in union (7)

x

4003-2/A3, A4,

A5, A6

EAAD082459 Piping (double)filter 8.17 redesigned x

4003-3/A2

(1,5,6,11,13,

15,16) EAAD082459


Systems

Pages 1, 15, 16: upgraded for A100-L type

Pages 5, 6 (path No. 50): Option back flushing filter added

Page 11, 13: Piping (double)filter 8.17 redesigned

x

6510-1/A3 2011 Cleaning Turbocharger in

Operation

upgraded for A100-L type x

7218-1/A2, A3

(2, 5)

2011-05 EAAD082459 Piping (double)filter 8.17 redesigned.

Accumulator: remark to Maintenance Manual 7218-1

added

x

8016-1/A5, A6 EAAD079930 Lubricating Oil System

(TC TPL and A100-L

type)

Pages 1-3: text and figure upgraded for A100-L type.

Fig. 'A': oil inlet pipe 28 moved to driving end and

crankcase venting pipe 38 added

x

8016-1/A7 Lubricating Oil System

(TC MET type)

Fig. 'A': oil inlet pipe 28 moved to driving end and

crankcase venting pipe 38 added

x

8016-1/A8 Lubricating Oil System

(TC MET type)

Fig. 'A': crankcase venting pipe 38 added x


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

misunderstanding of this function

x

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

misunderstanding of this function

x


Index 0 and 9 2012-06 0270-2 deleted, its content however, newly added in 0710-

1;

new groups 0546-1/A1 and 9308-1/A1 added

x



0120-1/A1 Prepare the Fuel Oil

System for Operation

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

Diagram'), text revised on three pages

x

0240-1/A1 (2) Normal Running x-ref 0270-2 changed to 0710-1 x

0250-2/A2 EAAD083783 Operating Data Sheet Remark 16) added to servo oil and remarks to alarms and

safeguards; x-ref on page 2 changed to 0710-1

x

Air feed to LLT valve (butterfly valve) altered from control

air to air spring air (path-No. A6_38A_300).

Back flushing filter (4.20) added.

Pipe connection between fuel leakage pipes RU and

rail/SU with drain valve 3.65 added.

4/5 29.1.2014


Date No.

new exch.

Manual

Page or


Modification


0260-1/A1 (1) 2012-06 Manoeuvring Last paragraph altered: in Viscosity-Temperature

Diagram 0710-1...

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 2006 Viscocity - Temperature

Diagram

Document removed. Viscocity diagram integrated in 0710-

1/A1 (paragraph 3.1 Viscocity)

x

0320-1/A2 (1) 2012-06 Measures to be Taken

after Stopping

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

Diagram')

x

0546-1/A1 2012 Overpressure in

Combustion Chamber

New group added x

0710-1/A1 2012-06 Diesel Engine Fuels Additional data added. x

0750-1/A1 Lubricating Oils Additional data added. x

0760-1/A1 Cooling Water / Cooling

Water Treatment

Additional data added. x

2124-1/A2 EAAD082805

EAAD082901

Cylinder Liner with Pulse

Feed

Illustration changed. Oil groove data added. Text changes. x

2124-1/A3 EAAD082805

EAAD082901

Cylinder Liner with Pulse

Jet

Illustration changed. Oil groove data added. Text changes. x

2138-1/A1 (2) Lubricating Quills on

Cylinder Liner

Annotation added to Fig. 'A': 16 - Union nut. x

2138-1/A2 EAAD083591 Lubricating Quills on

Cylinder Liner

Details of lubricating quill changed (Fig. 'B'). Annotation in

Fig. 'A' changed to 13 - Union nut.

2722-1/A1 (1) Injection Valve Text changes: 'finely sprayed fuel' to 'fuel mist' x

2751-1/A2 EAAD082936 Exhaust Valve New damper in valve drive Fig. 'B'. Text changes. x

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

3.9 kOhm)

x

4003-2/A0 Control Diagram 3.70 overflow pipe deleted;

4.17 inspection point added

x

5556-1/A1

(2, 3, 4, 6, 7)

EAAD082996

EAAD082683

Fuel Pump, Intermediate

Accumulator and Fuel

Pressure Control Valve

Fig. 'B': Second O-ring introduced, spring dowel pin

removed;

Fig. 'D': item 10 pressure transmitter position changed,

view 'I' annotation correction: 7 to 6.

Fig. 'E': sketch view - changed to show short stay

Fig. 'F': filter (16) replaced; text changes

x

6420-1/A1 EAAD082712 Scavenge Air Receiver Sketch of relief valves added to figure; annotation line 16

(relief valve) moved to correct position; text changes

x

7218-1/A2 EAAD082961 Cylinder Lubrication Fig. 'B' changed to larger illustration; Fig. 'C' added;

pressure regulating unit replaced;

minor changes to procedure (page 7, para 4.3 & page 8

para 4.4); plus other text changes

x

7218-1/A3 EAAD082961 Cylinder Lubrication Fig. 'B' changed to larger illustration; Fig. 'C' added;

pressure regulating unit replaced;

minor changes to procedure (page 7, para 4.3 & page 8

para 4.4); plus other text changes

x

8016-1/A7 (2) EAAD083229 Lubricating Oil System Turbocharger MET83MB detail added to existing schematic x

8016-1/A8 (2) EAAD083229 Lubricating Oil System Turbocharger MET83MB detail added to existing schematic x

9308-1/A1 2012 Intelligent Combustion

Control

New group added. x


0510-1/A1 (2) 2012-07 Operation under

Abnormal Conditions

Fig C changed to show correct location of drain screw x


0510-1/A2 2012-11 Operation under

Abnormal Conditions

Procedure to exchange defective injection control unit

updated according information from Technical Bulletin RT-

134.

x

2722-1/A1 (3, 4) Injection Valve Chapter "Pressure release and drainage of injection valve"

added. Information according Technical Bulletin RT-134.

x

5556-1/A1 (8) Fuel Pump, Intermediate

Accumulator and Fuel

Pressure Control Valve

Chapter "Pressure release and drainage of IFA and supply

unit" added. Information according Technical Bulletin RT-

134.

x


5/5 29.1.2014

Intentionally blank

01

2

3

4

5

6

7

8

9

OM

/ R

Tf

lex

/ 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

This page is intentionally left blank

Operation Group0RT-flex96C

Wrtsil Switzerland Ltd 1/ 1

Operating Descriptions Group 0

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. . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 and Control Oil System 01301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wrtsil Switzerland Ltd Pulse / RTflex96C / OM / 2012-06

OperationGroup0 RT-flex96C


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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation with an Exhaust Valve Drive Cut Out 05201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . Faults in Servo and Control Oil System 05251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation without Crosshead Lubricating Oil Pump 05351/A1. . . . . . . . . . . . . . . . . . . . . . Operation with Running Gear Partially or Totally Removed 05401/A2. . . . . . . . . . . . . . . . Operation with Water Leakage into the Combustion Chamber 05451/A1. . . . . . . . . . . . . Overpressure in Combustion Chamber 05461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scavenge Air Cooler Out of Service / Failure of Auxiliary Blowers 05501/A1. . . . . . . . . . Defective Remote Control 05601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Defective Speed Control System 05701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Out of Service 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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, 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 WECS9520 Components 08501/A2. . . . . . . . . . . . . . . . . . . . . . .

Wrtsil Switzerland Ltd2012-06 / OM / RTflex96C / Pulse

Operation 00001/A1RT-flex96C


This manual is put at the disposal of the recipient solely for use in connection withthe corresponding type of diesel engine.It has always to be treated as confidential.

The intellectual property regarding any and all of the contents of this manual, par-ticularly the copyright, remains with Wrtsil Switzerland Ltd. This documentand parts thereof must not be reproduced or copied without their written permis-sion, and the contents thereof must not be imparted to a third party nor be used forany unauthorized purpose.

Before the operator intends to use the engine or before maintenance work is un-dertaken, the Operating Instructions or the Maintenance Manual respectively is tobe read carefully.

To ensure the best efficiency, reliability and lifetime of the engine and its compo-nents, only original spare parts should be used.It is to be ensured as well that all equipment and tools for maintenance are in goodcondition.

The extent of any supplies and services is determined exclusively by the relevantsupply contract.

The data, instructions and graphical illustrations etc. in this manual are based ondrawings made by Wrtsil Switzerland Ltd and correspond to the actual stan-dard at the time of printing (year of printing is indicated on title page).Those specifications and recommendations of the classification societies whichare essential for the design have been considered therein. It must be recognizedthat such data, instructions and graphical illustrations may be subject to changesdue to further development, widened experience or any other reason.

This manual is primarily intended for use by the engine operating and maintenancepersonnel. It must be ensured that it will always be at the disposal of such person-nel for the operation of the engines and/or for the required maintenance work.

This manual has been prepared on the assumption that operation and mainte-nance of the engines concerned will always be carried out by qualified personnelhaving the special knowledge, training and qualifications needed to handle in aworkman-like manner diesel engines of the corresponding size, the associatedauxiliary equipment, as well as fuel and other operating media.

Therefore, generally applicable rules, which may also concern such items asprotection against danger, are specified in this manual in exceptional cases only.It must be made sure that the operating and maintenance personnel are familiarwith the rules concerned.

This manual has been prepared to the best knowledge and ability of its au-thors. However, neither Wrtsil Switzerland Ltd nor their employees as-sume any liability under any legal aspect whatsoever, including possiblenegligence in connection with this manual, its contents, or modificationsto it or in connection with its use.Claims relating to any damage whatsoever or claims of other nature such as,but not limited to, demands for additional spares supplies, service or othersare expressly excluded.

Wrtsil Switzerland Ltd

Winterthur

Switzerland

For Particular Attention

2006



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 the 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

2006

Operation00101/A1 RT-flex96C


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 / 42006

XXX / 2010-07Year of issue(or)

Modification dateInternal identification

Page numberTotal pages of group

Engine typeManual type

Group No.Design variant

Variantdescription

(Version)

RT-flex96C

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.

Preface

2010-07

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)

Preface

2010-07

Operation 00201/A2

Table of Contents

RT-flex96C

Wrtsil Switzerland Ltd 1/ 5 Pulse / 2012-06

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. . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 and Control Oil System 01301/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . .

Operation00201/A2

Table of Contents

RT-flex96C

2/ 5 Wrtsil Switzerland Ltd2012-06 / Pulse

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation with an Exhaust Valve Drive Cut Out 05201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . Faults in Servo and Control Oil System 05251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operation without Crosshead Lubricating Oil Pump 05351/A1. . . . . . . . . . . . . . . . . . . . . . Operation with Running Gear Partially or Totally Removed 05401/A2. . . . . . . . . . . . . . . . Operation with Water Leakage into the Combustion Chamber 05451/A1. . . . . . . . . . . . . Overpressure in Combustion Chamber 05461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scavenge Air Cooler Out of Service / Failure of Auxiliary Blowers 05501/A1. . . . . . . . . . Defective Remote Control 05601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Defective Speed Control System 05701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger Out of Service 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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, 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 WECS9520 Components 08501/A2. . . . . . . . . . . . . . . . . . . . . . .

Bedplate and Tie Rod Group 1Main Bearing 11321/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thrust Bearing 12031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tie Rod 19031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 00201/A2

Table of Contents

RT-flex96C


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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting Valve 27281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Valve 27511/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankshaft, Connecting Rod and Piston Group 3Axial Damper 31461/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting Rod and Connecting Rod Bearings 33031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crosshead and Guide Shoe 33261/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston 34031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crosshead Lubrication and Piston Cooling 36031/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Control and Control Elements Group 4

Engine Control

Engine Control System WECS9520 40021/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 for Pulse Feed Lubrication (8 to 14 Cylinders) 40032/A3. . . . . . . . . . . . Control Diagram for Pulse Feed Lubrication (6 and 7 Cylinders) 40032/A4. . . . . . . . . . . . Control Diagram for Pulse Jet Lubrication (8 to 14 Cylinders) 40032/A5. . . . . . . . . . . . . . Control Diagram for Pulse Jet Lubrication (6 and 7 Cylinders) 40032/A6. . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation00201/A2

Table of Contents

RT-flex96C

4/ 5 Wrtsil Switzerland Ltd2012-06 / Pulse

Supply Unit, Servo Oil Pump and Fuel Pump Group 5Servo Oil Pump 55511/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Supply Unit 55521/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Pump, Intermediate Fuel Accumulator, Fuel Pressure Control Valve 3.06 55561/A1. .Cutting Out and Cutting In of the Fuel Pump 55562/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control Oil Pump Unit 55711/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Regulating Linkage 58011/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Scavenge Air System Group 6Scavenge Air Receiver 64201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharging 65001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning the Turbocharger in Operation

Turbocharger TPL Type 65101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger MET Type 65101/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger A100-L Type 65101/A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Blower and Switch Box 65451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scavenge Air Cooler: Operating Instructions and Cleaning 66061/A1. . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piping Systems Group 8

Lubricating Oil System

Turbocharger TPL and A100-L Type with Internal Supply 80161/A5. . . . . . . . . . . . . . . . . Turbocharger TPL and A100-L Type with External Supply 80161/A6. . . . . . . . . . . . . . . . . Turbocharger MET Type with Internal Supply 80161/A7. . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharger MET Type with External Supply 80161/A8. . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling Water System 80171/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starting Air Diagram 80181/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel Oil System 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust Waste Gate (Low-Load Tuning) 81351/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drainage System and Wash-water Piping System 83451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation 00201/A2

Table of Contents

RT-flex96C


Engine Monitoring Group 9Instrument Panel 92151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crank Angle Sensor Unit 92231/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pressure Switches and Pressure Transmitters 92581/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Intelligent Combustion Control 93081/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil Mist Detector 93141/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Location of flex Electronic Components 93621/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .



AAbbreviations 00351/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abnormal operating condition 05001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Additional lubrication of exhaust valve spindle (pulse feed) 72181/A2. . . . . . . .Additional lubrication of exhaust valve spindle (pulse jet) 72181/A3. . . . . . . . . .Air flaps in the scavenge air receiver 64201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . .Alarms and safeguards at continuous service power 02502/A2. . . . . . . . . . . . . .Auxiliary blower and switch box 65451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 exhaust gas turbocharger in operation (TPL type) 65101/A1. . . . . . .Cleaning exhaust gas turbocharger in operation (MET type) 65101/A2. . . . . . .Cleaning exhaust gas turbocharger in operation (A100-L type) 65101/A3. . . . .Compressed air, starting air, control air 07401/A1. . . . . . . . . . . . . . . . . . . . . . . . .Control air supply 46051/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control diagram (Description to 40031, 40032 and 40033) 40032/A0. . . . .Control diagram for Pulse Feed Lubrication (8 to 14 Cylinders) 40032/A3. . . .Control diagram for Pulse Feed Lubrication (6 and 7 Cylinders) 40032/A4. . . .Control diagram for Pulse Jet Lubrication (8 to 14 Cylinders) 40032/A5. . . . . .Control diagram for Pulse Jet Lubrication (6 and 7 Cylinders) 40032/A6. . . . . .Control oil pump unit 55711/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Connecting rod, connecting rod bearing 33031/A1. . . . . . . . . . . . . . . . . . . . . . . .Cooling water system 80171/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cooling water treatment 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crank angle sensor unit 92231/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crankcase explosions, prevention of... 04601/A1. . . . . . . . . . . . . . . . . . . . . . . . . .Crosshead and guide shoe 33261/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crosshead lubrication and piston cooling 36031/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 drive 05201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 (pulse feed) 72181/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder lubrication (pulse jet) 72181/A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cylinder lubricating oil consumption, Instructions ... 72182/A2. . . . . . . . . . . . . .

Subject IndexAlphabetical Table of Contents

Pulse / 2011-05



Cylinder lubricating system, control (pulse feed) 72181/A2. . . . . . . . . . . . . . . . .Cylinder lubricating system, control (pulse jet) 72181/A3. . . . . . . . . . . . . . . . . . .Cylinder lubricating system, preparation before taking into service 01401/A2. .

D

Damage to engine parts 08401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Defect in speed control system 05701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . .Drive supply unit 41041/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E

Emergency operation with exhaust valve closed / opened 05201/A2. . . . . . . . .Engine, brief description of... 00501/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine control 40031/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine control system WECS9520 40021/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine numbering and designations 00801/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . .Exchange of filter element (pulse feed cylinder lubrication) 72181/A2. . . . . . . .Exchange of filter element (pulse feed cylinder lubrication) 72181/A3. . . . . . . .Exchange of shut off exhaust valve drive 05201/A2. . . . . . . . . . . . . . . . . . . . . . . .Exchange of shut off injection control unit 05101/A2. . . . . . . . . . . . . . . . . . . . . . .Exchange of a defective hydraulic piping 05201/A2. . . . . . . . . . . . . . . . . . . . . . . .Exhaust valve 27511/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Exhaust waste gate (Low-Load Tuning) 81351/A1. . . . . . . . . . . . . . . . . . . . . . . . .Explanations on the use of the Operating Manual 00401/A2. . . . . . . . . . . . . . . .

F

Failure of auxiliary blower 05501/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Failures and defects of WECS components 08501/A2. . . . . . . . . . . . . . . . . . . . .Faults in HP fuel system 05151/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Faults in servo and control oil system 05251/A1. . . . . . . . . . . . . . . . . . . . . . . . . . .Filling, draining of servo and control oil system 80161/A5, A6, A7, A8. . . . . . .Finding group and page numbers 00401/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 oil system 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel oil system, prepare for... 01201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump, cutting out and in 55562/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel pump, intermediate fuel accumulator, f.p. control valve 3.06 55561/A1. . .Fuel treatment 07201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12.08 / Pulse

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 inspection point (servo oil) 80161/A5, A6, A7, A8. . . . . . . . . . . . . . . . .Leakage monitoring (fuel oil) 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 (TC TPL and A100-L type with int. supply) 80161/A5. . .Lubricating oil system (TC TPL and A100-L type with ext. supply) 80161/A6. .Lubricating oil system (TC MET type with internal supply) 80161/A7. . . . . . . . .Lubricating oil system (TC MET type with external supply) 80161/A8. . . . . . . .Lubricating quills (pulse feed) 21381/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubricating quills (pulse jet) 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. . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulse / 2012-06




N

Normal 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. . . . . . . . . . . . . . . . . . . . . . . . . .Operation at low load 02801/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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/A1Operation with injection cut out (one or more cylinders) 05101/A2. . . . . . . . . . .Operation with a running gear removed 05401/A2. . . . . . . . . . . . . . . . . . . . . . . . .Operation with exhaust valve drive cut out 05201/A2. . . . . . . . . . . . . . . . . . . . . .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 the combustion chamber 05461/A1. . . . . . . . . . . . . . . . . . . . . . .

P

Particular attention, for your... 00001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Pick-up for speed measurement 46281/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piping systems Group 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Piston 34031/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 and control oil system 01301/A2. . . . . . . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . . . . . . . . . . . . .Priming the fuel system on the engine 01201/A1. . . . . . . . . . . . . . . . . . . . . . . . . .Propeller curve 00701/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2012-06 / Pulse




Q

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

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/A2. . . . . . . . . . . . . . . . . . . . . . . .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 out of service, failure of auxiliary blower 05501/A1. . . . . .Scavenge air receiver 64201/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Scavenge air waste gate (blow off valve for low suction temp.) 67351/A1. . . . .Servo and control oil leakage system 80161/A5, A6, A7, A8. . . . . . . . . . . . . . . .Servo oil pump 55511/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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. . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 (TPL type), cleaning in service 65101/A1. . . . . . . . . . . . . . . . . . . .Turbocharger (MET type), cleaning in service 65101/A2. . . . . . . . . . . . . . . . . . . .Turbocharger (A100-L type), cleaning in service 65101/A3. . . . . . . . . . . . . . . . .Turbocharger out of service 05901/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharger surging 08201/A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Turbocharging 65001/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pulse / 2011-05




U

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

V

Vapor trap 80191/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Venting the lubricating pump (pulse feed cylinder lubrication) 72181/A2. . . . . .Venting the lubricating pump (pulse jet cylinder lubrication) 72181/A3. . . . . . . .Viscosity-temperature diagram 07101/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W

Warnings and safety measures (general) 02101/A1. . . . . . . . . . . . . . . . . . . . . . .Wash-water piping system 83451/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Water, operating medium... 07601/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .WECS9520 manual control panel 46181/A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .WECS9520, engine control system 40021/A2. . . . . . . . . . . . . . . . . . . . . . . . . . .Working principle of two-stroke diesel engine 00601/A1. . . . . . . . . . . . . . . . . . . .

2012-06 / Pulse




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

G Supply unit

H Instrument panel

I Pressure switches and pressure transmitters

K Local control panel

L Control oil pump unit

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 the corre-sponding context.

Abbreviations Explanations

AHD Ahead

ALM Alarm

AST Astern

BDC Bottom Dead Center

BFO Bunker Fuel Oil

BN Base Number

CCAI Calculated Carbon Aromaticity Index

CMCR Contract Maximum Continuous Rating

COC Cleveland Open Cup

HFO Heavy Fuel Oil

IMO International Maritime Organisation

ISO International Standard Organisation

JIS Japanese Industrial Standards

MCR Maximum Continuous Rating

MCR Micro Carbon Residue

MDO Marine Diesel Oil

mep mean effective pressure

MGO Marine Gas Oil

PMCC Pensky Martens Closed Cup method

Guide for Symbols and Abbreviations

2006



Abbreviations Explanations

RCS Remote Control System

SCR Selective Catalytic Reduction

SHD SHut Down

SHF Sediment by Hot Filtration

SLD SLow Down

TDC Top Dead Center

WHR Waste Heat Recovery system

2.2 Concerning engine control system WECS9520

ALM20 Advanced Lubrication Module20AMS Alarm and Monitoring System

CANBus Controller Area NetworkCAN M CAN Modul bus

CAN S CAN System bus

COMFN COMon FuNction (engine-related control functions)CYLFN CYLinder FuNction (cylinder-related control functions)

DENIS9520Diesel Engine CoNtrol and OptImizing Specification forWECS9520

ECR Engine Control Room

FCM20 Flex Control Module20FQS Fuel Quality Setting

LED Light Emitting Diode

SCS Speed Control System

Modbus GouldModicon FieldbusOPI OPerator Interface (user interface in control room)

PCS Propulsion Control System

RCS Remote Control System

SIB Shipyard Interface Box (engine / remote control interface)

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

Guide for Symbols and Abbreviations

12.08 / Pulse



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.

GeneralExplanations on the Use of the Operating Manual

2006



Cross Section:

65451

80181

27281

27511

33031

55561

21241

80191

80161

80171

65101

65001

5551155521

58011

33261

66061

64201

41041

36031

80161

83451

34031

014.548/06

Explanations on the Use of the Operating Manual

12.08 / Pulse



Longitudinal Section:

43251

27221

27511

41041

31461

11321

19031

34031

21241

21381

33261

23031

014.549/06

12031

92231

Explanations on the Use of the Operating Manual

Pulse / 12.08



1. General

The RTflex engine is a single acting two-stroke diesel engine of crossheaddesign with exhaust gas turbocharging and uniflow scavenging.

For direct coupled propeller drive it is reversible.

The RTflex concept is based on the Wrtsil Common Rail, with full electron-ic control of fuel injection and exhaust valve actuation.

The engine control is devised in such a way that remote controls of recom-mended manufacturers which correspond to our specifications can be builton, because the locations of interfaces are exactly defined.

In case of failure of the remote control the engine can be controlled with emer-gency control from the local control panel.

Tie rods bind the bedplate, columns and cylinder jacket together.

Crankcase and cylinder jacket are separated from each other by a partitionwhich incorporates the sealing gland boxes for the piston rods.

The thrust bearing and turning gear are situated at the engine driving end.

The exhaust valve actuation, the electronic injection and cylinder lubricatingsystem are controlled by the engine control system WECS9520.

Lubricating oil, cooling water, fuel feed and booster pumps as well as air com-pressors are parts of the engine room installation (ancillary systems).

2. Systems

The exhaust valves are opened hydraulically by the servo oil system andclosed pneumatically. The oil supply is ensured from the bearing oil systemthrough a fine filter. Servo oil pumps in the supply unit provides the servo oilrail with the required pressure via two rising pipes.

One of the two electrically-driven control oil pumps generates the requiredcontrol oil pressure maintaining it over the entire load range.

The pistons are cooled by bearing oil.

Fuel pumps in the supply unit deliver fuel under high pressure into the fuel railvia HP pipes, intermediate fuel accumulator and rising pipes and subsequent-ly through the injection control units to each injection valves.

The injection control units are activated via the control oil system.

The cylinders and cylinder covers are fresh water cooled.

For cooling the scavenge air single-stage coolers are used as standard withfresh water cooling.Two-stage coolers are used as an option providing high and low pressure cir-cuits with fresh water in the central cooling system.

The engine is started by compressed air entering into the cylinders via startingvalves, controlled by the WECS9520.

GeneralBrief Description of the Engine

Pulse / 2006



The exhaust gases flow from the cylinders through the exhaust valves into anexhaust gas manifold.

The exhaust gas turbochargers work on the constant pressure charging prin-ciple.

The scavenge air delivered by the turbochargers flows through air coolers andwater separators into the air receiver.It enters the cylinders via air flaps through the scavenge ports when the pis-tons are nearly at their BDC.

At low loads independently driven auxiliary blowers supply additional air to thescavenging air space.

Brief Description of the Engine

2006



First Stroke: (Compression)

Piston in BDC (Bottom Dead Centre).

Scavenge ports and exhaust valve open.

Scavenge air flows into the cylinder and presses the exhaust gases throughthe exhaust valve into the exhaust gas manifold and from there to the turbo-charger.

Piston moves upwards.

Point ES:

Scavenge ports are being closed by the piston.

Point AS:

Exhaust valve shuts, compression begins.

Second Stroke: (Ignition Combustion Expansion Exhaustion Scavenging) At around the TDC (Top Dead Centre) fuel is injected into the cylinder. The fuel ignites in the compressed, heated air = ignition. With ignition combus-

tion begins.

The gases expand and press the piston downwards (working stroke).

Point AO:

The exhaust valve opens, exhaust gases flow out of the cylinder into the ex-haust gas manifold and from there to the turbocharger.

Point EO:

Scavenge ports are being uncovered by the downward moving piston. Scavenge air flows into the cylinder and presses the exhaust gases out

through the exhaust valve into the exhaust gas manifold and from there to theturbocharger.

(See schematic diagram of Turbocharging 65001)

TDC

BDC

AO

EOES

AS

GeneralWorking Principle of the Two-stroke Diesel Engine

2006



1. General

There is a defined relationship between the propeller speed and the absorbedpower in ships equipped with fixed pitch propellers.With a given propeller this relationship mainly depends on its rotational speed.The following formula provides us with an approximation which is adequate for thegeneral consideration of conventional vessels:

=P1

P2

n1

n2

3

Its graph is called the propeller characteristic.

If an engine is in good condition and properly supplied with air (i.e. turbocharger(s)in good order and the air and exhaust lines have low additional resistance) and thefuel injection quantity is properly adjusted (see setting table), the mean effectivepressure developed under service condition according to the specific reading ofthe load indication corresponds approximately with the mean effective pressureestablished for this particular position on the test bed.

In the diagram, the propeller characteristic line through the point of CMCR (Con-tract Maximum Continuous Rating), i.e. nominal power at nominal engine speed(100% power at 100% engine speed) is called the nominal propeller characteristic.Engines which are to be employed for the propulsion of vessels with fixed propel-lers are loaded on the test bed according to this propeller characteristic. However,the power requirement of a new ship with a smooth and clean hull should be lessand correspond to the range D.

With increasing resistance, changes in wake flow conditions, due to marine growthand ageing of the vessels hull, a rough or mechanically damaged propeller, unfa-vourable sea and weather conditions or operation in shallow water, the propellerwill require a higher torque to maintain its speed than it did at the time of sea trial.The mean effective pressure of the engine (and thus the fuel injection quantity) willincrease accordingly. In such a case, the operating point will then be located to theleft of the original propeller curve which was established during sea trials.

Although cleaning and re-painting will help to reduce the increased resistance ofthe ships hull, the original condition can no longer be attained.

Whereas the thermal loading of an engine depends chiefly on the mean effectivepressure, the position of the operating point is also important; the farther left it issituated from the propeller curve in the diagram (page 2), the poorer the air supplyto the engine and the more unfavourable the engines operating conditions will be-come.

In order to attain optimum working conditions, the operating point of the engine forcontinuous service should lie in range A on the right side of the nominal propellercharacteristic.

Explanations:CMCR = Contract Maximum Continuous RatingP = Powern = speedmep = mean effective pressure

See also Guide for Symbols and Abbreviations 00351.

GeneralInterrelationship between Engine and Propeller

2006



120

110

90

80

70

60

50

40

35

100

70 75 80 85 90 95 100 110

ENGINE SPEED

[%CMCR]

[%CMCR]

104 108

EN

GIN

E P

OW

ER

CMCR

60 65

B D A C

A'

93.7060

E

2. Load ranges

A The portion on the right of the nominal propeller characteristic is the ser-vice range without continuous operating restrictions related to the se-lected CMCR point.The portion on the left of the nominal propeller char

om-rt-flex96c_wecs-9520_pulse_2012-11

Documents

revised x08501a2

pulse feed

guide feed rate x05101a2

service revised x07101a1

adapted remarks

pulse jetpages

ball valve

modification x55521a1